BACKGROUND

[0001] Embodiments of the present disclosure generally relate to equipment and methods for coupling one or more tools to a top drive. The coupling may transfer both axial load and torque bi-directionally from the top drive to the one or more tools.

[0002] A wellbore is formed to access hydrocarbon-bearing formations {e.g., crude oil and/or natural gas) or for geothermal power generation by the use of drilling. Drilling is accomplished by utilizing a drill bit that is mounted on the end of a tool string. To drill within the wellbore to a predetermined depth, the tool string is often rotated by a top drive on a drilling rig. After drilling to a predetermined depth, the tool string and drill bit are removed, and a string of casing is lowered into the wellbore. Well construction and completion operations may then be conducted.

[0003] During drilling and well construction/completion, various tools are used which have to be attached to the top drive. The process of changing tools is very time consuming and dangerous, requiring personnel to work at heights. The attachments between the tools and the top drive typically include mechanical, electrical, optical, hydraulic, and/or pneumatic connections, conveying torque, load, data, signals, and/or power.

[0004] Typically, sections of a tool string are connected together with threaded connections. Such threaded connections are capable of transferring load. Right- hand (RH) threaded connections are also capable of transferring RH torque. However, application of left-hand (LH) torque to a tool string with RH threaded connections (and vice versa) risks breaking the string. Methods have been employed to obtain bi-directional torque holding capabilities for connections. Some examples of these bi-directional setting devices include thread locking mechanisms for saver subs, hydraulic locking rings, set screws, jam nuts, lock washers, keys, cross/thru-bolting, lock wires, clutches and thread locking compounds. However, these solutions have shortcomings. For example, many of the methods used to obtain bi-directional torque capabilities are limited by friction between component surfaces or compounds that typically result in a relative low torque resistant connection. Locking rings may provide only limited torque resistance, and it may be difficult to fully monitor any problem due to limited accessibility and location. For applications that require high bi-directional torque capabilities, only positive locking methods such as keys, clutches or cross/through-bolting are typically effective. Further, some high bi-directional torque connections require both turning and milling operations to manufacture, which increase the cost of the connection over just a turning operation required to manufacture a simple male-to-female threaded connection. Some high bidirectional torque connections also require significant additional components as compared to a simple male-to-female threaded connection, which adds to the cost.

[0005] There is, therefore, a need for a coupler to capable of addressing at least one of the problems described above.

SUMMARY OF THE DISCLOSURE

[0006] The present disclosure generally relates to equipment and methods for coupling a top drive to one or more tools. The coupling may transfer both axial load and torque bi-directionally from the top drive to the one or more tools.

[0007] In an embodiment, a tool coupler includes a first component having a shaft and a plurality of locking members; a second component having an inner housing for receiving the shaft and a plurality of complementary locking member; and an outer housing configured to rotationally lock the first component to the second component.

[0008] In an embodiment, a method of coupling a first component to a second component includes inserting a central shaft of the first component into an inner housing of the second component; rotating the first component relative to the second component to cause a plurality of locking members of the first component to engage a plurality of complementary locking members of the second component; and axially moving an outer housing of the second component relative to the inner housing to rotationally lock the first component relative to the second component.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments.

[0010] Figure 1 illustrates a drilling system, according to embodiments of the present disclosure.

[0011] Figure 2 illustrates an exemplary tool coupler for a top drive system according to embodiments described herein.

[0012] Figure 3 illustrates an exemplary tool adapter of the tool coupler of Figure 2.

[0013] Figure 4 is a cross-sectional view of an exemplary tool receiver of the tool coupler of Figure 2.

[0014] Figure 5 illustrates the tool coupler of Figure 2 without showing the inner housing.

[0015] Figure 6 illustrates one step of a multi-stop process for coupling the receiver assembly to the tool adapter of the tool coupler.

[0016] Figure 7 illustrates another step of a multi-stop process for coupling the receiver assembly to the tool adapter of the tool coupler.

[0017] Figure 8 illustrates another step of a multi-stop process for coupling the receiver assembly to the tool adapter of the tool coupler. [0018] Figure 9 illustrates another step of a multi-stop process for coupling the receiver assembly to the tool adapter of the tool coupler.

[0019] Figure 10 illustrates another view of the tool coupler of Figure 2 without showing the inner housing.

DETAILED DESCRIPTION

[0020] The present disclosure provides equipment and methods for coupling a top drive to one or more tools. In one embodiment, a tool coupler is used to couple a tool to the top drive. The tool coupler may transfer torque bi-directionally from the top drive to the one or more tools. The tool coupler may provide mechanical, electrical, optical, hydraulic, and/or pneumatic connections. The tool coupler may convey torque, load, data, signals, and/or power, tool coupler

[0021] Some of the many benefits provided by embodiments of this disclosure include a tool coupler having a simple mechanism that is low maintenance. Benefits also include a reliable method to transfer full bi-directional torque, thereby reducing the risk of accidental breakout of threaded connections along the tool string. Embodiments may also provide automatic connection for power and data communications.

[0022] Figure 1 illustrates a drilling system 1 , according to embodiments of the present disclosure. The drilling system 1 may include a drilling rig derrick 3d on a drilling rig floor 3f. As illustrated, drilling rig floor 3f is at the surface of a subsurface formation 7, but the drilling system 1 may also be an offshore drilling unit, having a platform or subsea wellhead in place of or in addition to rig floor 3f. The derrick may support a hoist 5, thereby supporting a top drive 4. In some embodiments, the hoist 5 may be connected to the top drive 4 by threaded couplings. The top drive 4 may be used to handle a tool string 2. At various times, the top drive 4 may support the axial load of the tool string 2. The rig floor 3f may have an opening through which the tool string 2 extends downwardly into a wellbore 9. At various times, the rig floor 3f may support the axial load of tool string 2. The top drive 4 may include a drive unit to provide torque to the tool string 2, for example to operate a drilling bit near the bottom of the wellbore 9. The tool string 2 may include joints of drill pipe connected together, such as by threaded couplings.

[0023] At various times, the top drive 4 may provide right hand (RH) or left hand (LH) torque to tool string 2, for example to make up or break out joints of drill pipe. Power and/or signals may be communicated between the top drive 4 and the tool string 2. For example, pneumatic, hydraulic, electrical, optical, or other power and/or signals may be communicated between top drive 4 and tool string 2.

[0024] Figure 2 illustrates a tool coupler 100 for use with a top drive system (e.g., top drive 4 in Figure 1 ) according to one embodiment. The tool coupler 100 is used to facilitate the connection of a tool 1 1 to the top drive 4. In some embodiments, the tool coupler is a multi-coupler for supporting load, transferring torque, and having couplings to transfer power, including hydraulic, electric, data, and/or pneumatic. In one embodiment, the tool coupler 100 includes a receiver assembly 1 10 and a tool adapter 150. The receiver assembly 1 10 is coupled to the top drive 4, and the tool adapter 150 is coupled to the tool. The tool adapter 150 is engageable with the receiver assembly 1 10 to connect the tool to the top drive 4.

[0025] Figure 3 illustrates an exemplary embodiment of a tool adapter 150. The tool adapter 150 includes a base 155, a central shaft 160 extending from the base 155, and a plurality of locking members 165 disposed on the shaft 160. The bottom of the base 155 may be connected to the tool via a threaded connection or may be integrated with the tool. A shaft stand 166 is optionally provided on the bottom of the shaft 160.

[0026] In one embodiment, the plurality of locking members 165 is disposed circumferentially around the shaft 160. Figure 3 shows two rows 161 , 162 of locking members 165 disposed around the shaft 160. In this embodiment, the locking members 165 on the top row 161 are aligned axially with the locking members 165 on the bottom row 162. An axial groove 153 is formed between adjacent locking members 165 on each row 161 , 162. A first circumferential groove 151 is formed between the first row 161 and the second row 162, and a second circumferential groove 152 is formed between the second row 162 and the shaft stand 166. While six locking members 165 are shown in each row 161 162, it is contemplated that two, three, four, five, seven, eight, or more locking members 165 may be used. In one embodiment, each row 161 , 162 may have between two and twelve locking members, between two and eight locking members, or between four and six locking members. In one embodiment, the tool adapter 150 may have between one and four rows of locking members 165, between one and three rows of locking members, or between one and two rows of locking members. In this embodiment, the locking members 165 are locking keys protruding radially from the shaft. In one embodiment, the locking members 165 are square shaped keys. It is contemplated that the locking members 165 may be configured with any suitable shape, such as rectangles and trapezoids.

[0027] The base 155 has a larger diameter than the shaft stand 166 and/or the outer perimeter of the locking members 165. One or more couplings 170 are disposed near the perimeter of the base 155. The couplings 170 are configured to transfer data and/or power, including hydraulic, electric, pneumatic, and combinations thereof. In one example, the coupling 170 is a tube extending upward from the base 155, and the bore in the tube is configured to communicate power and/or data. The coupling 170 is insertable into a channel in the receiver assembly 1 10.

[0028] Referring back to Figure 2, the receiver assembly 1 10 generally includes an inner housing 120, an outer housing 130, an actuator 1 12 for moving the outer housing 130 axially relative to the inner housing 120. An optional swivel connector 168 is provided to transfer hydraulics, pneumatics, and/or electronics from the top drive 4 to the tool and from the tool to the top drive 4.

[0029] Figure 4 illustrates a cross-sectional view of the tool coupler 100. As shown, the tool adapter 150 has engaged with the receiver assembly 1 10. The inner housing 120 is tubular shaped and is integrated with or attached to a shaft 20 extending from the top drive 4. The inner housing 120 has an opening for receiving the shaft 160 of the tool adapter 150. Figure 6 shows a partial view of the opening of the inner housing 120. A plurality of complementary locking members 185 are circumferentially disposed in the opening for mating with the locking members 165 of the tool adapter 150. Figures 4 and 5 show two rows 181 , 182 of complementary locking members 185. In this embodiment, the complementary locking members 185 on the top row 181 are aligned axially with the complementary locking members 185 on the bottom row 182. An axial groove 183 is formed between adjacent complementary locking members 185 on each row 181 , 182. The complementary locking members 185 are sized to move axially in the axial groove 153 between the locking members 165 of the shaft 160. The top row 181 of complementary locking members 185 is sized to fit in the first circumferential groove 151 formed between the first row 161 of locking members 165 and the second row 162 of locking members 165. Similarly, the bottom row 182 of complementary locking members 185 is sized to fit in the second circumferential groove 152 formed between the second row 162 of locking members 165 and the shaft stand 166. In this embodiment, six complementary locking members 185 are shown in each row 181 182 to complement the locking members 165 of the shaft 160. It is contemplated the inner housing 120 may have any suitable number of complementary locking members 185, such as two, three, four, five, seven, eight, or more complementary locking members 185, to mate with the locking members 165 of the shaft 160. In this embodiment, the locking members 165 are square shaped keys. It is contemplated that the locking members 165 may be configured with any suitable shape, such as rectangles and trapezoids. In one example, the locking members 165 include an angled top surface, an angled bottom surface, or both. The complementary locking members 185 include an complementary angled top and/or bottom surface for engaging the respective angled top and/or bottom surface of the locking members 165. The complementary angled surfaces may act as a stop against relative rotation between the shaft 160 and the inner housing 120.

[0030] The outer housing 130 is disposed around the exterior of the inner housing 120. The outer housing 130 is axially movable relative to the inner housing 120. The outer wall 132 of the outer housing includes one or more channels for receiving a coupling 170 of the shaft 160. The channels provide communication between the coupling 170 and the swivel connector 168. [0031] The outer housing 130 includes a plurality of inner beams 136 for engaging the locking members 165 of the shaft 160. Figure 5 shows the outer housing 130 with the inner housing 120 removed for clarity. The beams 136 are circumferentially spaced and configured to fit in the axial groove 161 between the locking members 165 and in the groove between the complementary locking members 185. The beams 136 are radially spaced from the outer wall 132 such that the inner housing 120 is disposed in an annular area therebetween. As shown Figure 7, the beams 136 are inserted through a portion of the inner housing 120.

[0032] In operation, the tool coupler 100 is used to connect a tool to a top drive 4. Exemplary tools include tubular gripping tools configured to grip an inner surface or an outer surface of the tubular, fill up tool, compensation tool, cementing tool, and elevators. The tool adapter 150 is integrated with or connected to the tool. The tool receiver 1 10 is coupled to or integrated with the shaft of the top drive 4. Referring to Figure 6, the tool receiver 1 10 is ready to receive the shaft 160 of the tool adapter 150. The outer housing 130 is in an upward position relative to the inner housing, and the beams 136 are located above the first row of the complementary locking members 185.

[0033] Before inserting the tool adapter 150, the axial grooves 153 of the shaft 160 are axially aligned with the complementary locking members 185 of the inner housing 120. The shaft 160 is inserted into the opening of the inner housing 120 until the base of the shaft 160 contacts the bottom of the inner housing 120. In this position, as shown in Figure 7, the top row 181 of complementary locking members 185 is aligned with the first circumferential groove 151 formed between the first row 161 of locking members 165 and the second row 162 of locking members 165. Also, the bottom row 182 of complementary locking members 185 is aligned with the second circumferential groove 152 formed between the second row 162 of locking members 165 and the shaft stand 166.

[0034] The tool adapter 150 is rotated until the axial grooves 153 of the shaft 160 are aligned with the axial grooves between the complementary locking members 185. In one example, the tool adapter 150 is rotated about 30 degrees. In another example, the locking members 165, 185 have angled surfaces that act as wedges to stop rotation of the shaft 160 relative to the inner housing 120. In this position, the top row 181 of complementary locking members 185 is located between the first row 161 of locking members 165 and the second row 162 of locking members 165, as shown in Figure 4. Also, the bottom row 182 of complementary locking members 185 is located between the second row 162 of locking members 165 and the shaft stand 166. As a result, the shaft 160 locked from relative axial movement with respect to the tool receiver 1 10. In this respect, axial load from the tool and components attached thereto is supported by the tool receiver 130 and the top drive 4.

[0035] After stopping rotation of the shaft 160, the outer housing 130 is moved axially downward relative to the inner housing 120, as shown in Figure 8. Downward movement of the outer housing 130 also moves the beams 136 downward in the grooves 153 between the locking members 165. Figure 10 shows the outer housing 130 after moving downward and the inner housing 120 removed for clarity. It can be seen that the beams 136 are located between the locking members 165, and the bottom of the beams 136 on the shaft stand. In this position, the shaft 160 is locked from relative rotation with respect to the tool receiver 1 10. As a result, torque may be transferred between the top drive 4 and the tool.

[0036] In Figures 10 and 4, it can also be seen that the couplings 170 have been inserted into a respective channel 132 in the outer housing 130. This connection allows communication of power and/or data between the top drive and the tool. For example, the hydraulic fluid, pneumatic fluid, or electric power can be supplied from the top drive to the tool for operation.

[0037] In one embodiment, an actuator is used to move the outer housing 130 downward relative to the inner housing 120 and the shaft 160. In one example, the actuator is a piston and cylinder assembly 1 12, as shown in Figure 2. The piston and cylinder assembly 1 12 is positioned proximate the lower end of the tool coupler 100 and couples the lower end of the inner housing 120 and the lower end of the outer housing 130. Actuation of the piston and cylinder assembly moves the outer housing 130 axially relative to the inner housing 120. In another example, the actuator is a piston and cylinder assembly that couples the swivel 168 to the top drive. In this example, actuation of the piston moves the swivel 168 and the outer housing 130 axially relative to the top drive 4, and therefore, the inner housing 120. In another example, the actuator is a piston and cylinder assembly that couples an upper end of the inner housing 120 to an upper end of the outer housing 130. In one example, the piston and cylinder assembly is at least partially disposed in the annular area between the inner beams 136 and the outer wall 132 of the outer housing 130.

[0038] In another embodiment, the shaft 160 of the tool adapter 150 is configured to sealingly engage the inner housing 120 of the tool receiver 1 10. For example, the upper portion of the shaft 160 includes a groove for retaining a sealing member such as an o-ring. The sealing member engages the inner housing 120 when the shaft 160 is inserted into engagement with the inner housing 120. In another example, the upper portion of the shaft 160 is configured to form a metal-to-metal seal with the inner housing 120.

[0039] In another embodiment, the outer housing 130 is coupled to the base 155 of the shaft 160 using castellations. For example, the lower end of the outer housing 130 has castellations that mate with complementary castellations on the base 155. When lowered, the castellations of the outer housing 130 engage the castellations of the base 155, thereby preventing relative rotation between the outer housing 130 and the base 155. In this embodiment, the inner beams 136 become optional due to the tool receiver 1 10.

[0040] It should be understood that the components of the tool coupler 100 described herein can be usefully implemented in reverse configurations. For example, the tool adapter 150 is connected to the top drive 4, and the tool receiver 1 10 is connected to the tool. In another example, the tool receiver includes the shaft and the outer housing, and the tool adapter includes the inner housing.

[0041] Optionally, a locking mechanism may be used to lock the tool adapter 150 to the tool receiver 1 10. The locking mechanism can remain locked while the tool coupler 100 conveys axial load, rotational load, or both. Decoupling may only occur when tool coupler 100 is not carrying load. In one example, the actuator 1 12 may be self-locking (e.g. , electronic interlock or hydraulic interlock). Alternatively, a locking pin may be used.

[0042] It should be appreciated that, for tool coupler 100, a variety of configurations, sensors, actuators, and/or adapters types and/or configurations may be considered to accommodate manufacturing and operational conditions. Possible actuators include, for example, worm drives, hydraulic cylinders, compensation cylinders, etc. The actuators may be hydraulically, pneumatically, electrically, and/or manually controlled. In some embodiments, multiple control mechanism may be utilized to provide redundancy. One or more sensors may be used to monitor relative positions of the components of the top drive system. The sensors may be position sensors, rotation sensors, pressure sensors, optical sensors, magnetic sensors, etc. In some embodiments, stop surfaces may be used in conjunction with or in lieu of sensors to identify when components are appropriately positioned and/or oriented. Likewise, optical guides may be utilized to identify or confirm when components are appropriately positioned and/or oriented. In some embodiments, guide elements (e.g., pins and holes, chamfers, etc.) may assist in aligning and/or orienting the components of tool coupler 100. Bearings and seals may be disposed between components to provide support, cushioning, rotational freedom, and/or fluid management.

[0043] In an embodiment, a tool coupler includes a first component having a shaft and a plurality of locking members; a second component having an inner housing for receiving the shaft and a plurality of complementary locking member; and an outer housing configured to rotationally lock the first component to the second component.

[0044] In one or more embodiments disclosed herein, the outer housing includes a locking beam configured to engage with the plurality of locking members to rotationally lock the first component. [0045] In one or more embodiments disclosed herein, the outer housing is axially movable relative to the inner housing.

[0046] In one or more embodiments disclosed herein, the locking beam is at least partially inserted through the inner housing.

[0047] In one or more embodiments disclosed herein, the tool coupler includes an actuator for moving the outer housing axially relative to the inner housing.

[0048] In one or more embodiments disclosed herein, the tool coupler includes a swivel in communication with the outer housing.

[0049] In one or more embodiments disclosed herein, the outer housing includes a channel for communication with the swivel.

[0050] In one or more embodiments disclosed herein, the first component includes a coupling for transmitting at least one of power and data.

[0051] In one or more embodiments disclosed herein, the outer housing includes a channel for communication with the coupling.

[0052] In one or more embodiments disclosed herein, the channel is formed in an outer wall of the outer housing.

[0053] In one or more embodiments disclosed herein, the coupling is insertable into the channel.

[0054] In one or more embodiments disclosed herein, the shaft sealingly engages the inner housing.

[0055] In an embodiment, a method of coupling a first component to a second component includes inserting a central shaft of the first component into an inner housing of the second component; rotating the first component relative to the second component to cause a plurality of locking members of the first component to engage a plurality of complementary locking members of the second component; and axially moving an outer housing of the second component relative to the inner housing to rotationally lock the first component relative to the second component.

[0056] In one or more embodiments disclosed herein, axially moving the outer housing comprises axially moving a locking beam into engagement with the plurality of locking members of the first component.

[0057] In one or more embodiments disclosed herein, the locking beam is moved into a groove between the plurality of locking members.

[0058] In one or more embodiments disclosed herein, rotating the first component axially aligns the plurality of locking members of the first component with the plurality of complementary locking members of the second component, thereby axially locking the first component to the second component.

[0059] In one or more embodiments disclosed herein, the method includes placing a coupling of the first component into communication with a channel in the second component.

[0060] In one or more embodiments disclosed herein, axially moving the outer housing relative to the inner housing places the coupling into communication with the channel.

[0061] In one or more embodiments disclosed herein, the method includes communicating at least one of power and data between the channel and the coupling.

[0062] While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.