Patent Publication Number: US-9428983-B2

Title: Top entry wireline apparatus and methods

Description:
PRIORITY 
     The present application claims priority to and the benefit of the filing date of U.S. Patent Application No. 61/846,125, titled “Top Entry Wireline Apparatus and Methods”, filed Jul. 15, 2013, which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The disclosure is directed to a top entry wireline apparatus for inserting and manipulating a wireline, along with methods of using such top entry wireline apparatus. 
     BACKGROUND OF THE DISCLOSURE 
     Top drive systems are used to rotate a drill string made up of tubulars within a wellbore. In many drilling operations, drilling operators need to lower equipment or measurement devices into the well for purposes of well intervention, reservoir evaluation and pipe recovery. In order to accomplish this, operators drop a series of electrical conduits, typically referred to as wirelines, through the top drive system and into the wellbore. The wireline provides power to equipment located at the end of the conduit and provides a pathway for electrical communication between the surface and the equipment at the end of the conduit adjacent the bottom of the wellbore. 
     Typically, a top entry wireline apparatus is attached to the top drive system to facilitate the entry of the wireline into the wellbore. However, stringing in the wireline from above the top drive can be dangerous if the system used is inadequate to support the weight of the wireline or if it is unable to adapt to the turns and twists of the drilling tubes as drilling operations continue. 
     Top entry wireline apparatuses generally consist of sheave and pulley systems. These systems are large and bulky, however, and if a component of the system breaks, the entire apparatus typically must be taken apart and repaired. Thus, the present disclosure seeks to eliminate these disadvantages by providing a unique structural arrangement for the apparatus that is compact, can be universally adapted to a variety of top drive systems, and can be repaired without disassembly of the top drive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present disclosure is best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion. 
         FIG. 1  is an elevation view of a top drive drilling rig with a top entry wireline apparatus installed thereon according to one or more aspects of the present disclosure. 
         FIG. 2  is a perspective view of the top entry wireline apparatus with pack-off body installed thereon according to one or more aspects of the present disclosure. 
         FIG. 3  is a perspective view of the top entry wireline apparatus without the pack-off body installed thereon according to one or more aspects of the present disclosure. 
         FIG. 4  is a perspective view of the top entry wireline apparatus without the pack-off body installed thereon according to one or more aspects of the present disclosure. 
         FIG. 5  is an exploded view of a roller chain housing assembly of the top entry wireline apparatus according to one or more aspects of the present disclosure. 
         FIG. 6  is a side view of the roller chain housing assembly according to one or more aspects of the present disclosure. 
         FIG. 7  is a perspective view of the roller chain housing assembly according to one or more aspects of the present disclosure. 
         FIG. 8  is a cross-section of the roller chain housing assembly along the line  8 - 8  shown in  FIG. 7  according to one or more aspects of the present disclosure. 
         FIG. 9  is a perspective view of a cross-section of a roller body of the roller chain housing assembly along the cross-section  10 - 10  shown in  FIG. 7  according to one or more aspects of the present disclosure. 
         FIG. 10  is a cross-section of the roller body coupled with a bearing pin having a lubrication channel along the cross-section  10 - 10  shown in  FIG. 7  according to one or more aspects of the present disclosure. 
         FIG. 11  is a representation of the bearing pin according to one or more aspects of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     It is to be understood that the following disclosure provides many different embodiments, or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. 
     The present disclosure provides for an apparatus and method for inserting and manipulating a wireline into a wellbore through a top drive unit. Because of its structural arrangement, the apparatus, which in some aspects is a top entry wireline apparatus, may be arranged to accomplish its desired functions while maintaining a lower profile than conventional systems. Because of its lower profile, the top entry wireline apparatus may be introduced onto various rigs, even being compatible with rigs by different manufacturers. In some aspects, the top entry wireline apparatus employs a plurality of roller chains to achieve a low profile. The low profile may enable the top entry wireline apparatus to fit between rig components, such as, for example only, between a top drive unit and suspension components carrying the top drive unit. The plurality of roller chains guide a wireline from a location laterally spaced from a well-center to a location above the well-center, so that the wireline may run downward into the drill string. Some aspects also include a separable portion, such as an assembly door, that may enable easier feeding of the wireline into the top entry wireline apparatus than conventional systems. This may reduce set-up time, thereby decreasing overall costs. A downhole tool may be attached to the wireline. 
     Referring to  FIG. 1 , an overview of the overall drilling system is illustrated demonstrating one or more aspects of the present disclosure. A wireline supply  12  is rigged up for operation in a land-based drilling rig  14 . One or more aspects of the present disclosure, however, are readily adaptable to any type of drilling rig, such as jack-up rigs, semisubmersibles, drill ships, coil tubing rigs, well service rigs adapted for drilling and/or re-entry operations, and casing drilling rigs, among others within the scope of the present disclosure. Drill pipe  16  may be rotated by top drive unit  18 . A wireline  20  is fed into the distal portion of top entry wireline apparatus  10 , such as via a hinged door  48  ( FIG. 2 ). The top entry wireline apparatus  10  is mounted above top drive unit  18 . 
       FIG. 2  shows a perspective view of the top entry wireline apparatus  10  connected to additional components that make up a part of the drilling rig  14  in  FIG. 1 . The top entry wireline apparatus  10  includes an S-shaped roller chain housing assembly  50  that includes proximal and distal portions,  52  and  54 , respectively, relative to an associated top drive unit or one or more operably connected components. In the example in  FIG. 2 , the proximal portion  52  of the roller chain housing assembly  50  is operably coupled to a T-shaped connector or gooseneck assembly  42 , and in some embodiments additionally with a pack-off body  22 . This may be connected to roller chain housing assembly  50  in any manner, including, for example, a threaded engagement, a bolted engagement, a weld, and may be sealed or not sealed. The pack-off body  22  is designed to provide a seal between the wireline  20  and debris that may come out of the top drive unit  18  during drilling operations. As such, the pack-off body  22  may include a wiper or other components that help maintain the wireline. Standard pack-offs with standard pack-off elements will typically seal with a stationary 7.94×10−3 m ( 5/16 inch) wireline at about (3.4×107 to 7.9×107 Pa) (5,000 to 10,000 psi), depending on the condition of the wireline; i.e., if the wireline is packed or covered with grease or well-oiled, then the seal pressure may be higher. A mounting bracket  26  may operably couple the top entry wireline apparatus  10  to the T-shaped connector  42 . 
     The pack-off body  22  when present mates with a T-shaped connector  42 , which in turn mates with a flange  24  to operably couple the top entry wireline apparatus  10  to the top drive unit  18 . In certain embodiments, the flange  24  is welded, clamped or threadably secured as with bolts or pins, to the T-shaped connector  42 , however, one or more aspects of the present disclosure are readily adaptable to any type of connection as deemed necessary by one of ordinary skill in the art. The flange  24  may be operably coupled directly to a portion of the top drive unit  18  ( FIG. 1 ) or to a bonnet  46 , which is configured to cover or mate with a portion the top drive unit  18 , thereby operably coupling the top entry wireline apparatus  10  to the top drive unit  18 . In certain embodiments, the flange  24  is welded, clamped or threadably secured to the bonnet  46  as with bolts or pins, however, one or more aspects of the present disclosure are readily adaptable to any type of connection as deemed necessary by one of ordinary skill in the art. 
       FIG. 3  shows a perspective of the top entry wireline apparatus  10  without the pack-off body  22 , according to another embodiment. In this embodiment, the roller chain housing assembly  50  couples with the T-shaped connector  42 . The T-shaped connector  42  is coupled to the flange  24 . The flange  24  is operably coupled to the bonnet  46  in the depicted embodiment, which is configured to cover or mate with a portion of the top drive unit  18 , thereby operably coupling the top entry wireline apparatus to the top drive unit  18 . 
     The exemplary top entry wireline apparatus  10  of  FIGS. 2 and 3  further includes a turnbuckle assembly  28  operably coupled to the apparatus  10  at the distal portion  54  of the roller chain housing assembly  50 , which may be via a latch  30  on the distal portion  54  of the roller chain housing assembly  50 , the latch  30  being operably configured to mate with a forked end  68  of the turnbuckle assembly  28  and secured with a nut-and-bolt assembly  32 . However, one or more aspects of the present disclosure are readily adaptable to any type of connection as deemed necessary by one of ordinary skill in the art. The turnbuckle assembly  28  is further coupled to a mudline clamp  34 , whereby a forked end  70  of the turnbuckle assembly  28  is mated with a latch  72  on the adjacent end of the mudline clamp  34 , such as via a nut-and-bolt assembly  74 . However, one or more aspects of the present disclosure are readily adaptable to any type of connection as deemed necessary by one of ordinary skill in the art. In the example shown in  FIG. 4 , the mudline clamp  34  includes a rectangular piece of metal  36  with a circular throughway  38 . The circular throughway  38  is operably configured to receive a pipe  40 . In certain embodiments, the pipe  40  ( FIGS. 2 and 3 ) feeds mud down to the wellbore via the top drive unit  18 . The T-shaped connector  42  of the top entry wireline apparatus  10  is operably configured to receive the terminal end of the pipe  40  at a connection point  44 . 
     Referring now to  FIG. 5 , a partially exploded view of the roller chain housing assembly  50  is shown and includes a receiving side wall  80  and a roller side wall  82 . Here, the roller side wall  82  carries a first roller chain  76 , a second roller chain  78 , a plurality of spacer bolts  60 , and a hinged door  48 . Conventional systems have typically included pulley and sheave systems in place of the roller chains described herein. Using a system of rollers, such as arranged in first and second roller chains  76 ,  78  as depicted, reduces the axial space requirements of the top entry wireline apparatus  10 . This is important due to the limited axial space often available between the top drive unit  18  and other drilling rig equipment, such as drilling blocks and hooks. 
     The first roller chain  76  and the second roller chain  78  include a plurality of roller bodies  56 , which may be secured to the roller side wall  82  with a plurality of bearing pins  64 .  FIG. 10  shows a cross-section of a roller body  56  with a bearing pin  64 , and  FIG. 11  shows a representation of one of the bearing pins  64 . As shown in  FIG. 10 , one bearing pin  64  of the plurality of bearing pins  64  traverses one roller body  56  of the plurality of roller bodies  56 . Each bearing pin of the plurality of bearing pins  64  includes a pin head  98  and an opening  84  ( FIG. 10 ), which leads to a lubrication channel  96  ( FIG. 10 ) extending between the pin head  98  and the opening  84 . The lubrication channel  96  may traverse approximately half of the bearing pin  64  as shown in  FIG. 10 , and may be pressurized with lubrication oil or grease to help maintain the lubrication of the wireline  20  as it is guided through roller chain housing assembly  50 . 
     In this embodiment, each roller includes bearings  95  and one-way seals  97 . Using the pin head  98 , which may also be a grease nipple, an operator may inject grease through the lubrication channel  96  and into the cavity of the roller body  56 . Injected grease may be forced to flow through and lubricate the bearings  95 . Additional grease may cause grease to flow out of the one-way seals  97 . Accordingly, an operator may visually see grease flowing from the seal of the roller body  56  and conclude that the bearings are sufficiently lubricated. In addition, the one-way seals  97  prevent the ingress of contaminating elements, such as dirt, water, or other contaminants, into the bearings. 
     In certain embodiments, the first roller chain  76  includes nine of the roller bodies  56  in a j-shaped convex arcuate configuration (viewed from the bottom of  FIG. 5 ), such as with eight of the roller bodies  56  located along the top side of the arc, and one roller body on the lower side of the arc. As such, the first roller chain  76  forms an arcuate shape about a point  81  located above the roller chain and above the receiving side wall  80  and the roller side wall  82 . One or more aspects of the present disclosure are readily adaptable to any number of roller bodies  56 . In some examples, each roller chain  76 ,  78  includes between about four to sixteen roller bodies. In other examples, each roller chain  76 ,  78  includes between about six to fourteen roller bodies. In some examples, the roller bodies are all uniform in size. In other examples, the roller bodies differ in size, depending upon the size of the wireline and design requirements of the top drive unit. In some embodiments, the roller bodies are primarily comprised of steel. In alternative embodiments, the roller bodies are primarily comprised of aluminum, plastic, or combinations thereof. In some embodiments, the top entry wireline apparatus includes a securement roller body  77  on the outer radius or lower side of the arc formed by the roller chain  76 . This securement roller body  77  is secured to the hinged door  48  instead of the roller side wall  82 . 
     In certain embodiments, the second roller chain  78  includes eight of the roller bodies  56  in a concave arcuate configuration, with the eight of the roller bodies  56  located along the lower side of the arc. As such, the second roller chain  78  forms an arcuate shape about a point  83  located below the second roller chain  78  and below the receiving side wall  80  and the roller side wall  82 . One or more aspects of the present disclosure are readily adaptable to any number of roller bodies  56 , for example, about four to sixteen roller bodies, or about six to fourteen roller bodies. As shown in  FIGS. 2, 3, 5, 7, 9, and 10 , each roller body in the plurality of roller bodies  56  includes a recess  58  about an outside circumference of each roller body located generally in the middle of the roller body  56  and being operably configured to guide the wireline  20  through the roller chain housing assembly  50 . In one or more aspects of the present disclosure, the recess  58  additionally retains the wireline  20  in close cooperation with one or more roller bodies  56 . In one or more aspects of the present disclosure, the circumference of the recess  58  is sized according to the size of the wireline  20  that is used. 
     In the exemplary embodiments shown, the hinged door  48  is located at the distal portion  54 , e.g., at the top of a distal end, of the roller chain housing assembly  50  and is configured to secure the securement roller body  77 . As can be seen, the securement roller body  77  is located distally along the arc in the first roller chain  76 . The hinged door  48  includes a hinge  92  and a handle  100  to facilitate the threading of the wireline  20  into the recesses  58  of the plurality of roller bodies  56 . In prior art systems using a pulley and sheave arrangement, threading the wireline onto the first pulley is a difficult and time-consuming operation. In the present disclosure, however, the handle  100  may be operated to open the hinged door  48 , exposing the recess  58  distally located first roller body  56  secured to the roller side wall  82 , enabling the wireline  20  to be easily fed into the recess  58 . When the door is closed, the recess  58  of the securement roller body  77  that is secured to the hinged door  48  also receives the wireline  20 , enabling efficient and easy threading of the wireline  20  through the entire roller chain housing assembly  50 . 
     Referring again to  FIG. 5 , the receiving side wall  80  connects to the roller chain side wall  82  via spacer bolts  60  that extend through one or both of the receiving side wall  80  and the roller chain side wall  82  and are secured via nuts  86 . Each of the nuts  86  is operably configured to receive one pin of the plurality of spacer bolts  60  associated with the roller side wall  82  to operably couple the receiving side wall  80  to the roller chain side wall  82 . In one or more aspects of the present disclosure, the number of the plurality of spacer bolts  60  and the plurality of nuts  86  can be customized depending on the size and operating requirements of the roller chain housing assembly. Although disclosed as being connected via spacer bolts  60  and nuts  86 , the receiving and roller chain side walls may be connected via any suitable type of connection. 
     The receiving side wall  80  further includes a plurality of roller holes  88  which are operably configured to receive the bearing pins  64 . As shown in  FIGS. 2, 3, 4, 6, and 7 , the bearing pins  64  may be secured in the roller holes  88  via a snap ring  90 , or any other connection one of ordinary skill in the art might deem appropriate. As such, the bearing pins include snap ring grooves formed on both ends. Because each bearing pin  64  is individually maintained, an operator easy access to the plurality of roller bodies  56 , enabling individual replacement and repair of the roller bodies as needed. 
     In use, an operator may feed a conduit, such as a wireline, through the top entry wireline apparatus  10  into the T-shaped connector  42 , through a top drive, and into a drill string being driven by the top drive. To do this, the operator may lead the wireline from a location such as the wireline supply  12  ( FIG. 1 ), up to the top entry wireline apparatus  10 . The operator may open the hinged door  48 , thereby separating the securement roller  77  from the first roller chain  76 . The wireline may then be introduced between the securement roller  77  and the first roller chain  76 . With the wireline disposed in place, the operator may close the hinged door to capture the wireline between the securement roller  77  and the first roller chain  76 . Then the wireline may be fed under the first roller chain and above the second roller chain to a location directly above well center. This may include arranging the wireline in the recesses formed in each of the rollers of the roller chains. The wireline may then be fed through the pack-off assembly, if present, and through the T-shaped connector  42 , and down through the top drive and through the drill pipe. 
     The disclosure encompasses wireline apparatus having a receiving side wall comprising a plurality of first roller holes; a roller side wall comprising a plurality of second roller holes; a first roller chain comprising a first plurality of roller bodies disposed to form an arcuate shape about a point above the receiving side wall and the roller side wall, the first plurality of roller bodies being connected between the roller side wall and the receiving side wall; a second roller chain comprising a second plurality of roller bodies disposed to form an arcuate shape about a point below the receiving side wall and the roller side wall, the second plurality of roller bodies being connected between the roller side wall and the receiving side wall; and a plurality of bearing pins each supporting one of the roller bodies of the first and second pan apparatus having a proximal portion adjacent a top drive unit and a distal portion, wherein the apparatus includes a receiving side wall and a roller side wall. In some aspects, the apparatus further includes a hinged door and a securement roller body, the securement roller body being carried by the hinged door and being disposed to cooperate with the first roller chain to capture a wireline therebetween. In some aspects, the first plurality of roller bodies comprises a recess formed therein operably configured to receive and guide a wireline. In some aspects, the recess is a circumferential recess. In some aspects, the receiving side wall and the roller side wall include a proximal end and a distal end, the first roller chain being disposed at the proximal end and the second roller chain being disposed at the distal end. In some aspects, the apparatus further includes a removable pack-off assembly operably coupled to the distal end of the receiving side wall and the roller side wall. In some aspects, the apparatus further includes a turnbuckle assembly, wherein said turnbuckle assembly is operably coupled to the distal portion of the apparatus. In some aspects, the apparatus further includes a mudline clamp, wherein said mudline clamp is operably coupled to the distal end of the turnbuckle assembly and configured to attach to a mudline on a drilling rig. In some aspects, the apparatus further comprises a t-shaped connector connecting the mudline clamp to a location below the distal portion of the receiving side wall and the roller side wall. In some aspects, the apparatus is operably configured to accept a conduit. In some aspects, the conduit can be wireline, slickline, coiled tubing, fiber optic cable, electrical conduit, or a combination thereof. In some aspects, the plurality of roller bodies are arranged to guide the conduit through the apparatus. In some aspects, each bearing pin of the plurality of bearing pins includes a lubrication channel. In some aspects, the lubrication channel traverses a central portion along part of the bearing pin. In some aspects, each roller of the first plurality of roller bodies comprises bearings and one-way seals. In some aspects, the one-way seals are arranged to permit passage of grease out of the respective roller body. In some aspects, the first roller chain and the second roller chain each include about four to fourteen roller bodies. In some aspects, the plurality of bearing pins are operably secured to the roller holes via a snap ring. 
     The present disclosure also introduces a wireline apparatus including a receiving side wall; a roller side wall; a first roller chain disposed between the receiving side wall and the roller side wall; a second roller chain disposed between the receiving side wall and the roller side wall, the first and the second roller chains together forming an S-shape for the direction of a wireline; and a securement roller body adjacent the first roller chain, the securement roller being displaceable between a first location securing a wireline between the first roller chain and the securement roller body and a second location allowing the wireline to be laterally introduced between or removed from between the first roller chain and the securement roller body. In some aspects, the apparatus further includes a hinged door, the securement roller body being carried by the hinged door between the first and second locations. In some aspects, the first roller chain further includes a first plurality of roller bodies disposed to form an arcuate shape about a point above the receiving side wall and the roller side wall. In some aspects, the second roller chain comprises a second plurality of roller bodies disposed to form an arcuate shape about a point below the receiving side wall and the roller side wall. In some aspects, the apparatus further includes a plurality of bearing pins supporting the first and second roller chains, the bearing pins being operably configured to extend through holes in the receiving side wall and the roller side wall. and the second roller chain includes about four to twelve of the plurality of the roller bodies. 
     The present disclosure also introduces a method including: securing a roller chain housing assembly apparatus to an upper portion of a top drive unit, wherein the apparatus is adapted to laterally guide a conduit to an aperture in the top drive unit under a first roller chain comprising a first plurality of roller bodies disposed to form an arcuate shape about a point above the first roller chain and over a second roller chain comprising a second plurality of roller bodies disposed to form an arcuate shape about a point below the second roller chain; running the conduit through the roller chain housing assembly apparatus and into the top drive unit aperture, wherein the top drive is operably coupled to a drill string; and introducing the conduit into a bore in the drill string. In some aspects, the method further includes opening a door to feed the conduit through the roller chain housing assembly apparatus and closing the door to capture the conduit against a portion of the first roller chain. In some aspects, the method further includes a securement roller on the door that is moveable with the door. In some aspects, the method further includes rotating the drill string with at least the top drive unit while the conduit is present in the drill string. In some aspects, the method further includes attaching a downhole tool to a portion of the conduit disposed in the drill string. 
     The foregoing outlines features of several embodiments so that a person of ordinary skill in the art may better understand the aspects of the present disclosure. Such features may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed herein. One of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. One of ordinary skill in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions and alterations herein without departing from the spirit and scope of the present disclosure. 
     The Abstract at the end of this disclosure is provided to comply with 37 C.F.R. §1.72(b) to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 
     Moreover, it is the express intention of the applicant not to invoke 35 U.S.C. §112(f) for any limitations of any of the claims herein, except for those in which the claim expressly uses the word “means” together with an associated function.