GB2513824A - Flow diverter cross-over sub - Google Patents

Abstract

A system and apparatus for transmitting a signal between different types of data transmission or telemetry systems within a drill string. A downhole data interface sub 200 includes a tubular body 230 comprising two ends 206 & 204 and defining a throughbore 210 extending between the two ends and a male electrical connection member 430 disposed within the throughbore, the member extending from an interior surface within the tubular body towards the center of the throughbore, Data transmission element 400 is disposed at one end of the sub and has a wire 410 that extends through the sidewall 233 of the sub body 230 to the electrical connector for receiving an electrical connection 430 on the end of male member 220.

Description

FLOW DIVERTER CROSS-OVER SUB

BACKGROUND OF THE INVENTION

Description of the Related Art

[00011 Well logging instruments are devices configured to move through a wellbore drilled through subsurface rock formations. The devices include one or more tools and other devices that measure various properties of the subsurface formations and/or perform certain mechanical acts on the formations. Such acts include drilling or percussively obtaining samples of the rock formations and withdrawing samples of connate fluid from the rock formations. Measurements of the properties of the rock formations may be recorded with respect to the instrument axial position (depth) within the wellbore and/or time of measurement that is correlated to depth as the instrument is moved along the wellbore. Such recording is referred to as "well logging." [0002] Well logging instruments can be conveyed along the wellbore by extending and withdrawing well logging instruments that are connected to the end of a drill pipe or similar threadably coupled pipe string. The well logging instruments may be positioned at the end of a drill pipe as part of a bottom hole assembly (BHA).

A wired drill pipe (WDP) system may be used along the drill string to transmit the well logging data from the wellbore to the surface. The use of WDP has provided increased signal telemetry speed for use with "measuring while drilling" (MWD) instruments and "logging while drilling" ("LWD") instruments over conventional MWD signal telemetry, which MWD typically is performed by mud pressure modulation or by very low frequency electromagnetic signal transmission. However, the well logging instruments and tools may utilize a different telemetry system than the WDP telemetry system, having different types of electrical connections. Moreover, the WDP system may have thread types and sizes that are different from that of a BHA.

At present, no acceptable solution exists to provide couple two different types of telemetry systems having different types of electrical connections together.

[0003] Therefore, to effectively use MWD and LWD instruments using telemetry systems different than the WDP telemetry systems, an apparatus, system, and method for coupling the two telemetry systems together is needed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] So that the manner in which the above-recited features of the present invention can be understood in detail, a more particular description of the invention, 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 invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

[0005] Figure 1 depicts a schematic representation of a downhole telemetry system in use on a drilling rig.

[0006] Figure 2 is a partial cross-sectional view of a downhole tool according to an embodiment of the present invention.

[0007] Figure 3 is a cross-sectional view of one end of the downhole tool shown in Figure 2 along lines 3-3.

[0008] Figure 4 is a cross-sectional view of the downhole tool shown in Figure 2.

[0009] Figure 5 is a partial cross-sectional view of one end of the downhole tool shown in Figure 2.

[0010] Figure 6 is a partial cross-sectional view of one end of the downhole tool shown in Figure 2.

[0011] Figure 7 is a cross-sectional view of a downhole tool according to an embodiment of the present invention.

[0012] Figure 8 is a cross-sectional view of a downhole tool according to an embodiment of the present invention.

[0013] Figure 9 is a cross-sectional view of a downhole tool according to an embodiment of the present invention connected to another downhole component forming an electrical connection therebetween.

[0014] Figure 10 is a cross-sectional view of a downhole tool according to an embodiment of the present invention.

[0015] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements disclosed in one embodiment may be beneficially utilized on other embodiments without specific recitation.

DETAILED DESCRIPTION

[0016] Embodiments of the invention generally provide systems, apparatus, and methods for transmitting a signal between different types of data transmission systems within a drill string. Embodiments of the invention also provide a downhole interface sub that connects two downhole components together that have different thread types or means of joining together, and forms an electrical connection between the two downhole components Embodiments of the invention may be used while drilling and for enabling signals to be transmitted along a drill string having various types of telemetry systems. Embodiments of the invention enable two different types of telemetry systems to communicate with each other and transmit power and/or data between the telemetry systems along a drill string.

[0017] In an embodiment, a downhole interface sub facilitates a mechanical and communication interface between a wired drill pipe (WDP) telemetry system and one or more wellbore tools. For example, the wellbore tool may be positioned in a drill string on which the wellbore tool may be deployed and/or in a bottom hole assembly (BHA) comprising one or more tools that measure a property of the wellbore and/or a formation about the wellbore. The wellbore tool may be a drilling and measurement (D&M) tool, and/or a formation evaluation tool (FE). The wellbore tool may also be a production logging tool, a wireline configurable tool (such as tools commonly conveyed on wireline) and/or a drilling tool. In an embodiment, the downhole interface sub functions as a cross-over sub having an internal flow diverter for use in downhole drilling applications utilizing WDP technology for transmission of data and/or commands to andlor from the welibore tool to a surface system or component above the downhole interface sub.

[0018] Figure 1 is a schematic representation of a downhole telemetry system in use on a drilling rig, such as a top drive or rotary table type drilling rig. A rotary table type of drilling rig is illustrated in Figure 1. A platform and derrick assembly 100 is positioned over a wellbore 105 penetrating a subsurface formation F. A drill string is suspended within the wellbore 105 and includes a drill bit 115 at its lower end.

The drill string 110 may be rotated by a rotary table 120, energized by means not shown, which engages a kelly 121 at the upper end of the drill string. The drill string is suspended from a hook 123, attached to a traveling block (not shown), through the kelly 121 and a rotary swivel 125 which permits rotation of the drill string relative to the hook. Other configurations known in the art for rotating the drill string may be used.

[0019] Drilling fluid 130, sometimes referred to as "mud", is stored in a pit 131 formed at the well site. A mud pump 133 delivers drilling fluid 130 to the interior of the drill string 110 via a port (not shown) in the swivel 125, inducing the drilling fluid to flow downwardly through the drill string 110 as indicated by directional arrow 102.

The drilling fluid subsequently exits the drill string 110 via ports in the drill bit 115, and then circulates upwardly through the region between the outside of the drill string and the wall of the wellbore 105, sometimes called the annulus, as indicated by direction arrows 104. In this manner, the drilling fluid lubricates the drill bit 115 and carries formation cuttings up to the surface as the drilling fluid is returned to the pit 131 for screening and recirculation.

[0020] The drill string 110 may utilize a wired drill pipe (WDP) telemetry system comprising a WDP assembly 112 wherein multiple WDP components 113 are interconnected as part of the drill string 110. The WDP assembly 112 may comprise WDP components 113 communicatively coupled together such that data and/or power may be transmitted across each component. For example, WDP may include a cable, either partially or fully embedded within the structure of the pipe, associated with each WDP component 113 that serves as a signal communication channel and possibly for electrical power delivery. The cable may be any type of cable capable of transmitting data, power, and/or signals, such as an electrically conductive wire, a coaxial cable, an optical fiber, or the like.

L0021] WDP typically includes a communication element, such as a data transmission element, electrically coupled to the signal communication channel to communicate signals between adjacent WDP components 113 when the WDP components 113 are coupled end to end as shown in Figure. 1. Data transmission elements may be located at each end of the WDP components 113 and are used to transmit a signal between WDP components 113. Some examples of data transmission elements include inductive couplers, non-toroidal inductive couplers, flux couplers, direct connect couplers, or any component for transmitting data and/or power across tool joints. In an embodiment, the WDP assembly 112 may be similar to the WDP assembly described in U.S. Patent No. 7,413,021, filed by Madhavan, et at, and assigned to the assignee of the present invention, or U.S. Patent No. 6,641,434 issued to Boyle et all., and assigned to the assignee of the present invention.

L0022] The drill string 110 further includes a bottom hole assembly (BHA) 117 disposed near an end of the drill string 110 and/or near the drill bit 115, if present.

The BHA 117 may include wellbore instruments for measuring, processing, and storing information, as well as for communicating with the surface. The wellbore instruments may comprise one or more tools, sensors, or other devices for obtaining measurements related to the drill string 110, the wellbore 105, and/or the formation F about the wellbore 105. The wellbore instruments may include well logging instruments as part of the BHA 117. The term "well logging instruments" or a string of such instruments may mean one or more well logging instruments that are capable of being conveyed through a wellbore 105 using logging while drilling ("LWD") tools, measure while drilling ("MWD") tools, formation evaluation tools, formation sampling tools, and/or other tools capable of measuring a characteristic of the formation. A communication signal from the BHA 117, such as from well logging instruments, may be received at the surface by a transducer 140, which is coupled to an uphole surface receiving system 142. The output of the uphole surface receiving system 142 may be in communication with a processor 146 and a recorder 144. The system may further include a transmitting system 148 for communicating with the downhole instruments.

[0023] As shown in Figure 1, the drill string 110 may have a portion that uses a WDF telemetry system along with other types of telemetry systems. For example, the drill string 110 may use a WDP telemetry system in combination with other types of wellbore tools, such as may be found in BHA 117, that have telemetry systems which use direct electrical connections to transmit signals, data, and/or commands between the wellbore tools along the drill string 110 or BHA 117. Thus, the BHA 117 may comprise a different type of telemetry system than the WDP system having a direct connect system for propagating signals along the BHA 117. For example, the well logging instruments of MWD or other tools in BHA 117 may transmit data and/or power via a series of interconnected electrical cables, while the WDP components 113 use data transmission elements and cables as previously described. Thus, the BHA 117 may utilize a telemetry system in which a signal transmission element is physically connected along the BHA 117 providing a direct electrical connection between the downhole components of the BHA 117 to transmit signals therebetween. On the other hand, the WDP telemetry system may use data transmission elements that may abut or be separated by some distance without a physical direct electrical connection to transmit signals along the WDP assembly 112 of the drill string 110. The WDP assembly 112 and BHA 117, and thus the WDP and BHA telemetry systems, may include various types of downhole components, such as drill pipe, drill collars, heavy weight drill pipe, saver subs, cross-over subs, and jars. The individual components, however, are configured to match the type of telemetry system employed, such as the WDP or BHA telemetry systems.

[0024] In order to transmit data, signals, and/or power between the two types of systems, a downhole interface sub 200 is positioned between and/or connected to the WDP assembly 112 and the BHA 117. The downhole interface sub 200 may be secured to the BHA 117 and a WDP component 113 of the WDP assembly 112.

The downhole interface sub 200 may have a communication element for providing communication between and/or electrically coupling with the WDP telemetry system on one end and the BHA telemetry system on the other.

[0025] Figure 2 is a partial cross-sectional perspective view of a downhole interface sub 200 for operatively coupling together two different types of telemetry systems. The downhole interface sub 200includes a tubular body 230 comprising two ends 204, 206. In an embodiment, one end of the downhole interface sub 200 may comprise a pin end tool joint 204 and the other end may comprise a box end tool joint 206. The pin end tool joint 204 may comprise external threads 203 that taper from a pin end primary shoulder 201 to a pin face 202. The pin face 202 may function as a secondary shoulder. The box end tool joint 206 may comprise internal threads 207 that taper from a box end primary shoulder 208 to a box shoulder 205 within the box end tool joint 206. A recessed groove 211 may be formed in the box shoulder 205 to house a data transmission element as will be shown in the Figures below.

[0026] Additionally, in some embodiments, one end of the downhole interface sub 200 may have a first type of thread for mating with a WDP assembly 112 and the other end may have a second type of thread different from the first type for mating with the BHA components. The threads 203, 207 may be different types or sizes depending on the type of downhole component and its desired use. For example, box end threads 207 may be one type of custom, proprietary, or API standard thread and pin end threads 203 may be another type of custom, proprietary, or API standard thread. In an embodiment of downhole interface sub 200, the ends 204, 206 may be the same end type, e.g. each end may be a pin end tool joint or a box end tool joint, an example of which is shown in Figure 10. The exact configuration of each end, including end type, thread type, and thread size, will depend on the type of adjacent component and telemetry system that is to be joined with the downhole interface sub 200.

[0027] The tubular body 230 also defines a centrally located throughbore 210 extending between the two ends 204, 206. The throughbore 210 serves as the intended passageway for drilling fluid (directional arrow 102) to flow through the tubular body 230 and thus through the drill string 110. A male member 220 is disposed within the throughbore 210 and includes an electrical connector 430 at its distal end for receiving an electrical connection. The male member 220 extends from an interior surface within the tubular body 230 and at least a portion of the male member 220 is completely surrounded by the throughbore. In an embodiment, the interior surface within the tubular body 230 is the interior surface 212 of tubular body 230. Thus, in some embodiments, the male member 220 may be integral with the tubular body 230.

[0028] The male member 220 extends towards the center of the throughbore 210, such as central axis 232 illustrated by the centrally located dashed lines in the box end 206 and pin end 204. Figure 3 is a cross-sectional view of one end of the downhole tool shown in Figure 2 along lines 3-3. A portion of the throughbore 210 thereby comprises an annulus 214 between the male member 220 and the tubular body 230, as shown in Figures 2 and 3. The annulus 214 may be concentric or non-concentric depending on the exact contiguration of the male member 220 and the tubular body 230. The male member 220 also functions as a flow diverter as fluid passes through the tubular body 230 via throughbore 210, yet with the annulus 214, it also minimizes the constriction of fluid flow through the throughbore 210. The male member 220 extends towards one of the two ends 204, 206 at least partially along a central axis 232 of the tubular body 230. For example, as shown in Figure 2, the male member 220 extends towards the pin end 204 along central axis 232.

The male member 220 may comprise a tubular housing 222 having a base end 224 connected to the interior surface 212 and a receiving end 226 at its distal end. The base end 224 may be integral with an interior surface 212 of the tubular body 230.

The integrated design of the male member 220 with the tubular body 230 may minimize the amount of servicing required.

[0029] At least a portion of the male member may be concentric with the tubular body 230. For example, a portion of the tubular housing 222 may be concentric with tubular body 230 as shown in Figure 3. The receiving end 226 extends towards one end of the tubular body, such as the pin end 204, but does not extend the entire distance to the end face. The receiving end 226 extends a distance 228 between the primary and secondary shoulders of an end. For example, the receiving end face 227 may be axially displaced from the primary shoulder 201 by a distance 228 as shown in Figure 5. The distance 228 is sized to achieve an acceptable stress in a custom, proprietary, or API standard threaded connection while drilling, such as connection 900 shown in Figure 9 between the downhole interface sub 200 and another downhole component, such as downhole tool 300. For example, the receiving end may extend to a location that is less than eighty percent of the axial distance from a primary shoulder to a secondary shoulder of a pin end.

Alternatively, the receiving end may extend to a location that is less than eighty percent of the axial distance from a secondary shoulder to a primary shoulder of a box end.

[0030] An acceptable amount of stress in a custom, proprietary, or API standard threaded connection may be determined by the bending strength or stiffness ratio (BSR) of the connection. The BSR is a ratio of the box to pin modulus and is used to measure how well "balanced" the mating pin and box rotary connections are in their ability to resist any bending moment while drilling. A balanced connection improves fatigue life of the components. Thus, the distance between the receiving end 226 and the adjacent end of the downhole interface sub 200, such as pin end 204, as well as the length of the annulus 214 created between the male member 220 and the tubular body 230, enables the use of the downhole interface sub 200 for drilling operations when those distances are computed to maintain proper BSRs.

Altering the distance between the receiving end 226 and the pin face 202 or the length of the annulus 214 along the central axis 232 may increase or decrease stiffness of the connection, thus changing the BRS of the connection between the downhole interface sub 200 and another downhole component. The mechanical integrity of the custom, proprietary, or API standard threaded connection may then be maintained without altering or degrading the mechanical performance of a pin and box threaded connection between the interface sub 200 and an adjacent downhole tool by forming an annulus 214 and by locating the receiving end face 227 at a position between the primary and secondary shoulders at an acceptable distance to maintain mechanical integrity during drilling operations. As a mere example, the receiving end face 227 may be positioned between the primary shoulder 201 of a pin end 204 but less than half way between the primary shoulder 201 and the secondary shoulder 202.

[0031] Figures 4-6 further illustrate the electrical coupling components housed in the downhole interface sub 200 for communicating between two different telemetry systems. Figure 4 shows a cross-sectional view of the downhole interface sub 200 shown in Figure 2. Figure 5 shows a partial cross-sectional view of the pin end 204 of the downhole interface sub 200 and Figure 6 shows a partial cross-sectional view of box end 206 of the downhole interface sub 200. A data transmission element 400 is disposed adjacent one end of the tubular body 230, such as box end 206. The data transmission element may be disposed in a recessed groove 211 formed, for example, in the box shoulder 205. The data transmission element 400 includes a wire 410 that extends from the data transmission element 400 through a passageway 420 formed within a sidewall 233 of the tubular body 230. The wire 410 is electrically coupled with an electrical connector 430 that is at least partially disposed within the receiving end 226 of male member 220. The electrical connector 430 may be locked into place with a jam nut (not shown) or other similar device. An anti-rotation/alignment pin 433 may prevent the electrical connector from rotating while drilling and aligns the electrical connector 430 within the receiving end 226 of the male member 220. A ground connection between the data transmission element 400 and the electrical connector 430 may be made via a small contact ring or spring 431 on the connector body 430 that touch the second passageway 426.

The data transmission element 400 established a ground contact in the recessed groove 211 and the contact ring or spring 431 are electrically coupled with the electrical connection in a way to pick up that ground signal.

[0032] The passageway 420 may include a series of passageways. For example, a first passage way 422 may extend axially within the sidewall 233 from recessed groove 211 and a second passageway 426 may extend axially within the male member 220. An angled passageway 424 intersects the first passageway 422 and second passageway 426 and extends through the sidewall 233 and into the base end 224 of the male member 220. A welded plug 428 closes the angled passageway 424 so that no fluid or other debris and material may enter the angled passageway 424 from outside the downhole interface sub 200 after the passageway 424 is formed. The angled passageway 424 may be formed at an angle from between about 1 degree to about 180 degrees, such as between about 15 degrees to about 90 degrees from the center axis 232 of the downhole interface sub 200.

[0033] The wire 410 may be a solid conductor rigid enough to provide stiffness so that the wire 410 can be pushed through the passageways 422, 424, 426. The wire 410 may extend from the data transmission element 400 and may extend through a series of seal stacks and back up components 402 through a wire insulator 412.

The wire 410 may bend through angled passageway 424 and into centering insulator 432, which centers the wire 410 to align and electrically couple with electrical connector 430 housed in receiving end 226. The wire 410 may have a length that is substantially similar to the distance between the data transmission element 400 and the electrical connector 430. The wire insulator 412 and centering insulator 432 may be formed from a tube of Teflon, PEEK (polyether ether ketone), or other suitable insulating material. The receiving end 226 is configured to receive an electrically connecting extender assembly 320 (Figure 9) from an adjacent downhole component, such as downhole tool 300, when joined with the downhole interface sub 200 whereby the electrical connector 430 is electrically coupled with an adjacent interface wire 322.

L0034] Drilling mud and other fluids may pass through the throughbore 210 and around the annulus 214. The throughbore diameter may be larger along the annulus 214 portion of the throughbore 210 compared to the non-annulus portion of the throughbore 210. The throughbore 210 and annulus 214, provides passage for the fluid flow through the downhole interface sub 200.

L0035] The downhole interface sub 200 provides the mechanical interface connection between two different custom, proprietary, or API standard threaded connection types or sizes. In some embodiments, the thread types or sizes may be the same. Additionally, the internal flow diverter elements (220, 222, 224) divert the mud or other types of drilling fluid by separating or diverting the fluid column around the flow diverter elements (220, 222, 224) which houses the single or multi-contact electrical connector, and thus provides a mechanism for electrical connection from the WDP data transmission element located in the box shoulder 205 to the centrally located electrical connector 430. The downhole interface sub 200 may be a mechanical and electrical cross-over apparatus with various applications for the drilling environment, and encompasses many different sizes and embodiments. The downhole interface sub 200 may, in the alternative or in addition to the cross-over apparatus, provide a communication interface between adjacent downhole tools that have different types of electrical connections, such as between a downhole tool having an inductive type of electrical connection and another downhole tool having a direct electrical connection. Utilizing a centrally located (on axis) electrical connector may allow the downhole interface sub 200 to be rotated for completing the rotary dill pipe threaded connections to the BHA 117 while also maximizing the flow area, and diverting the fluid flow around the centrally located electrical connector 430 while flowing fluid through the drill string 110.

[0036] Embodiments of the downhole interface sub 200 are also shown in Figures 7 and 8. Figures 7 is a cross-sectional view of a downhole interface sub according to an embodiment of the present invention. The downhole interface sub 200 may have a longer male member 220 as shown in Figure 7. A spacer 434, which may be a tube of insulating material such as Teflon, PEEK, or other insulating material, is disposed within the second passageway 426. The embodiment shown in Figure 7 allows for the pin and box threads 203, 207, to be recut and reconditioned after extended use in the field which typically results in shortening of the downhole interface sub 200. To maintain the desired distances between the male member 220 and the pin end 204, the male member is then remachined and the electrical system components, such as electrical connector 430, spacer 434, and centering insulator 432, may be removed and replaced and/or serviced.

Alternatively, adjustable components may be inserted to allow adjustment after the connection has been re-cut. The spacer 434 is recut to adjust for the difference in length of the male member, while the centering insulator 432 may be put back into the second passageway 426. The data transmission element 400 may be removed and replaced with another data transmission element 400, if needed. The length of wire 410 may need to be adjusted as the distances between the electrical connector 430 and data transmission element 400 are shortened. The downhole interface sub shown in Figure 7 may be reused multiple times and the service lifetime thereby extended.

[0037] Figure 8 is a cross-sectional view of a downhole interface sub according to an embodiment of the present invention. The downhole interface sub of Figure 8 uses a combination of a data transmission element wire 410 and a single conductor insulated wire 435 to electrically couple the electrical connector 430 and data transmission element 400. The single conductor insulated wire 435 may be an insulated stranded wire. The data transmission element wire 410 extends through the first passageway 422 but then stops at a port opening 427 formed between the angled passageway 424 and the first passageway 422. A wire electrical connector socket 436 receives the end of the data transmission element wire 410. The single conductor insulated wire 435 electrically couples the electrical connector socket 436 with the electrical connector 430 by passing through the angled passageway 424 and the second passageway 426 in the male member 220. A port plug 429 is used to close the port opening 427 after the electrical connector socket 436 is placed within the port opening 427 and connected with the single conductor insulated wire 435. The data transmission element wire 410 thus has a shorter length, and is not required to bend around angled passageways, thus reducing the potential for an electrical short between the data transmission element wire 410 and the tubular body 230.

L0038] Figure 9 is a cross-sectional view of a downhole interface sub according to an embodiment of the present invention and another downhole component joined together to form an electrical connection therebetween. BHA 117 may include a downhole tool 300 for coupling with the downhole interface sub 200. The downhole tool 300 includes an electrically connecting extender assembly 320 for coupling with the electrical connector 430 and the receiving end 226 of the male member 220.

The electrically connecting extender assembly 320 includes an interface wire 322 to electrically couples with the electrical connector 430, thereby enabling transmission of data, signals, and/or power between the WDP telemetry system and BHA telemetry system. A connecting member 324 enables mechanical coupling between the receiving end 226 of the male member 220 and the electrically connecting extender assembly 320. The interface wire 322 may be electrically insulated by or from connecting member 324 depending on the material used for forming the connecting member. Insulation may surround the interface wire 322 and may be positioned between the connecting member 324 and interface wire 322 as needed.

Drilling fluid flows through the throughbore 210 of tubular body 230, around the male member 220, and into the downhole tool 300 as indicated by directional arrow 102.

Thus, drilling fluid surrounds the electrical connection between downhole interface sub 200 and downhole tool 300.

[0039] Figure 10 is a cross-sectional view of a downhole interface sub 200 according to an embodiment of the present invention. The downhole interface sub in Figure 10 includes a removable body 600 disposed within the tubular body 230. A throughbore 610 is formed within the removable body 600. The tubular body 230 and the removable body 600 thus together may define a throughbore 210, 610 extending between the two ends 206A, 206B of downhole interface sub 200 and through the removable body 600. In this embodiment, the downhole interface sub includes two box ends 206A, 206B for connecting to pin ends of adjacent downhole components. The male member 220 extends from the removable body 600 and is disposed within the throughbore 210. The male member 220 may extend from an interior surface 612 of the removable body 600.

[0040] The data transmission element 400 is disposed adjacent one of the box ends 206 of the tubular body 230. The wire 410 extends through the first passageway 422, though a removable body centering insulator 632 and into a removable body electrical connector 630 disposed in an end of the removable body 600 opposite the male member 220. A single conductor insulated wire 435 is connected to the removable body electrical connector 630 and may pass through a removable body outer opening 625, through a removable body angled passageway 624, and into a removable body second passageway 626 to connect with the electrical connector 430. Thus, the wire 410 passes through the sidewall 233 of the tubular body 230 and into the removable body 600.

[0041] An aligning/anti-rotation pin 602 is used to align the first passageway 422 with the removable body centering insulator 632. A spring pack assembly 652is disposed along a spring carrier 650 that surrounds a portion of the male member 220. A spacer 656 is coupled to the spring pack assembly 652 and spring carrier 650 by a bolt 654. The spring pack assembly 652 holds the removable body in place after it is installed. The spring pack assembly 652 also functions as a load support for the constant force of axial shock based on the weight of the removable body 600. Moreover, the spacer 656 can adjust to the length of the adjacent pin end of a downhole component joined with the downhole interface sub 200, La it can compress if necessary as the downhole interface sub 200 is joined with the adjacent downhole component. Seals 605 along the outer diameter of the removable body 600 prevent drilling fluid from flowing between the removable body 600 and the tubular body 230. Alternatively, other embodiments of the invention may use a jam-nut to secure the removable body in place.

[0042] The downhole interface sub 200 and the removable body 600 may be formed using various machining methods known in the art. In an embodiment, the downhole interface sub 200 is integrally formed from a single body of material, such as a solid bar that may have the desired material properties requirements for the component. For example, the material properties of the solid bar may be for a drill collar type of application. The removable body 600 may also be integrally formed from a single body of material in a similar manner as the downhole interface sub 200.

[0043] The interface sub 200 and/or removable body 600 threads, passageways, box and pin ends, and other features such as recessed groove 211 in box end 206, may be machined by turning, milling, and drilling operations. For example, the first passage way 422, second passageway 426, and angled passageway 424 in the interface sub may be formed by gun hole drilling. Similar processes may be used to form passageways 622, 624, 625, and 626 in removable body 600. At least a portion of the throughbores 210, 610, surfaces 212, 612, 224 and the male member 220 of the interface sub 20 and/or removable body 600 may be formed by electrical discharge machining (EDM). EDM type processes are used to create the difficult geometries of the male member 220 and adjacent surfaces within the tubular body 230. The resulting EDM surface may be shot peened to enhance the desired surface roughness finish to minimize potential stress corrosion cracking of the male member 220 and the tubular body 230.

[0044] In an embodiment, a system for transmitting data between downhole components is disclosed. The system includes a wired drill pipe assembly 112 that forms a wired drill pipe telemetry system and a bottom hole assembly 117 that forms a bottom hole telemetry system that is different from the wired drill pipe telemetry system. A downhole interface sub 200 transmits data between the wired drill pipe telemetry system and another downhole component using a telemetry system having direct electrical connections. The downhole interface sub 200 used in the system may be formed according to the previously described embodiments.

L0045] While the foregoing is directed to embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof.

Claims (8)

1. CLAIMS1. A downhole interface sub for transmitting data, comprising: a tubular body comprising two ends and defining a centrally located throughbore extending between the two ends for drilling fluid to pass therethrough; and a male member comprising an electrical connector, the male member disposed within the throughbore and extending from an interior surface within the tubular body towards the center of the throughbore.
2. 2. The downhole interface sub of claim 1, wherein a portion of the male member is completely surrounded by the throughbore such that a portion of the throughbore comprises an annulus between the male member and the tubular body.
3. 3. The downhole interface sub of claim 2, wherein a portion of the male member is integrally formed with a sidewall of the interior surface of the tubular body.
4. 4. The downhole interface sub of claim 2, wherein the male member further comprises a flow diverter within the tubular body.
5. 5. The downhole interface sub of claim 1, wherein the electrical connector is connected to a data transmission element located adjacent an end of the interface sub.
6. 6. The downhole interface sub of claim 5, wherein the electrical connector is adapted to receive data from a wellbore tool positioned at one end of the tubular body and transmit data via the data transmission element to a wired drill pipe joint positioned at the opposing end of the tubular body.
7. 7. The downhole interface sub of claim 1, wherein the male member further comprises: a tubular housing comprising a base end connected to the interior surface and a receiving end that extends towards an end of the tubular body, wherein the receiving end extends to a location that is less than eighty percent of the axial distance from a primary shoulder to a secondary shoulder of the end.
8. 8. The downhole interface sub of claim 7, wherein the axial distance from the receiving end to the primary shoulder is sized to achieve acceptable stress in a threaded connection between the downhole interface sub and a wellbore tool positioned at one end of the tubular body while drilling.10. Adownhole interface sub for transmitting data, comprising: a tubular body comprising a first end and a second end and defining a centrally located throughbore extending between the first and second ends for drilling fluid to pass therethrough; a male member comprising an electrical connector for receiving an electrical connection, the male member disposed within the throughbore and extending from an interior surface within the tubular body towards the first end of the tubular body such that a portion of the male member is completely surrounded by the throughbore; and a data transmission element disposed adjacent the second end of the tubular body, the data transmission element having a wire that extends from the data transmission element through a passageway formed within a sidewall of the tubular body, and is electrically coupled with the electrical connector.11. The downhole interface sub of claim 10, wherein the male member further comprises: a tubular housing comprising a base end connected to the interior surface and a receiving end that extends towards the first end of the tubular body, wherein the electrical connector disposed within the receiving end of the male member.12. The downhole interface sub of claim 11, wherein the receiving end is configured to receive an electrical connector from an adjacent downhole component threadably connected to the downhole interface sub at the first end.13. The downhole interface sub of claim 11, wherein the passageway comprises: a first passageway that extends axially within the sidewall; a second passageway that extends axially within the male member; and an angled passageway that intersects the first and second passageways and extends through the sidewall and into the base end of the male member.14. The downhole interface sub of claim 10, wherein the downhole interface sub is integrally formed from a single body.15. The downhole interface sub of claim 10, further comprising: a removable body disposed within the tubular body, wherein the tubular body and the removable body together define a portion of the throughbore extending between the first and second ends and through the removable body, and wherein the male member extends from the removable body and is disposed within the throughbore.16. The downhole interface sub of claim 15, wherein the male member extends from an interior surface of the removable body.17. The downhole interface sub of claim 16, wherein the first end comprises a pin end tool joint and the second end comprises a box end tool joint.18. A system for transmitting data, comprising: a wired drill pipe telemetry system; one or more wellbore tools; and a downhole interface sub for transmitting data between the wired drill pipe telemetry system and the one or more wellbore tools having a telemetry system different from the wired drill pipe telemetry system, wherein the downhole interface sub comprises: a tubular body comprising a first end and a second end and defining a centrally located throughbore for drilling fluid to pass through, the throughbore extending between the first and second ends; and a male member comprising an electrical connector for receiving an electrical connection, the male member disposed within the throughbore and extending from an interior surface within the tubular body such that a portion of the male member is completely surrounded by the throughbore.19. The system of claim 20, wherein the downhole interface sub further comprises: a data transmission element disposed adjacent the second end of the tubular body, the data transmission element having a wire that extends from the data transmission element through a passageway formed within a sidewall of the tubular body, and is electrically coupled with the electrical connector.20. The system of claim 19, wherein the telemetry system of the one or more wellbore tools comprises a direct electrical connection for connecting with the electrical connector, the electrical connector at least partially disposed within a receiving end of the male member.