U.S. patent application number 11/728401 was filed with the patent office on 2008-10-02 for casing profiling and recovery system.
Invention is credited to Gerald D. Lynde.
Application Number | 20080236829 11/728401 |
Document ID | / |
Family ID | 39745165 |
Filed Date | 2008-10-02 |
United States Patent
Application |
20080236829 |
Kind Code |
A1 |
Lynde; Gerald D. |
October 2, 2008 |
Casing profiling and recovery system
Abstract
A casing cutting and recovery tool having a cutting assembly, an
expansion assembly having one or more deforming members, and a
recovery assembly is used to cut a window in wellbore casing,
secure a removable segment of wellbore casing that was previously
disposed within the window, and recover the removable segment of
wellbore casing with the tool. One or more cutting assemblies
provides one or more cuts in the wellbore casing. The deforming
members of the expansion assembly then expand outwardly at least
two portions of the wellbore casing shaped by the cut or cuts. The
recovery assembly secures the removable segment of the wellbore
casing to the tool so that the tool and the removable segment of
wellbore casing can be recovered together from the wellbore.
Inventors: |
Lynde; Gerald D.; (Houston,
TX) |
Correspondence
Address: |
GREENBERG TRAURIG (HOU);INTELLECTUAL PROPERTY DEPARTMENT
1000 Louisiana Street, Suite 1800
Houston
TX
77002
US
|
Family ID: |
39745165 |
Appl. No.: |
11/728401 |
Filed: |
March 26, 2007 |
Current U.S.
Class: |
166/298 ;
102/306 |
Current CPC
Class: |
E21B 31/16 20130101;
E21B 29/06 20130101; E21B 31/06 20130101; E21B 29/02 20130101 |
Class at
Publication: |
166/298 ;
102/306 |
International
Class: |
E21B 29/00 20060101
E21B029/00 |
Claims
1. An apparatus for forming an opening in casing in a well, the
apparatus comprising: a cutting assembly for lowering into a casing
of a well, the cutting assembly having at least one cutting member
for cutting at least one slot in the casing to define a segment for
removal; a deforming member carried with the cutting assembly, the
deforming member being selectively actuated from a surface of the
well for deforming outward at least two portions of the casing
adjacent the slot; and a recovery assembly carried with the cutting
assembly for engaging and removing the segment from the casing.
2. The apparatus of claim 1, wherein the cutting assembly is
disposed above the deforming member.
3. The apparatus of claim 2, wherein the deforming member is
disposed above the recovery assembly.
4. The apparatus of claim 1, wherein the deforming member comprises
at least two rollers.
5. The apparatus of claim 1, further comprising a secondary cutting
assembly, wherein the cutting assembly and the secondary cutting
assembly each include at least two linear charges.
6. The apparatus of claim 1, wherein the recovery assembly includes
a magnet and an actuating member for moving the magnet radially
outward to engage and remove the segment from the casing.
7. The apparatus of claim 1, wherein the deforming member is
operatively associated with a piston disposed within a piston
chamber, a lower portion of the piston being operatively associated
with a conically shaped deforming member housing.
8. The apparatus of claim 7, wherein the lower portion of the
piston includes a conically shaped drive wedge, the drive wedge
being slidingly engaged with the conically shaped deforming member
housing.
9. The apparatus of claim 8, wherein the piston and drive wedge
include a bore, the bore having disposed therein a ball seat, a
ball, and a ball release.
10. The apparatus of claim 9, wherein the piston chamber includes
hydraulic fluid.
11. The apparatus of claim 10, wherein the piston chamber further
includes a vent port.
12. An apparatus for forming an opening in casing in a well, the
apparatus comprising: a cutting assembly for lowering into a casing
of a well, the cutting assembly having at least one linear shaped
charge for cutting at least one slot in the casing to define a
segment for removal; a piston movable by high pressure against a
wedge member to radially expand a deforming member carried with the
cutting assembly, the deforming member being selectively actuated
by the piston for deforming outward at least two portions of the
casing adjacent the slot; and a recovery assembly carried with the
cutting assembly for engaging and removing the segment from the
casing, the recovery assembly having a radially moveable
magnet.
13. The apparatus of claim 12, wherein the piston and wedge member
each include a bore, the bore having disposed therein a ball seat,
a ball, and a ball release.
14. The apparatus of claim 13, wherein the piston is disposed
within a piston chamber having an upwardly biased spring and
hydraulic fluid.
15. The apparatus of claim 14, wherein the piston chamber further
includes a vent port.
16. A method of cutting and removing a segment of casing disposed
in a well to form an opening in the casing, the method comprising
the steps of: (a) lowering a casing cutting tool into a bore of a
casing; (b) cutting at least one slot in the casing with the casing
cutting tool to define a segment of casing to be removed; (c) with
the casing cutting tool, forcing outward at least two portions of
the casing adjacent the slot, thereby freeing the segment from the
casing; then (d) removing the segment, thereby leaving an opening
in the casing.
17. The method of claim 16, further comprising the step of: (e)
raising the casing cutting tool with the segment of the casing from
the bore of the casing.
18. The method of claim 16, wherein step (c) is performed by
applying downward pressure on a piston disposed within casing
cutting tool causing the piston to move downward, the downward
movement of the piston causing at least two expansion members to
move radially outward to engage each of the at least two portions
of the casing adjacent the slots to force outward each of the at
least two portions of the casing against the slot.
19. The method of claim 18, wherein the downward pressure is
created by fluid pumped into a bore within casing cutting tool, the
bore being in fluid communication with the piston.
20. The method of claim 20, wherein step (d) is performed by
actuating an actuating member to move a magnet radially outward to
engage the segment o the casing and withdraw the segment of casing
into the bore of the casing.
Description
BACKGROUND
[0001] 1. Field of Invention
[0002] The invention is directed to a casing profiling, or cutting,
and recovery systems for use in oil and gas wellbores and, in
particular, to a downhole tool for cutting a section of wellbore
casing and recovering the section from the wellbore.
[0003] 2. Description of Art
[0004] In general, cutting "windows" or openings in oil and gas
wellbore casing so that "offshoot," "lateral," or "branch"
wellbores are well known in the art. Previously, the windows were
cut using a whipstock or whipstock-packer assembly and a cutting or
milling tool disposed on the end of a drill string. Cutting the
windows using these milling tools usually results in jagged edged
and irregularly shaped openings. As a result, if it is desired to
close the window, sealing the irregularly shaped opening is
extremely difficult, if not impossible.
[0005] Additionally, cutting the windows using these prior milling
tools resulted in various sized debris falling into or remain in
the wellbore after being cut by the milling tools. As a result,
these pieces had to be recovered using wellbore fluid or fishing
tools, both of which requires the wellbore to be "off-line" or
"down" during the recovery efforts.
[0006] Accordingly, prior to the development of the present
invention, there has been no downhole tool for cutting and
recovering a section or segment of wellbore casing or method for
forming an opening in casing in a well that: permits cutting the
casing segment and removing the segment of wellbore casing from the
wellbore in a single downhole trip; permits cutting a segment of
wellbore casing with relatively smooth edges, thereby increasing
the possibility that the window can be re-sealed; and decreases the
amount of debris within the wellbore as a result of cutting the
window. Therefore, the art has sought a downhole tool for cutting
and recovering a section or segment of wellbore casing and a method
for forming an opening in casing in a well that: permits cutting
the casing segment and removing the segment of wellbore casing from
the wellbore in a single downhole trip; permits cutting a segment
of wellbore casing with relatively smooth edges, thereby increasing
the possibility that the window can be re-sealed; and decreases the
amount of debris within the wellbore as a result of cutting the
window.
SUMMARY OF INVENTION
[0007] Broadly, the disclosure is directed to a casing cutting and
recovery tool having a cutting assembly, an expansion assembly
having one or more deforming members, and a recovery assembly that
preferably includes a magnet. The casing cutting and recovery tool
is used to cut a window in wellbore casing, secure a removable
section of wellbore casing that was previously disposed within the
window, and recover the removable section of wellbore casing with
the tool. One or more cutting assemblies provide primary cuts and
secondary cuts in the wellbore casing. The expansion assembly
expands outwardly two portions of the wellbore casing shaped by the
primary cuts. The magnet secures the removable section of wellbore
casing to the tool so that the tool and the removable section of
wellbore casing can be recovered together from the wellbore.
[0008] In one specific embodiment, the casing cutting and recovery
tool comprises a housing having a housing bore. The housing bore
has a piston chamber and piston operatively associated therein. The
piston is operatively associated with the expansion assembly and
the expansion assembly has at least two expansion members
operatively associated therewith. The recovery assembly includes an
actuating member, such as a motor or solenoid and a recovery
assembly housing. The magnet is disposed on the outer wall surface
of the recovery assembly. The recovery assembly housing is moveable
radially outward and inward relative to the housing by the
actuating member.
[0009] The downhole tools for cutting and recovering a section or
segment of wellbore casing and methods for forming an opening in
casing in a well have the advantages of: permitting cutting the
casing segment and removing the segment of wellbore casing from the
wellbore in a single downhole trip; permitting cutting a segment of
wellbore casing with relatively smooth edges, thereby increasing
the possibility that the window can be re-sealed; and decreasing
the amount of debris within the wellbore as a result of cutting the
window.
[0010] In one aspect, one or more of the foregoing advantages is
achieved by an apparatus for forming an opening in casing in a well
in which the apparatus comprises a cutting assembly for lowering
into a casing of a well, the cutting assembly having at least one
cutting member for Cutting at least one slot in the casing to
define a segment for removal; a deforming member carried with the
cutting assembly, the deforming member being selectively actuated
from a surface of the well for deforming outward at least two
portions of the casing adjacent the slot; and a recovery assembly
carried with the cutting assembly for engaging and removing the
segment from the casing.
[0011] A further feature of the apparatus is that the cutting
assembly may be disposed above the deforming member. Another
feature of the apparatus is that the deforming member may be
disposed above the recovery assembly. An additional feature of the
apparatus is that the deforming member may comprise at least two
rollers. Still another feature of the apparatus is that the
apparatus may further comprise a secondary cutting assembly,
wherein the cutting assembly and the secondary cutting assembly
each include at least two linear charges. A further feature of the
apparatus is that the recovery assembly may include a magnet and an
actuating member for moving the magnet radially outward to engage
and remove the segment from the casing. Another feature of the
apparatus is that the deforming member may be operatively
associated with a piston disposed within a piston chamber, a lower
portion of the piston being operatively associated with a conically
shaped deforming member housing. An additional feature of the
apparatus is that the lower portion of the piston may include a
conically shaped drive wedge, the drive wedge being slidingly
engaged with the conically shaped deforming member housing. Still
another feature of the apparatus is that the piston and drive wedge
may include a bore, the bore having disposed therein a ball seat, a
ball, and a ball release. A further feature of the apparatus is
that the piston chamber may include hydraulic fluid. Another
feature of the apparatus is that the piston chamber may further
include a vent port.
[0012] In another aspect, one or more of the foregoing advantages
is achieved by an apparatus for forming an opening in casing in a
well in which the apparatus comprises a cutting assembly for
lowering into a casing of a well, the cutting assembly having at
least one linear shaped charge for cutting at least one slot in the
casing to define a segment for removal; a piston movable by high
pressure against a wedge member to radially expand a deforming
member carried with the cutting assembly, the deforming member
being selectively actuated by the piston for deforming outward at
least two portions of the casing adjacent the slot; and a recovery
assembly carried with the cutting assembly for engaging and
removing the segment from the casing, the recovery assembly having
a radially moveable magnet.
[0013] A further feature of the apparatus is that the piston and
wedge member each may include a bore, the bore having disposed
therein a ball seat, a ball, and a ball release. Another feature of
the apparatus is that the piston may be disposed within a piston
chamber having an upwardly biased spring and hydraulic fluid. An
additional feature of the apparatus is that the piston chamber may
further include a vent port.
[0014] In an additional aspect, one or more of the foregoing
advantages is achieved by a method of cutting and removing a
segment of casing disposed in a well to form an opening in the
casing in which the method comprises the steps of: (a) lowering a
casing cutting tool into a bore of a casing; (b) cutting at least
one slot in the casing with the casing cutting tool to define a
segment of casing to be removed; (c) with the casing cutting tool,
forcing outward at least two portions of the casing adjacent the
slot, thereby freeing the segment from the casing; then (d)
removing the segment, thereby leaving an opening in the casing.
[0015] A further feature of the method is that the method may
further comprise the step of: (e) raising the casing cutting tool
with the segment of the casing from the bore of the casing. Another
feature of the method is that step (c) may be performed by applying
downward pressure on a piston disposed within casing cutting tool
causing the piston to move downward, the downward movement of the
piston causing at least two expansion members to move radially
outward to engage each of the at least two portions of the casing
adjacent the slots to force outward each of the at least two
portions of the casing against the slot. An additional feature of
the method is that the downward pressure may be created by fluid
pumped into a bore within casing cutting tool, the bore being in
fluid communication with the piston. Still another feature of the
method is that step (d) may be performed by actuating an actuating
member to move a magnet radially outward to engage the segment o
the casing and withdraw the segment of casing into the bore of the
casing.
BRIEF DESCRIPTION OF DRAWINGS
[0016] FIG. 1 is a partial cross-sectional view of one specific
embodiment of a casing cutting and recovery tool, or system, of the
present invention shown in its run-in position.
[0017] FIG. 2 is an elevational perspective view of the exterior of
wellbore casing showing primary longitudinal and primary
latitudinal cuts made in the wellbore casing by the casing cutting
and recovery tool shown in FIG. 1.
[0018] FIG. 3 is a cross-sectional view of the wellbore casing
shown in FIG. 2 taken along line 3-3.
[0019] FIG. 4 is an elevational view of the exterior of the
wellbore casing of FIGS. 2-3 showing the expanded casing portions
formed by the casing cutting and recovery tool shown in FIG. 1.
[0020] FIG. 5 is a cross-sectional view of the wellbore casing
shown in FIG. 4 taken along line 5-5.
[0021] FIG. 6 is an elevational view of the exterior of the
wellbore casing of FIGS. 2-5 showing secondary cuts made in the
wellbore casing by the casing cutting and recovery tool shown in
FIG. 1.
[0022] FIG. 7 is a cross-sectional view of the wellbore casing
shown in FIG. 6, taken along line 7-7.
[0023] FIG. 8 is cross-sectional view of the casing cutting and
recovery tool shown in FIG. 1 disposed within the wellbore casing
shown in FIGS. 2-7 showing the expanded casing portions formed by
the casing cutting and recovery tool shown in FIG. 1 and showing
the section of the wellbore casing to be engaged by the recovery
assembly of the casing cutting and recovery tool shown in FIG.
1.
[0024] FIG. 9 is cross-sectional view of the casing cutting and
recovery tool shown in FIG. 1 disposed within the wellbore casing
shown in FIGS. 2-7 showing the section of the wellbore casing
engaged by the recovery assembly of the casing cutting and recovery
tool shown in FIG. 1.
[0025] FIG. 10 is cross-sectional view of the casing cutting and
recovery tool shown in FIG. 1 disposed within the wellbore casing
shown in FIGS. 2-7 showing the section of the wellbore casing
engaged and withdrawn into the bore of the wellbore casing by the
recovery assembly of the casing cutting and recovery tool shown in
FIG. 1.
[0026] FIG. 11 is an elevational view of the exterior of the
wellbore casing shown in FIGS. 2-7 showing the window made in the
wellbore casing by the casing cutting and recovery tool shown in
FIG. 1.
[0027] FIG. 12 is a cross-sectional view of the wellbore casing
shown in FIG. 11 taken along line 11-11.
[0028] While the invention will be described in connection with the
preferred embodiments, it will be understood that it is not
intended to limit the invention to that embodiment. On the
contrary, it is intended to cover all alternatives, modifications,
and equivalents, as may be included within the spirit and scope of
the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
[0029] Referring now to FIGS. 1-12, casing cutting and recovery
tool 10, or tool 10 or downhlole tool 10, comprises upper end 12,
lower end 14 and housing 16. Upper end 12 and lower end 14 both
include threads 18 for securing tool 10 to a casing, drill pipe,
tubing string, or wireline (not shown) or other downhole tools (not
shown). Housing 16 includes housing bore 20 longitudinally disposed
at least partially through housing 16 and outer wall surface
22.
[0030] Tool 10 includes at least one cutting assembly 21. In the
embodiment shown in FIG. 1, Cutting assembly 21 includes linear
charges 24, 26, 28, 30, 32, 34 disposed along a radial arc of outer
wall surface 22. Linear charges are known in the art and may be
obtained from Accurate Arms Company, Inc. located in McEwen, Tenn.
Briefly, linear charges 24, 26, 28, 30, 32, 34 are shaped explosive
devices having a substantially V or U cross-section. When
detonated, the explosive force is expelled out of an opening along
the top of the V or U cross-section so that the explosive force is
directed in a desired direction. As shown in FIG. 1, linear charges
24, 26, 28, 30, 32, 34 are arranged in such a way that there is a
left upper horizontal linear charge 24, a left vertical linear
charge 26, a left lower horizontal linear charge 28, a right upper
horizontal linear charge 30, a right vertical linear charge 32, and
a right lower horizontal linear charge 34. It is to be understood,
however, that a single linear charge may be shaped to have the same
arrangement as shown in FIG. 1. Preferably, each linear charge 24,
26, 28, 30, 32, 34 is disposed along outer wall surface 22 such
that the tops of each linear charge 24, 26, 28, 30, 32, 34 are
flush with outer wall surface 22. In other embodiments (not shown),
cutting assembly 21 include devices for abrasive jetting, milling,
electronic discharge machining, chemical jetting or erosion, flame
cutting, broaching, scarring, wheel cutting, perforating, slotting,
or other device, or using any method, known to persons skilled in
the art. Further, linear charges 24, 26, 28, 30, 32, 34 do not have
to provide straight cuts or parallel cuts. Instead, linear charges
24, 26, 28, 30, 32, 34 can be arranged to cut one or more arcuate
shaped cuts, including circular shaped cuts.
[0031] Housing 16 also includes piston chamber 36 disposed within
housing 16. In the embodiment shown in FIG. 1, piston chamber 36 is
disposed below linear charges 24, 26, 28, 30, 32, 34. Piston
chamber 36 includes vent port 38 and piston 40 slidingly engaged
within piston chamber 36. In a preferred embodiment, hydraulic
fluid is disposed within piston chamber 36 and vent port 38
includes a plug (not shown) for maintaining the hydraulic fluid
within piston chamber 36 during run. The plug is easily dislodged
from vent port 38 during operation of piston 40 (discussed in
greater detail below). Piston 40 includes piston seals 42, piston
rod 43, and piston bore 44 extending through piston rod 43 and
piston 40. Vent port 38 is always below piston seals 42. Spring 46
acts to force piston 40 in the upward direction (arrow 47). In
other words, piston 40 is upwardly biased. Piston rod 43 can also
include fastener hole 48 through its side wall for receiving a
fastener (not shown) such as a screw (not shown).
[0032] The lower end of piston rod 43 is secured by a fastener (not
shown) to drive wedge 50 by inserting the lower end of piston rod
43 into upper bore portion 52 of wedge bore 54 of drive wedge 50.
Alternatively, drive wedge 50 and piston rod 43 can be a single
component. Wedge bore 54 includes lower bore portion 56 that has a
smaller inner diameter compared to the inner diameter of upper bore
portion 52.
[0033] Drive wedge 50 has a conical shape with the narrow end at
the bottom of drive wedge 50. The outer surface of drive wedge 50
is in sliding engagement with expansion assembly 60. As illustrated
in FIG. 1, expansion assembly 60 includes expansion assembly
housing 62. In one specific embodiment, the outer surface of drive
wedge 50 has lands and grooves (not shown) and expansion assembly
housing 62 has reciprocal lands and grooves (not shown) so that
upward and downward movement of wedge driver 50 pushes or pulls
expansion assembly housing 62 through the connecting lands and
grooves.
[0034] Expansion assembly housing 62 includes expansion assembly
housing chamber 64 for receiving drive wedge 50. Expansion assembly
60 also includes at least two expansion members shown in FIG. 1 as
expansion rollers 66. In this arrangement, as drive wedge 50 moves
downward, in the direction of arrow 51, expansion assembly housing
62 is forced outward radially, in the direction of arrows 68, 69,
so that expansion rollers 66 engage the wellbore casing to bend or
force "open" the wellbore casing as discussed in greater detail
below. Ball seat 70 is disposed within wedge upper bore portion 52.
Ball seat 70 includes ball 72 that initially blocks the downward
flow of fluid through piston bore 44. As discussed in greater
detail below, after piston 40 has been forced downward (arrow 51)
to radially expand expansion rollers 66, ball release 74 having
stem 75 and head 76 engages ball 72 and forces ball 72 off of ball
seat 70 so that fluid is permitted to flow downward through piston
bore 44 and into expansion assembly housing chamber 64. As a
result, drive wedge 50 can be forced upward, in the direction of
arrow 47, so that each expansion rollers 66 can be retracted into
housing 16 of tool 10 (discussed in greater detail below). In a
preferred embodiment, head 76 is disposed within chamber 78 of
housing 16 such that head 76 can move slightly within chamber
78.
[0035] Disposed below expansion assembly 60 is recovery assembly
80. Recovery assembly 80 includes housing 82 that is operatively
associated with a source of movement, i.e., an actuating member of
device such as a motor or a solenoid 85 (FIGS. 8-10). The outer
surface of housing 82 includes magnet 84. In this specific
embodiment, outer surface of housing 82 also includes a second
cutting assembly made up of upper horizontal linear charge 86 and
lower horizontal linear charge 88. Housing 82 is radially moveable
relative to housing 16 by solenoid 85. Although housing 82 is shown
as being flush with outer wall surface 22 of housing 16, it is to
be understood that housing 82 may be slightly recessed within
housing 16 during the period of time that recovery assembly 80 is
not in use, i.e., during run-in of the tool 10 or during operation
of Cutting assembly 21 or expansion assembly 60.
[0036] Referring now to FIGS. 2-12, in operation, tool 10 is
lowered through wellbore casing 90 by a work string (not shown) to
the desired location where a window is to be cut in wellbore casing
90. Wellbore casing has casing bore 91 defined by inner casing wall
surface 92 and casing outer wall surface 93. Once properly located
within wellbore casing 90, linear charges 24, 26, 28, 30, 32, 34
are initiated using known devices and techniques, such as detonator
and prima cord activated electronically from the surface of the
well. In the embodiment shown in FIGS. 2-12, the explosive force
from linear charges 24, 26, 28, 30, 32, 34 creates primary
longitudinal cuts 95, 98 and primary horizontal cuts 94, 96, 97, 99
in wellbore casing 90 (FIGS. 2-3).
[0037] Thereafter, tool 100 is raised up in wellbore casing 90
until rollers 66 of expansion assembly 60 are disposed on the inner
wall surface 92 of wellbore casing 90 parallel to primary
longitudinal cuts 95, 98 and in between primary horizontal cuts 94,
96, 97, 99. Referring to FIG. 1, fluid (not shown), such as
wellbore fluid or hydraulic fluid, is then pumped down the work
string and into housing bore 20 to actuate piston 40. Once
actuated, piston 40 is forced downward in the direction of arrow 51
causing drive wedge 50 to radially expand expansion assembly
housing 62 and, thus, expansion rollers 66 outwards in the
direction of arrows 68, 69. In so doing, the plug is forced out of
vent port 38 causing piston chamber 36 to be in fluid communication
with the wellbore. Thus, the hydraulic fluid within piston chamber
36 is forced out of piston chamber 36 allowing piston 40 to move
downward. Further, the pressure within piston chamber 36 is
hydrostatic pressure.
[0038] Piston 40 is forced downward until ball release 74 engages
ball 72 and removes ball 72 from ball seat 70. As a result, fluid
being pumped down work string and housing bore 20 is permitted to
flow through piston bore 44 and wedge bore 54 alongside ball
release 74 and into expansion assembly housing chamber 64. Fluid is
continued to be pumped resulting in pressure equilibrium being
established above and below piston 40, i.e., within housing bore
20, piston chamber 36, and expansion assembly housing chamber 64.
Due to the equilibrium established in these spaces, expansion
rollers 66 remain extended to contact inner wall surface 92 of
wellbore casing 90 and force outward two portions of wellbore
casing 90, referred to herein as expanded casing portions 100, 102
(FIG. 5). Tool 10 is then either raised or lowered as appropriate
so that expansion rollers 66 move along the entire longitudinal
length of primary longitudinal cuts 95, 98 in between primary
horizontal cuts 94, 96, 97, 99. As a result, longitudinal openings
101, 103 are formed in wellbore casing 90 (FIGS. 4-5).
[0039] After longitudinal openings 101, 103 are formed, expansion
rollers 66 are retracted into housing 16 by decreasing or
eliminating the pumping of fluid down housing bore 20 (FIG. 1). The
reduced or elimination of pumping pressure down housing bore 20
allows spring 46 to force piston 40 upward in the direction of
arrow 47. As piston 40 moves upwards in the direction of arrow 47,
fluid within expansion assembly chamber 64 flows upwards past ball
seat 70, through piston bore 44, and through housing bore 20. Also,
wellbore fluid (not shown) flows into piston chamber 36 through
vent port 38. The flow of fluid flows upwards past ball seat 70,
through piston bore 44, and through housing bore 20 and/or through
vent port 38 can also assist in the movement of piston 40 upward.
As piston 40 moves upwards (arrow 47), drive wedge 50 also moves
upwardly causing expansion assembly housing 62 and, thus, expansion
rollers 66 to retract into housing 16.
[0040] Tool 10 is then raised further up wellbore casing 90 until
magnet assembly 80 is disposed between primary longitudinal cuts
95, 98 and in between primary horizontal cuts 94, 96, 97, 99. A top
cross-sectional view of the location of tool 10 at this stage of
operation is shown in FIG. 8. Tool 10 may include verification
tools to ensure that tool 10 is properly located and expanded
casing portions 100, 102 are properly formed. The verification
tools can include one or more video, acoustic, ultrasonic, or
tactile system known in the art that can easily be adapted for
these functions. If expanded casing portions 100, 102 are not in
their correct position, tool 10 can be repositioned so that
expansion assembly 60 can be re-engaged to expand expanded casing
portions 100, 102.
[0041] The second cutting assembly, linear charges 86, 88 in FIG.
1, is initiated using known devices and techniques, such as prima
cord activated electronically from the surface of the well. The
explosive force from linear charges 86, 88 creates secondary
horizontal cuts 112, 114 in wellbore casing 90 (FIG. 6). In a
preferred embodiment, motor or solenoid 85 radially moves magnet
housing 82 outward in the direction of arrow 130 until magnet 84
and linear charges 86, 88 contact casing inner wall surface 92
(FIG. 9). It is to be understood, however, that linear charges 86,
88 do not have to be in contact with inner wall surface 92. It is
also to be understood that magnet 84 does not have to be in contact
with inner wall surface 92 at the time linear charges 86, 88 or
activated.
[0042] It is also to be understood that a second cutting assembly
such as linear charges 86, 88 is not required. For example, in
embodiments in which cutting assembly 21 is capable of abrasive
jetting, milling, electronic discharge machining, chemical jetting
or erosion, flame cutting, or wheel cutting, second cutting
assembly is not needed because cutting assembly 21 can be used to
make secondary horizontal cuts 112, 114. Therefore, in these
embodiments, a single cutting assembly 21 can be part of tool
10.
[0043] After secondary horizontal cuts 112, 114, wellbore casing
section 110 is now removable from the remainder of wellbore casing
90. If magnet 84 is not already in contact with wellbore casing
section 110, magnet 84 is moved into contact with wellbore casing
section 110 by motor/solenoid 85. Motor/solenoid 85 may be
activated through any device or method known in the art such as
through electronic activation from the surface.
[0044] Wellbore casing section 110, secured by magnet 84 is then
moved into wellbore casing bore 91 by moving motor/solenoid 85 in
the direction of arrow 132. Tool 10 and wellbore casing section 110
can then be raised up wellbore casing bore 91 by the work string,
thereby leaving wellbore casing 90 with window 120 (FIGS.
11-12).
[0045] Tool 10 provides the advantages of creating a smooth walled
window 120 in wellbore casing 90. Thus, potential damage to other
downhole tools, components and strings is lessened because window
120 includes few, if any, jagged cuts and sharp edges.
Additionally, the possibility of being able to reseal window 120 is
raised because there are less irregularly shaped spaces that need
to be filled or covered. Further, tool 10 lessens the amount of
debris that may be left in the wellbore or that needs to be
recovered using recovery fluids or recovery tools. Moreover, tool
10 permits window 120 to be cut and removed using a single tool
making a single downhole run. Thus, cost savings are achieved using
tool 10.
[0046] Further, additional components, such as a measurement while
drilling component, flow sub, J & shear joint, bottom trip
anchor, and/or whipstock may be secured to lower end 14 to
facilitate placement or operation of tool 10 or to allow additional
components, such as a whipstock, to be placed within wellbore as
part of the operation of tool 10 during its single trip
downhole.
[0047] It is to be understood that the invention is not limited to
the exact details of construction, operation, exact materials, or
embodiments shown and described, as modifications and equivalents
will be apparent to one skilled in the art. For example, piston 40
may be actuated using any method or device known to persons of
ordinary skill in the art. Additionally, one or more linear charges
24, 26, 28, 30, 32, 34 may be disposed along outer wall surface 22
of housing 16 such that the outer surfaces of linear charges 24,
26, 28, 30, 32, 34 are either recessed into housing 16 or protrude
outside of outer wall surface 22. Further, upper horizontal linear
charge 86 and lower horizontal linear charge 88 are not required to
be disposed on outer surface of magnet housing 82. In other words,
upper horizontal linear charge 86 and lower horizontal linear
charge 88 are not required to be moveable radially. Instead, upper
horizontal linear charge 86 and lower horizontal linear charge 88
may be disposed on outer wall surface 22 of housing 16. Moreover,
the primary and secondary cuts may be formed using abrasive
jetting, milling, electronic discharge machining, chemical jetting
or erosion, flame cutting, perforating, slotting, broaching,
scarring, wheel cutting, or using any other device or method known
to persons skilled in the art. Further, a single cutting assembly
may be included as part of tool 10 to provide all of the primary
and secondary cuts. Additionally, the expansion members may be
inflatable components shaped to correspond to expanded casing
portions 100, 102 that can be inflated to force expanded casing
portions 100, 102 outwardly. Alternatively, the expansion member
may be swage having a ramp profile. Accordingly, the invention is
therefore to be limited only by the scope of the appended
claims.
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