Wellsite Communication System and Method

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

The invention relates generally to a communication system for a wellsite. More particularly, the invention relates to a surface communication system with a communication interface configured to connect to a downhole system, such as a wired drill pipe system.

Oil rigs are positioned at wellsites to locate and gather valuable downhole fluids. Downhole tools, such as drilling tools, may be deployed from a surface platform of the oil rig, and advanced into the earth to form a wellbore. The drilling tool (with a bit at a downhole end thereof) may be advanced into the earth by adding a series of drill pipes thereto. Each drill pipe may be added at the surface platform to form a drill string. A top drive unit may be used to hoist, lower, and/or rotate the drill string, and may have a data swivel that is connectable to the drill pipe to provide a connection for communication with a surface unit. Fluid, such as drilling mud, may be passed through the drill string to cool the drill bit and circulated back to the surface to remove cuttings during drilling.

The drilling tool may be provided with a telemetry system for communication with the surface. The telemetry system may be, for example, a wired drill pipe (“WDP”) telemetry system for communicating with a surface unit. With WDP telemetry, each drill pipe is provided with electrical devices for passing signals through the drill string. Examples of WDP telemetry are provided in U.S. Pat. Nos. 6,670,880 and 6,641,434. The WDP telemetry system may be connected to surface units using various communication links as shown, for example, in U.S. Pat. No. 7,198,118.

During certain operations, such as ‘tripping’ (i.e. inserting or removing at least a part of the drill string, typically while disconnected from the top drive), communication with the drill string may be interrupted. During such ‘tripping,’ the drill string may be disconnected from surface communication devices, thereby resulting in a loss of communication between the surface equipment and the drilling tool. Techniques for providing communication during tripping involving WDP telemetry are described in US Patent Application Nos. 20100243324 and 20100243325. However, many of these techniques suffer from deficiencies and other shortcomings. For example, many conventional designs involve modification of equipment disposed on the drilling rig and the installation of wiring and controls within the derrick of the rig itself, both of which are time consuming, relatively expensive, and difficult to maintain.

BRIEF SUMMARY OF THE DISCLOSURE

These and other needs in the art are addressed in one embodiment by an apparatus for communication with a downhole tool linked to a plurality of wired drill pipes forming a tool string extending from the surface to the downhole tool. In an embodiment, the apparatus comprises a base. In addition, the apparatus comprises an extension assembly having a first end pivotally coupled to the base and a second end. Further, the apparatus comprises a head assembly pivotally coupled to the second end of the extension assembly. Still further, the apparatus comprises an interface connector moveably coupled to the head assembly and configured to connect to an uphole end of the tool string and form an interface link between a surface unit and the downhole tool.

These and other needs in the art are addressed in another embodiment by a communication system for communicating with a downhole tool linked to a plurality of wired drill pipes forming a tool string extending from the surface to the downhole tool. In an embodiment, the system comprises a surface unit configured to receive a signal from the downhole tool. In addition, the system comprises a communication interface electrically coupled to the surface unit and configured to receive the signal from the downhole tool and direct the signal to the surface unit. The communication interface comprises a base. The communication interface also comprises an extension assembly having a first end pivotally coupled to the base and a second end. Moreover, the communication interface comprises a head assembly pivotally coupled to the second end of the extension assembly. Still further, the communication interface comprises an interface connector moveably coupled to the head assembly and configured to connect to an uphole end of the tool string and form an interface link between the surface unit and the downhole tool.

These and other needs in the art are addressed in another embodiment by a method for communicating with a downhole tool linked to a plurality of wire drill pipes forming a tool string extending from the surface to the downhole tool. In an embodiment, the method comprises (a) providing an interface connector on a communication interface. In addition, the method comprises (b) extending the communication interface horizontally to position the interface connector substantially over an uphole end of the tool string. Further, the method comprises (c) lowering the interface connector with the communication interface until the interface connector engages the uphole end of the tool string. Still further, the method comprises (d) connecting the interface connector to the tool string to form a communication link between the interface connector and the tool string.

Embodiments described herein comprise a combination of features and advantages intended to address various shortcomings associated with certain prior devices, systems, and methods. The foregoing has outlined rather broadly the features and technical advantages of the invention in order that the detailed description of the invention that follows may be better understood. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description, and by referring to the accompanying drawings. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:

FIGS. 1 is a schematic side view of a wellsite having a surface communication system and a downhole tool with a downhole communication system, the surface communication system including a surface unit and a portable communication interface;

FIG. 2 is a schematic top view of the wellsite of FIG. 1;

FIGS. 3-7 are schematic perspective views of a communication interface as it is moved into position for communication with a drill string;

FIG. 8 is a schematic side view of a communication connector usable with the communication interface in accordance with the principles disclosed herein;

FIG. 9 is a side view of an embodiment of a communication interface in a retracted position in accordance with the principles disclosed herein;

FIG. 10 is a side view of the communication interface of FIG. 9 in an extended position;

FIG. 11 is an enlarged side view of the base of FIG. 9;

FIG. 12 is an exploded side view of the extension assembly of FIG. 9;

FIG. 13 is an exploded side view of the head assembly of FIG. 9;

FIG. 14 is a cross-sectional view taken along section XIII-XIII of FIG. 13;

FIG. 15 is a top view of the head bracket of FIG. 9;

FIG. 16 is an enlarged partial cross-sectional front view of the drive assembly and communication connector of FIG. 9;

FIG. 17 is a side view of the communication interface of FIG. 9 in a stowed position;

FIG. 18 is a perspective view of an embodiment of a communication interface in a retracted position in accordance with the principles disclosed herein;

FIG. 19 is a side view of the communication interface of FIG. 18 in an extended position;

FIG. 20 is an enlarged perspective view of the pedestal of the communication interface of FIG. 18;

FIG. 21 is an enlarged perspective view of the base of the communication interface of FIG. 18;

FIG. 22 is a partially schematic cross-sectional view taken along section XXII-XXII of FIG. 18;

FIG. 23 shows a partially schematic cross-sectional view taken along section XXIII-XXIII of FIG. 18; and

FIG. 24 is a schematic side view of a communication connector usable with the communication interface in accordance with the principles disclosed herein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following discussion is directed to various exemplary embodiments. However, one skilled in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.

Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to. . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices, components, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the central axis. For instance, an axial distance refers to a distance measured along or parallel to the central axis, and a radial distance means a distance measured perpendicular to the central axis.

Embodiments of devices, systems, and methods disclosed herein relate to a communication system for providing a communication link between a surface unit and a downhole tool. The communication system may be a portable communication interface positionable at the wellsite (e.g., rig floor), for example during tripping, for connection to an uphole end of a tool string of the downhole tool. The communication interface may be provided with devices for positioning an interface connector for connection to the tool string. The communication interface may also be provided with devices for communication with one or more onsite or offsite surface units and/or computers.

Referring now to FIGS. 1 and 2, wherein a wellsite 10 including a surface portion 102 and a downhole portion 104 is shown. The downhole portion 104 is disposed in a wellbore 105 and includes a downhole tool 106 with a bit 108 at an end thereof, and a series of drill pipes 110 forming a tool string 112 (e.g., a drill string). Each of the drill pipes 110 is a wired drill pipe provided with a wire 114 and a coupler 116 at each end of the wired drill pipe for forming a downhole communication link through the drill string 112. Examples of wired drill pipe are described in U.S. Pat. Nos. 6,670,880 and/or 6,641,434, the entire contents of which are hereby incorporated herein.

The surface portion 102 includes a derrick 120 on a platform 122. An uphole end 124 of the drill string 112 is positioned through the platform 122. In this embodiment, a box-type female connector 127 is disposed at the uphole end 124 of drill string 112. The surface portion 102 also includes an elevator 126, a top drive 128, and draw works (not shown) for positioning and threading a new drill pipe 130 to the uphole end 124 of drill string 112.

The surface portion 102 also includes a surface communication system 132 for communicating with the downhole tool 106. The surface communication system 132 includes a surface unit 134 and a communication interface 100. The surface unit 134 may be, for example, one or more computers for receiving, processing, analyzing, sending or otherwise handling data from the surface portion 102 and/or downhole portion 104. The surface unit 134 may be linked to the surface portion 102, a network 138, and/or one or more offsite computers 140 by links 142a,b,c, respectively.

As is best shown in FIG. 2, in some embodiments, the communication interface 100 is automatically, manually, and/or remotely operated by an operator 153 and/or one or more controllers 151, which may be disposed on the surface unit 134. In this embodiment, an operator 153 is positioned at the surface unit 134 which, in this embodiment, is located on the platform 122 but outside of a red zone 155 (i.e. an area around the wellbore where the drill pipe installation is performed and where most operations on the rig occur; see, e.g., www.dropsonline.org) of the wellsite 10.

The link 142a is used to link the surface unit 134 to the top drive 128. The uphole end 124 of the drill string 112 may be provided with a surface connector (not shown) for linking to the top drive 128 and the surface unit 134. Examples of a surface connector are provided in US U.S. Pat. No. 7,198,118; Application Nos. 20100243324; and/or 20100243325, the entire contents of which are hereby incorporated by reference herein. When the top drive 128 is connected to the uphole end 124 of the drill string 112, the surface unit 134 may be in communication with the downhole tool 106 through the link 142a. During such connection, the communication link 142a may be used to pass power and/or data signals between the downhole tool 106 and the surface unit 134.

In some cases, such as during tripping, the uphole end 124 of the drill string 112 is disconnected from the top drive 128 as shown in FIG. 1. During such disconnected conditions, the communication interface 100 is positioned at the wellsite 100 in order to provide communication between the downhole tool 106 and the surface unit 134 to form an ‘interface link’ therebetween. The communication interface 100 is then used to establish a link 142d with the downhole portion 104 and a link 142e with the surface unit 134 for providing communication therebetween as schematically shown. The configuration of the communication interface 100 provides a portable and floor mounted configuration for use at the wellsite 10. It should be appreciated that in some embodiments, the communication interface 100 may be either integrated or non-integrated with the surface equipment at the rig (e.g., iron roughnecks, top drives, elevators, etc.).

Referring now to FIGS. 3 and 4, wherein an embodiment of the communication interface 100, for connection to the uphole end 124 of the drill string 112 is shown. In general, interface 100 comprises a base 240, a frame 250 coupled to the base 240, a head assembly 280, and an interface connector positioning apparatus 260.

Frame 250 generally includes a central longitudinal axis 255, a first or upper end 250a, and a second or lower end 250b opposite the upper end 250a. In this embodiment, the lower end 250b includes a plurality of lower members 252 oriented along a plane that is perpendicular to the axis 255. In this embodiment, lower end 250b comprises a first pair of members 252a and second pair of members 252b. Each of the members 252a is parallel to one another, while each of the members 252b is parallel to one another. Further, each of the members 252a extends between each of the members 252b in a direction that is perpendicular to each of the members 252b, while each of the members 252b extends between each of the members 252a in a direction that is perpendicular to each of the members 252a. Thus, the members 252a, b are arranged about the axis 255 in a generally rectangular configuration, such that a corner 253 is formed at the intersection points of each member 252a,b. Upper end 250a includes a plurality of upper members 256 oriented along a plane that is perpendicular to the axis 255 and axially separated from the members 252 of lower end 250b. In this embodiment, upper end 250a comprises a first pair of members 256a and a second pair of members 256b. Each of the members 256a is parallel to one another, while each of the members 256b is parallel to one another. Further, each of the members 256 extends between each of the members 256b in a direction that is perpendicular to each of the members 256b, while ach of the members 256b extends between each of the members 256a in a direction that is perpendicular to each of the members 256a. Thus, the members 256a, b are arranged about the axis 255 in a generally rectangular configuration, such that a corner 257 is formed at the intersection point of each member 256a, b. In this embodiment, each of the corners 257 is axially aligned with each of the corners 253. A plurality of vertical members 258 extend axially between each corner 253 and corresponding corner 257. Furthermore, a plurality of coupling members 259 are disposed at each of the corners 257 on upper end 250a to allow a lifting device (e.g., a crane) to lift and/or position interface 100. Additionally, in this embodiment, a plurality of cross-members 247 each extend generally diagonally between a pair of corners 253, 257, such that the stability and/or structural rigidity of frame 250 is enhanced.

Base 240 is disposed on the frame 250 at the lower end 250a. More particularly, in this embodiment, base 240 is coupled to and extends between the members 252b. An electrical junction box 248 is disposed on the base 240 and, as will be described in more detail below, provides an electrical connection site for electrical conductors or cables 249 which are routed to interface connector 284. An upright post or mast 242 is coupled to the base 240, adjacent the box 248 and extends axially upward therefrom along a longitudinal axis 245. In this embodiment, the axis 245 is generally parallel to and radially offset from the axis 255. A support sleeve 244 is slidingly disposed about the mast 242 such that sleeve 244 may traverse axially along the mast 242 and may rotate about the axis 265. In general, any suitable method for inducing axial and/or rotational motion of a mechanical member may be utilized for sleeve 244. For example, in some embodiments, a pneumatic or hydraulic cylinder is disposed inside mast 242 to induce axial movement of sleeve 244. Additionally, in some embodiments, sleeve 244 may include one or more radially inwardly extending pins which engage with one or more corresponding grooves disposed on the outer surface of mast 242. These grooves guide and induce rotation of sleeve 244 as sleeve 244 is traversed axially along mast 242. Sleeve 244 generally comprises a first or upper end 244a and a second or lower end 244b opposite the upper end 244a. In this embodiment, the upper end 244a comprises a connection flange 246. A substantially horizontal boom 260 is disposed at the upper end 244a of sleeve 244, and generally includes a first or proximal end 260a, a second or distal end 260b opposite the proximal end 260a, and a connection flange 262 disposed between the ends 260a, b, proximate the proximal end 260a. Connection flange 262 is coupled to the flange 246, thus securing the boom 260 to the sleeve 244 such that boom 260 is oriented substantially perpendicular to sleeve 244. Boom 260 is substantially hollow and thus has an inner receptacle 264 which extends from the distal end 260b toward the proximal end 260a. An extension member 270 is disposed within the receptacle 264 and supports head assembly 280 on a distal end thereof. Further, member 270 is configured to extend from and retract within the receptacle 264 at the distal end 260b in order to extend and withdrawal head assembly 280, respectively. For example, a pneumatic or hydraulic cylinder can be disposed within member 270 to allow member 270 to extend from or retract within receptacle 264 during operation.

Referring now to FIG. 4, head assembly 280 generally comprises a central axis 285, a driver 282, and an interface connector 284 disposed axially below the driver 282. As will be described in more detail below, driver 282 is configured to rotate the connector 284 about the axis 285 in order to engage the upper end 124 of the drill string 112 during operations. Referring briefly now to FIG. 8, wherein an embodiment of the interface connector 284 is shown. Connector 284 generally comprises a body 286 which further includes a central longitudinal axis 287, which is aligned with axis 285 during operation, a first or upper end 286a, a second or lower end 286b opposite the upper end 286a, a mid-body radial projection or flange 283 axially positioned between the ends 286a, b, an attachment section 288 extending axially from the upper end 286a to the flange 283, and an interface engagement section 290 extending axially from the flange 283 to the lower end 286b.

Attachment section 288 generally comprises a manual engagement surface 281 disposed axially adjacent the flange 283 and configured to receive a manual engagement member (not shown) (e.g., a wrench), and a slot 289 which extends axially from the upper end 286a. As will be described in more detail below, during operation, slot 289 receives a torque transfer mechanism (not shown) coupled to the output shaft (not shown) of the driver 282 engages with slot 296 in order to transfer torque from the driver 282 to the connector 284. Engagement section 290 generally comprises a housing 294 disposed axially adjacent the flange 283 and an engagement tip 292 disposed axially below the housing 294. Housing 294 is generally defined by a substantially cylindrical surface 294a extending axially downward from the flange 283. Threads 296 are disposed on the surface 294a proximate the flange 283, and as will be described in more detail below, are configured to engage with the threads disposed within the box-end connector 127 on the upper end 124 of drill string 112. Further, in at least some embodiments threads 296 are sized such that they require fewer turns to fully make up the connection between the connector 284 and the uphole end 124, than would typically be necessary for other components utilizing a conventional pin-end type connector. Additionally, engagement tip 292 is generally defined by a first or upper substantially cylindrical surface 29a extending axially from the housing and a frustoconical surface 292b extending axially downward from the surface 292a. Further, a radially oriented surface or shoulder 295 extends between the surfaces 294a, 292a. As will be described in more detail below, shoulder 295 is configured to abut or engage with an inner shoulder of a box-end connection of the upper end 124 of drill string 112, when the interface connector 284 is in a testing position. An induction coil (or induction coupler) 291 is disposed within the housing 294 proximate the shoulder 295, and is configured to receive a signal from a corresponding coupling (not shown) disposed on the inner shoulder the connector 127 of uphole end 124. A conductor (e.g., a wire or cable) 292 extends from the coupling 293 toward the upper end 286a, such that the signal received by the coupling 291 can be routed through the conductor 293 during operation. It should be appreciated that in other embodiments, no slot 289 may be included on the connector 284, and some other attachment method, such as threads disposed on the attachment section proximate the upper end 286a, may be used to couple the connector to the head assembly 280.

Referring now to FIGS. 3-6, during operation, frame 250 may be rested in position on the platform 122 a distance out of the way of machinery used during operations (e.g., outside red zone 155), and sufficiently close to the drill string 11 for connection therewith. In some embodiments, the interface 236 may be positioned, for example, from about 4 ft. to about 8 ft. from the drill string 112. Further, to connect interface connector 284 to uphole end 124 of drill string 112, the sleeve 244 is axially elevated along mast 242 and is rotated about the axis 245 such that the connector 284 is generally aligned with drill string 112 as shown in FIG. 4. Thereafter, the extension member 270 extends out of the receptacle 264 such that the axis 285 of connector 284 is generally aligned with a central axis of the drill string 112, such as is shown in FIG. 5. The sleeve 244 is then lowered along the axis 245 such that the engagement section 292 of connector 284 engages with the uphole end 124, such as is shown in FIG. 6, and the driver 282 drives the connector 284 to rotate about the axis 285 such that threads 296 engage with corresponding threads disposed within connector 127 on uphole end 124 until the shoulder 295 on connector 284 abuts or engages with an inner shoulder of the connector 127.

Referring now to FIG. 7, once interface connector 284 fully engages with the uphole end 124 of drill string 112, electrical signals are routed through the induction coupler 291 in connector 284, through conductor 292, and the conductor(s) 249 into electrical junction box 248 on base 240. The signals are then routed to the surface unit 134 via conductor 142e.

Referring now to FIGS. 9 and 10, wherein another embodiment of a communication interface 300 for connection to the uphole end 124 of the drill string 112 is shown is shown. In this embodiment, communication interface 300 includes a base 301, an extension assembly 310 coupled to the base 301, a head assembly 340 coupled to extension assembly 310, and an interface connector 284, previously described, coupled to head assembly 340. Extension assembly 310 is designed to extend head assembly 340 to uphole end 124 and retract head assembly 340 from uphole end 124, and head assembly 340 is designed to move interface connector 284 up and down relative to uphole end 124 and rotate interface connector 348 to thread it into and out of uphole end 124. In the description to follow, the terms “rearward” and “forward” are used to describe relative horizontal positions of different components and parts of communication interface 300. As used herein, “rearward” refers to positions horizontally closer to base 301, and “forward” refers to positions horizontally closer to interface connector 284.

Referring now to FIGS. 9-11, base 301 includes a horizontal bottom plate 302, and a pair of vertical side plates 303 (note: only one vertical side plate 303 is visible in FIGS. 9-11) extending perpendicularly upward from the lateral sides of base plate 302. Each side plate 303 includes a pair of arm mounting holes 304a, 304b, an actuator mounting hole 305a, and a stowage hole 305b. As will be described in more detail below, holes 305b are employed while loading and unloading communication interface 300 from a storage crate (not shown). Base 301 may include a rotation mechanism to allow base 301 to rotate in either direction about a vertical axis to increase the degrees of freedom of movement of interface connector 284.

Referring now to FIGS. 9, 10, and 12, extension assembly 310 includes a first pair of parallel arms 311, 312, a second pair of parallel arms 321, 322, an elbow 330 extending between arms 311, 312 and arms 321, 322, and a linking member 335 extending between arms 312, 321. Although arms 311, 312 are parallel to each other, and arms 321, 322 are parallel to each other, arms 321, 322 are configured to move relative to arms 311, 312, and thus, are generally not parallel to arms 311, 312.

Each arm 311, 312, 321, 322 is an elongate, linear, rigid tubular having a first end 311a, 312a, 321a, 322a, respectively, and a second end 311b, 312b, 321b, 322b, respectively, opposite first end 311a, 312a, 321a, 322a, respectively. Elbow 330 comprises a pair of parallel vertical plates 331 shaped as inverted trapezoids (note: only one plate 331 is visible in FIGS. 9, 10, and 12). The non-parallel sides of each plate 331 include arm connection holes 332. In addition, a coupling member 333 is attached to plates 431 for connecting a shackle or other device employed to lift communication interface 300 at elbow 330. Linking member 335 is an elongate arm having ends 335a, 335b.

Ends 311a, 312a of the arms 311, 312, respectively, are disposed between side plates 303 on base 301 and pivotally coupled thereto, and ends 311b, 312b are disposed between elbow plates 331 and pivotally coupled thereto. Further, ends 321a, 322a of arms 321, 322, respectively, are disposed between elbow plates 331 and pivotally thereto and ends 321b, 322b are pivotally coupled to head assembly 340. In particular, each end 311a, 312a is pinned at hole 304a, 304b, in base 301, respectively, each end 311b, 312b is pinned at one hole 332 of elbow 330, each end 321a, 322a is pinned at one hole 332 of elbow 330, and each end 321b, 322b is pinned to head assembly 340. In addition, arms 312, 321 are pivotally coupled to ends 335a, 335b, respectively, of linking member 335 at points that are proximate to ends 312b, 321a, respectively.

Extension assembly 310 has a fully retracted position shown in FIG. 9 and a fully extended position shown in FIG. 10. Extension assembly 310 is actuated between the retracted and extended positions, as well as any intermediate positions between the fully retracted and extended positions, with a linear actuator 306 extending between base 301 and arm 311. In particular, actuator 306 has a central or longitudinal axis 307, a first end 306a pivotally coupled to arm 311 between ends 311a, 311b and a second end 306b disposed between and pivotally coupled to side plates 303 of base 301 at hole 305a. Linear actuator 306 is configured to axially extend and retract end 306a relative to end 306b. In general, actuator 306 may be any suitable type of linear actuator including, without limitation, a hydraulic cylinder, a motor that rotates a threaded shaft, etc. In this embodiment, actuator 306 is a pneumatic cylinder.

As best shown in FIGS. 9 and 10, as actuator 306 is extended along axis 307 the arms 311, 312 rotate rearward (counterclockwise in FIGS. 9 and 10) about ends 311a, 312a, respectively, thereby moving ends 311b, 312b and elbow 330 to a position generally over base 301. The movement of elbow 330 and link member 335 causes arms 321, 322 to rotate rearward or downward (clockwise in FIGS. 9 and 10) about ends 321a, 322a, respectively, thereby moving ends 321b, 322b and head assembly 340 toward and generally over base 301, and moving arms 321, 322 towards arms 311, 312. Conversely, as actuator 306 is retracted along axis 307 the arms 311, 312 rotate forward (clockwise in FIGS. 9 and 10) about ends 311a, 312a, respectively, thereby moving ends 311b, 312b and elbow 330 from a position over base 301 to a position forward of base 301. The movement of elbow 330 and link member 335 causes arms 321, 322 to rotate upward (counterclockwise in FIGS. 9 and 10) about ends 321a, 322a, respectively, thereby moving ends 321b, 322b and head assembly 340 away from base 301, and moving arms 321, 322 away from arms 311, 312. In this manner, the extension and retraction of actuator 306 can be used to move head assembly 340 toward and away from base 301, respectively, and to move head assembly 340 away and toward uphole end 124 of the drill string 112, respectively. Extension assembly 310 is sized and configured to extend to a horizontal distance D measured from base 301 to drill string 112. In general, the horizontal distance D can be varied depending on the particular application. However, for most applications, the horizontal distance D preferably ranges from 1.0 to 10.0 ft., and may more preferably ranges from 4.0 to 8.0 ft. In this embodiment, the horizontal distance D is approximately 8 ft. In other words, in this embodiment extension assembly 310 is configured to move head assembly 340 a horizontal distance D of up to approximately to 8 ft. from base 301. Accordingly, base 301 is preferably positioned less than or equal to approximately 8 ft. from the uphole end 124 of the drillstring 112 during operation.

Referring now to FIGS. 9, 10, and 13, head assembly 340 includes a gooseneck 341 pivotally coupled to ends 321b, 322b of arms 321, 322, respectively, a drillstring centralizer 350 mounted to gooseneck 341, a head bracket 360 suspended from and moveably coupled to gooseneck 341, and a drive assembly 370 coupled to head bracket 360. Interface connector 284 is coupled to drive assembly 370, which is further configured to rotate interface connector 284 in both directions to thread it into and out of uphole end 124 of drillstring 112 during operation.

Gooseneck 341 is an elongate beam having a central or longitudinal axis 345, a first or upper end 341a, and a second or lower end 341b opposite end 341a. A pulley 342 is rotatably connected to upper end 341a, a cable coupling 343 is attached to gooseneck 341 at upper end 341a rearward of pulley 342, and a pair of parallel vertical connection plates 344 extend rearwardly (to the left in FIGS. 9, 10, and 13) from lower end 341b (note: only one plate 344 is visible in FIGS. 9, 10, and 13). Ends 321b, 322b of arms 321, 322, respectively, are disposed between and pivotally coupled to plates 344. In particular, each plate 344 includes an upper arm mounting hole 344a and a pair of lower arm mounting holes 344b and 344c. Hole 344b is horizontally positioned rearward of hole 344c and vertically positioned slightly above hole 344c. In other words, hole 344c is radially disposed between hole 344b and gooseneck 341 and axially slightly below hole 344b. As best shown in FIGS. 9 and 10, ends 321b, 322b are pinned at holes 344a, 344c, respectively, during operation of communication interface 300. As best shown in FIG. 17, ends 321b, 322b are pinned at holes 344a, 344b, respectively, while stowing and transporting communication interface 300. Holes 344a, 344c are positioned such that gooseneck 341 remains vertically oriented during operation of communication interface 300 (i.e., extension and retraction of extension assembly 310). However, holes 344a, 344b are oriented such that gooseneck 341 is tilted backward or toward the fully retracted extension assembly 310 during stowing and transport of communication interface 300 (such as is shown in FIG. 17).

Referring to FIGS. 10 and 14, centralizer 350 is coupled to gooseneck 341 proximal lower end 341b and includes a pair of laterally spaced horizontally extending arms 351, 353. Arms 351, 353 each have a first or rearward end 351a, 353a, respectively, and a second or forward end 351b, 353b, respectively, extending horizontally from gooseneck 341. Arms 351, 353 are generally parallel, however, forward ends 351b, 353b flare outwardly or away from each other, thereby defining a funnel-shaped receptacle 352 between ends 351b, 353b, which is configured to receive drillstring 112. Rearward ends 351a, 353a of arms 351, 353, respectively, are disposed between plates 344 and are pivotally coupled to gooseneck 341. In particular, arm 351 pivots about a vertical axis 355 extending through its rearward end 351a, while arm 353 pivots about a vertical axis 357 extending through its rearward end 353a. By pivoting arms 351, 353 about rearward ends 351a, 353a, respectively, forward ends 351b, 353b can be moved in a horizontal plane (i.e. a plane that is perpendicular to the axes 355, 357) toward and away from each other. In this embodiment, forward ends 351b, 353b are biased toward each other. In particular, a biasing member 452 has a first end 452a coupled to one arm 351 between its ends 351a, 351b, and a second end 452b coupled to the other arm 353 between its ends 353a, 353b. In this embodiment, biasing member 452 is a resilient coil spring placed in tension between ends 352a, 352b, thereby urging forward ends 351b, 353b of arms 351, 353, respectively together. As will be described in more detail below, as uphole end 124 of drillstring 112 is received into receptacle 452 between arms 351, 353, the biasing action of centralizer 350 facilitates the alignment of head assembly 340 with uphole end 124 and laterally centers head assembly 340 relative to uphole end 124.

Referring now to FIGS. 13 and 15, head bracket 360 includes a horizontal base plate 361 and a generally C-shaped vertical wall 362 extending perpendicularly upward from plate 361. Base plate 361 is symmetric about a horizontal central axis 365 and has a rearward end 361a, a forward end 361b, and a recess or cutout 363 extending along axis 365 from end 361a. Recess 363 defines a pair of arms 364. A through bore 366 extends vertically or radially with respect to axis 365, through base plate 361 and is positioned between recess 363 and forward end 36 lb. Wall 362 extends around recess 363 and has a lower end 362a fixed to base plate 361 and an upper or free end 362b distal base plate 361. A cable coupling 367 is attached to wall 362 at upper end 362b.

Referring now to FIGS. 9, 10, 13, and 15, head bracket 360 can be controllably moved vertically up and down relative to gooseneck 341. More specifically, gooseneck 341 is slidably disposed between arms 364 in receptacle 363. In addition, a linear actuator 308, as previously described, has a lower end 308a coupled to lower end 341b of gooseneck 341 and an upper end 308b coupled to a pulley 368. A cable 368 extends under and around pulley 368, over and around pulley 342, and has a first end 368a connected to cable coupling 343, a second end 368b connected to cable coupling 367. Extension of linear actuator 308 lowers head bracket 360 along gooseneck 341, and contraction of linear actuator 308 raises head bracket 360 along gooseneck 341. Thus, by controlling the extension and contraction of actuator 308, the vertical position of head bracket 360 is controlled. As will be described in more detail below, positioning arms 364 on opposite sides of gooseneck 341 prevents head bracket 360 from rotating relative to gooseneck 341 about a vertical axis.

Referring now to FIGS. 9, 10, 13, and 16, drive assembly 370 includes a central axis 379, a gearbox 371 having an outer housing 373 mounted to plate 361 between wall 362 and end 361b, and a pair of drive units 380a and 380b mounted to the gearbox 371 on opposing sides of the axis 379. The drive units 380a, 380b include vertical axes 385a, 385b, respectively, motors 372a, 372b with output shafts 378a, 378b substantially aligned with the axes 385a, 385b, respectively, and torque transfer gears 374a, 374b, axially disposed about the shafts 385a, 385b, respectively. Torque transfer gears 374a, 374b and shafts 378a, 378b are rotatably disposed in housing 373 and are configured to rotate about the axes 385a, 385b, respectively. Further, an output drive shaft 375 extends downward from housing 373 along the axis 379, through bore 366 on bracket 360 and a drive gear 376 is mounted to drive shaft 375, about the axis 379, between gears 374a, 374b. Each torque transfer gear 374a, 374b engages and meshes with drive gear 376. Output shaft 375 has a lower end comprising an internally threaded receptacle 377 that threadably receives the upper externally threaded end 286a of interface connector 284.

Motors 372a, 372b drive the rotation of gears 374a, 374b, respectively, which in turn drive the rotation of gear 376, shaft 375, and interface connector 284. In general, each motor 372a, 372b can be any motor known in the art including, without limitation, an electric motor, a hydraulic motor, a pneumatic motor, or the like. In this embodiment, each motor 372a, 372b is a pneumatic motor. Motors 372a, 372b rotate shaft 375 and interface connector 284 in a first direction 379a to thread interface connector 284 into connector 127 on uphole end 124 of drill string 112, and rotate shaft 375 and interface connector 284 in a second direction 379b that is opposite the first direction 379a to unthread interface connector 284 from connector 127 on uphole end 124 of drill string 112. As previously described, arms 364 of head bracket 360 are disposed on opposite sides of gooseneck 341, and thus, reactive torques applied to head bracket 360 during threading or unthreading of interface connector 284 are resisted by engagement of arms 364 and gooseneck 341.

Referring now to FIG. 17, communication interface 300 is shown in a stowed position for storage and transport (e.g., transport to, from, or at the wellsite 10). In the stowed position, extension assembly 310 is in a fully collapsed position and head assembly 340 is tilted back from vertical toward extension assembly 310. In particular, actuator 306 of extension assembly 310 is fully extended and end 322b is pinned at hole 344b. In addition, base 301 is preferably pivotally coupled to a crate or frame (not shown) within which it is disposed at hole 305b. To deploy communication interface 300, a cable (not shown) is connected to coupling member 333 and tension is applied to the cable to pivot communication interface 300 upward about hole 305b to a vertical position. Next, a pin (not shown) extending through the crate or frame and hole 305b is removed, and communication interface 300 is lifted from the storage crate or frame and seated on base 301 at the desired location at the wellsite 10. Communication interface 300 is preferably positioned such that extension assembly 310 is generally aligned with uphole end 124 of drillstring 112. Next, end 322b is unpinned from hole 344b, gooseneck 341 is tilted to a substantially vertical orientation, and end 322b is pinned at hole 344c such as shown in FIG. 9.

Referring now to FIGS. 9 and 10, to connect interface connector 284 to the uphole end 124 of the drill string 112, actuator 308 of head assembly 340 is contracted to raise interface connector 284 (if not already done) and actuator 306 of extension assembly 310 is contracted to extend arms 311, 312, 321, 322 toward uphole end 124, thereby moving head assembly 340 toward uphole end 124. With extension assembly 310 generally aligned with uphole end 124, receptacle 352 of receives uphole end 124 and centralizes head assembly 340 relative to uphole end 124, and coaxially aligns interface connector 284 with uphole end 124. Next, actuator 308 of head assembly 340 is extended to lower interface connector 284 downward into uphole end 124 of drillstring 112, and drive assembly 370 rotates interface connector 284 in direction 379a to thread interface connector 284 into connector 127 on uphole end 124.

Once the interface connector 284 is in the testing position, a communication link (e.g., 142d of FIG. 1) may be established between the interface connector 284 and the drill string 112. With base 301 linked to the surface unit 134, communication is now established between the drill string 112 and to the surface unit 134. The surface unit 134 may be, for example, a remote control console for operating the interface connector 284 disposed at some distance from the rig floor. The interface connections used to link the connector 284 to the unit 134 may be for example, a coax cable for measurement while tripping (“MWT”) and/or performing network diagnostic tests (“ND”). The interface connections may also include pneumatic (and/or hydraulic) lines (for example, those used in a hose bundle) for operation of the interface connector 284. Line and/or cable connectors may be provided about the communication interface 100 for distribution and/or moving one or more of the cables and/or lines thereabout.

Referring still to FIGS. 9 and 10, interface connector 284 is decoupled from uphole end 124 by reversing the process. In particular, drive assembly 370 rotates interface connector 284 in direction 379b to unthread interface connector 284 from connector 127 on uphole end 124, and actuator 308 of head assembly 340 is contracted to lift interface connector 284 upward from uphole end 124. Next, extension assembly 310 is contracted by extending actuator 306 of extension assembly 310, thereby moving head assembly 340 away from uphole end 124.

Referring now to FIGS. 18 and 19, another embodiment of a communication interface 400 for connection to uphole end 124 of drill string 112 is shown. Communication interface 400 is substantially the same as the communication interface 300 previously described in structure and function. Accordingly, like numerals will be used to refer to components which are configured the same in both of the interfaces 300, 400. In this embodiment, communication interface 400 includes a base 401, an extension assembly 310 coupled to the base 401, a head assembly 440 coupled to extension assembly 310, and an interface connector 484 coupled to head assembly 440. Extension assembly 310 is as previously described with respect to communication interface 300. In addition, communication interface 400 includes a pedestal 420 supporting base 401, and a housing 410 coupled to the pedestal 420 adjacent base 401. Housing 410 encloses various electronic, pneumatic, hydraulic, and/or other components used to operate communication interface 400.

Referring now to FIGS. 18-20, pedestal 420 includes a horizontal top plate 422a, a horizontal bottom plate 422b disposed below top plate 422a, and a pair of parallel, vertical side plates 424 extending between plates 422a, 422b. Top plate 422b includes a plurality of mounting holes 426 for bolting housing 410 and base 401 thereto.

Referring now to FIGS. 18, 19, and 21, base 401 includes a horizontal bottom plate 402, and a pair of parallel, vertical side plates 403 extending perpendicularly upward from the lateral sides of base plate 402. Each side plate 403 includes a pair of arm mounting holes 404a, 404b, an actuator mounting hole 405a, and a stowage hole 405b. In addition, base 401 includes a substantially vertical back plate 406 coupled to the bottom plate 402 and the vertical side plates 403.

Referring now to FIGS. 18, 19, and 22, head assembly 440 includes a gooseneck 441, a drillstring centralizer 350 mounted to gooseneck 441, a head bracket 460 suspended from and moveably coupled to gooseneck 441, and a drive assembly 370 coupled to head bracket 460. Centralizer 350 and drive assembly 370 are each as previously described with respect to communication interface 300. Gooseneck 441 is substantially the same as gooseneck 341 previously described, except that in this embodiment, gooseneck 441 includes a pair of elongate, vertically oriented tracks or rails 444 extending outward from the lateral sides thereof. In addition, head bracket 460 is substantially the same as head bracket 360 previously described, except that the generally C-shaped vertical wall 362 includes a pair of outward facing followers 442. Each follower 442 mates and slidingly engages a corresponding track 444 to guide the movement of bracket 460 along gooseneck 441 and limit rotation of bracket 460 relative to the gooseneck 441 about a vertical axis.

In this embodiment, a bumper or stop member 446 is also provided on gooseneck 441 to engage uphole end 124 as extension assembly 310 extends the head assembly 440 forward, thereby preventing overextension of head assembly 440 during operation. Stop member 446 includes a concave engagement surface 448 having a radius of curvature that is substantially the same as the radius of curvature of the outer surface uphole end 124. During operation, as head assembly 440 is moved forward with extension assembly 310, uphole end 124 of drill string 112 is engaged by surface 448, which funnels or guides assembly 440 into alignment with uphole end 124 and ensures optimal spacing between drill string 112 and gooseneck 441.

Referring now to FIG. 24, interface connector 484 is substantially the same as connector 284 previously described except that no engagement tip 292 is provided, and further, a pair of pressure relief ports 486 are provided to equalize pressure differentials between the inside of drill string 112 and the outside environment when connector 484 is coupled to uphole end 124. In this embodiment, each port 486 comprises an elongated port or passage extending vertically through flange 283 and housing 294 to lower end 286b, which is positioned at the surface 295 for the connector 484.

Although connector 484 is shown and described in connection with communication interface 400, in general, either connector 384, 484 can be used in connection with any embodiment of a communication interface described herein (e.g., communication interface 200, 300, 400). In addition, while base 401, head assembly 440, pedestal 420, housing 410, and interface connector 484 as well as various associated subcomponents have been shown and described in connection with communication interface 400, in general, any of these components can be employed in other embodiments of communication interfaces disclosed herein (e.g., communication interface 200, 300).

Among the potential advantages provided by the disclosure is the real-time control of ventilation. Additionally, communication during detached conditions may reduce blind time, or time in which signals emitted by downhole tools are not being received, and provide information about downhole operations during such conditions. Downhole tools and software applications may be used to analyze the data even during such detached conditions. By way of example, measurements of pressure, temperature, and strain on drill string 112 may be collected and/or analyzed during detached conditions, such as, for example, well control operations, running casing, fracturing, perforating, gravel packing, tripping, and/or other operations. Such analysis may provide, for example, analysis of hole cleaning, detailing wellbore tortuosity, etc.

It will be appreciated by those skilled in the art that the techniques disclosed herein can be fully automated via software configured with algorithms to perform operations as described herein. These aspects can be implemented by programming one or more suitable general-purpose computers having appropriate hardware. The programming may be accomplished through the use of one or more program storage devices readable by the processor(s) and encoding one or more programs of instructions executable by the computer for performing the operations described herein. The program storage device may take the form of, e.g., floppy disks; CD ROMs or other optical disk devices; magnetic tape; read-only memory chips (ROM); and other forms of the kind well-known in the art or subsequently developed. The program of instructions may be “object code,” i.e., in binary form that is executable more-or-less directly by the computer; in “source code” that requires compilation or interpretation before execution; or in some intermediate form such as partially compiled code. The precise forms of the program storage device, the encoding of instructions, and use of suitable controllers are immaterial here. Aspects of the invention may also be configured to perform the described functions under direction from a remote site (e.g. using conventional wireless telemetry links) (not shown).

Further, while the wellsite 10 of FIG. 1 has been shown and described as a land-based rig, it should be appreciated that embodiments described herein can also be used on offshore structures (e.g., platforms and rigs). Additionally, while a specific configuration of the surface portion 102, downhole portion 104, and surface communication system 132 of the wellsite 10 shown in FIGS. 1 and 2 has been disclosed and described, many variations are possible while still complying with the principles disclosed herein. For example, the wellsite 10 may have a drill string 112 of one or more wired drill pipes, and one or more surface units 134, networks 138, and/or offsite computers 140. The downhole tool 106 is depicted as a drilling tool deployed into the wellbore by a drill string 112. However, it will be appreciated that the downhole tool 106 may be a drilling or other downhole tool (e.g., sources/sensors, motors, LWD/MWD tools, repeaters, etc.), and the drill string may be any tool string usable therewith, while still complying with the principles disclosed herein.

While preferred embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of the invention. For example, the relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.

	Number	Date	Country
	61594719	Feb 2012	US
	61684559	Aug 2012	US

Wellsite Communication System and Method

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CPC

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CROSS-REFERENCE TO RELATED APPLICATIONS

Provisional Applications (2)