U.S. patent application number 14/344473 was filed with the patent office on 2014-12-25 for punching tool.
This patent application is currently assigned to WELLTEC A/S. The applicant listed for this patent is WELLTEC A/S. Invention is credited to Jorgen Hallundbaek, Rasmus Sommer.
Application Number | 20140374100 14/344473 |
Document ID | / |
Family ID | 46924462 |
Filed Date | 2014-12-25 |
United States Patent
Application |
20140374100 |
Kind Code |
A1 |
Hallundbaek; Jorgen ; et
al. |
December 25, 2014 |
PUNCHING TOOL
Abstract
The present invention relates to a punching tool for providing a
hole or a dimple in a metal casing in a borehole. The punching tool
comprises a tool body having an axial extension, and a punching
unit connected with the tool body comprising: a fluid inlet, a
punch movable between a retracted and a projected position and
extending substantially radially in relation to the axial
extension, and at least one hydraulic punch cylinder moving the
punch between the retracted and the projected position. The present
invention further relates to a method for providing a hole or a
dimple in a metal casing downhole and to a method for installing a
plug in an existing hole in the casing downhole.
Inventors: |
Hallundbaek; Jorgen;
(Graested, DK) ; Sommer; Rasmus; (Valby,
DK) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WELLTEC A/S |
Allerod |
|
DK |
|
|
Assignee: |
WELLTEC A/S
Allerod
DK
|
Family ID: |
46924462 |
Appl. No.: |
14/344473 |
Filed: |
September 27, 2012 |
PCT Filed: |
September 27, 2012 |
PCT NO: |
PCT/EP2012/069084 |
371 Date: |
March 12, 2014 |
Current U.S.
Class: |
166/298 ;
166/386; 166/55 |
Current CPC
Class: |
E21B 29/08 20130101;
E21B 43/112 20130101 |
Class at
Publication: |
166/298 ; 166/55;
166/386 |
International
Class: |
E21B 29/08 20060101
E21B029/08 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 30, 2011 |
EP |
11183494.1 |
Claims
1.-25. (canceled)
26. A punching tool (1) for providing a hole (2a) or a dimple (2b)
in a metal casing (3) in a borehole (4), comprising: a tool body
(5) having an axial extension (6), and a punching unit (11)
connected with the tool body, comprising: a bore (27a) provided in
the tool body, extending substantially radially in relation to the
axial extension, a fluid inlet (26) in fluid communication with the
bore, and a hydraulically activated punch (9) arranged in the bore,
being movable between a retracted and a projected position, wherein
the hydraulically activated punch is moved into the projected
position by injecting a fluid into the bore through the fluid
inlet.
27. A punching tool according to claim 26, further comprising two
isolation devices (70) circumferenting the tool body and arranged
spaced apart in the axial extension on opposite sides of the
punching unit, the isolation devices being expandable from the tool
body in a radial direction, thereby providing zonal isolation of a
section (75) of the casing downhole, and wherein the punching tool
further comprises one or more injection nozzles (80) for injecting
a fluid into the section of the casing being isolated by the
isolation devices, the injection nozzle being arranged between the
isolation devices.
28. A punching tool according to claim 27, further comprising a
pump (18) arranged in association with the tool body, the pump
being connected to the fluid inlet for supplying a hydraulic fluid
to the bore to move the hydraulically activated punch into the
projected position.
29. A punching tool according to claim 28, wherein the isolation
devices are constituted by inflatable packers being inflated and
expanded from the tool body by the pump supplying a fluid to the
inflatable packers.
30. A punching tool according to claim 28, wherein the pump is in
fluid communication with the one or more injection nozzles and the
pump is adapted to inject a fluid into the section of the casing
being isolated by the isolation devices through the one or more
injection nozzles.
31. A punching tool according to claim 30, further comprising an
inlet (81) fluidly connecting the pump with an annulus (82)
surrounding the punching tool, wherein the pump is adapted to draw
fluid from the annulus and inject the fluid from the annulus
through the one or more injection nozzles into the section of the
casing being isolated by the isolation devices.
32. A punching tool according to claim 26, wherein the punching
unit comprises an abutment (10) arranged circumferentially opposite
the hydraulically activated punch around the tool body.
33. A punching tool according to claim 32, wherein part of the
hydraulically activated punch engages part of the abutment to
control the radial movement between the retracted and the projected
position of the hydraulically activated punch.
34. A punching tool according to claim 32, wherein one of the
hydraulically activated punch and the abutment comprises one or
more radially extending guide elements (50) and the other of the
hydraulically activated punch and the abutment comprises one or
more radially extending tracks (51) being adapted to engage with
the guide elements to control the radial movement between the
retracted and the projected position of the hydraulically activated
punch.
35. A punching tool according to claim 32, wherein the
hydraulically activated punch and the abutment define an expandable
space (31).
36. A punching tool according to claim 26, wherein the
hydraulically activated punch and the abutment are arranged in a
through-bore (27b) in the tool body.
37. A punching tool according to claim 36, wherein the piston is
movable in a hollow space (19a, 19b) defined by the hydraulically
activated punch or a base part (42) of the hydraulically activated
punch, and wherein the piston is connected with the abutment
through a piston rod (23).
38. A punching tool according to claim 36, wherein one of the
hydraulically activated punch and the abutment is connected with
the piston through a piston rod (23) and the other of the
hydraulically activated punch and the abutment has an end arranged
inside the tool body, the end comprising a flange (22), and wherein
a spring (24) is arranged between the piston and the flange.
39. A punching tool according to claim 26, wherein a stop element
(45) is arranged in connection with the hydraulically activated
punch and the abutment to avoid separation of the hydraulically
activated punch and the abutment.
40. A punching tool according to claim 26, wherein the
hydraulically activated punch is a punch adapted to install a plug
(61) in an existing hole (2c) in the casing downhole to seal the
existing hole.
41. A punching tool according to claim 40, wherein the
hydraulically activated punch is further adapted to hold on to the
plug prior to installing the plug in the existing hole, to place
the plug in the existing hole when the hydraulically activated
punch is moved into a projected position, and to deform the plug
when the hydraulically activated punch is moved into a fully
projected position.
42. A method for providing a hole or a dimple in a metal casing
downhole, comprising the steps of: providing a punching tool
according to claim 26 in the metal casing downhole, positioning the
punching unit of the punching tool at a location where a hole or
dimple is to be provided, positioning the abutment arranged
circumferentially opposite the hydraulically activated punch around
the tool body so that it abuts a casing wall at a position
circumferentially opposite the hydraulically activated punch, and
moving the hydraulically activated punch radially from a retracted
position to a projected position so that a hole or dimple is
provided in the metal casing by the hydraulically activated punch
in its projected position.
43. A method according to claim 42, wherein the hydraulically
activated punch is moved radially to provide a hole in the metal
casing, the method further comprising the steps of: expanding the
isolation devices from the tool body in a radial direction, thereby
providing zonal isolation of a section (75) of the casing downhole,
and injecting a fluid into the section of the casing being isolated
by the isolation devices, thereby forcing a fluid through the hole
provided in the casing.
44. A method according to claim 42, wherein the hydraulically
activated punch is moved radially to provide a dimple in the metal
casing, the method further comprising the step of: arranging an
electronic device (60) in the dimple or hole, the electronic device
comprising a radio-frequency identification (RFID) chip, a
radio-frequency tag (RFT) and/or one or more sensors, such as a
temperature sensor.
45. A method for installing a plug, such as a Lee-plug, in an
existing hole in the casing downhole, the method comprising the
steps of: providing a punching tool according to claim 40, in the
casing downhole, positioning the punching unit of the punching tool
at a location opposite the existing hole, positioning the abutment
arranged circumferentially opposite the hydraulically activated
punch around the tool body so that it abuts a casing wall at a
position circumferentially opposite the hydraulically activated
punch, moving the hydraulically activated punch radially from a
retracted position to a projected position to place the plug in the
existing hole, and moving the hydraulically activated punch to a
fully projected position, thereby deforming the plug to secure the
plug and seal the existing hole.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a punching tool for
providing a hole or a dimple in a metal casing in a borehole. The
present invention further relates to a method for providing a hole
or a dimple in a metal casing downhole and to a method for
installing a plug in an existing hole in the casing downhole.
BACKGROUND ART
[0002] When producing hydrocarbons from a well, the casing is most
often perforated by means of detonations to provide holes in the
casing for letting the formation fluid into the casing. However,
using detonations for perforating is risky, and there is therefore
an increasing demand for alternative methods for making such
holes.
[0003] Perforations or holes in a casing may be used for various
purposes, such as for injection purposes, for insertion of
completion elements, e.g. valves after making the completion, or
for allowing fluid to flow from the formation into the casing.
There is thus a need for an apparatus and a method for providing
perforations or holes without using detonation of charges.
[0004] Further, when a hole or perforations are to be used for
injection purposes, e.g. for providing an annular seal in an
annulus, determination of the exact position of the hole in
relation to an injection apparatus is a difficult task. If the
exact position cannot be established, a large section of the casing
has to be sealed off to perform the injection. In this regard, one
applied solution is to provide a seal downhole well below the
injection hole and simply pressurise the entire well down to the
seal to inject the fluid. Such an operation is cumbersome and
requires a great amount of injection fluid, making it a
cost-intensive operation.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to wholly or partly
overcome the above disadvantages and drawbacks of the prior art.
More specifically, it is an object to provide a solution for
providing holes in a casing without using detonation of
charges.
[0006] The above objects, together with numerous other objects,
advantages, and features, which will become evident from the below
description, are accomplished by a solution in accordance with the
present invention by a punching tool for providing a hole or a
dimple in a metal casing in a borehole, comprising:
[0007] a tool body having an axial extension, and
[0008] a punching unit connected with the tool body, comprising:
[0009] a bore provided in the tool body, extending substantially
radially in relation to the axial extension, [0010] a fluid inlet
in fluid communication with the bore, and [0011] a hydraulically
activated punch arranged in the bore, being movable between a
retracted and a projected position,
[0012] wherein the hydraulically activated punch is moved into the
projected position by injecting a fluid into the bore through the
fluid inlet.
[0013] The punching tool described above may further comprise two
isolation devices circumferenting the tool body and arranged spaced
apart in the axial extension on opposite sides of the punching
unit, the isolation devices being expandable from the tool body in
a radial direction, thereby providing zonal isolation of a section
of the casing downhole, wherein the punching tool further comprises
one or more injection nozzles for injecting a fluid into the
section of the casing being isolated by the isolation devices, the
injection nozzle being arranged between the isolation devices.
[0014] Hereby, when a section of the casing downhole has been
isolated and a hole in the casing has been punched, a fluid may be
injected into the section inside the casing isolated by the
isolation devices to inflate an annular barrier arranged in fluid
communication with the isolated section via the punched hole. The
punching tool may thus be used for providing a hole in the casing
downhole and subsequently for injecting a fluid though the hole. By
using a tool having a punching unit arranged between a set of
isolation devices, it is guaranteed that the hole in the casing is
provided in the isolated section. Had the hole been punched by a
first punching tool and the section of the casing been isolated by
a second isolation and injection tool, great care would have to be
taken to position the isolation and injection tools to secure that
the hole punched was in fact in the isolated section of the casing.
The punching tool may also be used for other injection purposes,
such as for inflating a packer, for stimulating the pressure in
inflatable packers or other types of annular barriers, for acid
treatment of a formation outside a casing or for fracking
purposes.
[0015] In one embodiment, the hydraulically activated punch may
have a punching edge for providing a hole in a metal casing.
[0016] The punching tool described above may further comprise a
pump arranged in association with the tool body, the pump being
connected to the fluid inlet for supplying a hydraulic fluid to the
bore to move the hydraulically activated punch into the projected
position.
[0017] In an embodiment, the isolation devices may be constituted
by inflatable packers being inflated and expanded from the tool
body by the pump supplying a fluid to the inflatable packers.
[0018] Furthermore, the isolation devices may be inflatable
packers, swellable packers, compression or cup packers, other
downhole packers, retrieval packers or combinations thereof.
[0019] Additionally, the pump may be in fluid communication with
the one or more injection nozzles, and the pump may be adapted to
inject a fluid into the section of the casing being isolated by the
isolation devices through the one or more injection nozzles.
[0020] The punching tool described above may further comprise an
inlet fluidly connecting the pump with an annulus surrounding the
punching tool, wherein the pump is adapted to draw fluid from the
annulus and inject the fluid from the annulus through the one or
more injection nozzles into the section of the casing being
isolated by the isolation devices.
[0021] Moreover, the punching unit may comprise an abutment
arranged circumferentially opposite the hydraulically activated
punch around the tool body.
[0022] In addition, part of the hydraulically activated punch may
engage part of the abutment to control the radial movement between
the retracted and the projected position of the hydraulically
activated punch.
[0023] Furthermore, one of the hydraulically activated punch and
the abutment may comprise one or more radially extending guide
elements, and the other of the hydraulically activated punch and
the abutment may comprise one or more radially extending tracks
being adapted to engage with the guide elements to control the
radial movement between the retracted and the projected position of
the hydraulically activated punch.
[0024] Also, the hydraulically activated punch and the abutment may
define an expandable space.
[0025] The punching unit may further comprise a piston and a spring
which is compressed when the hydraulically activated punch is moved
into the projected position.
[0026] Moreover, the hydraulically activated punch and the abutment
may be arranged in a through-bore in the tool body.
[0027] In addition, sealing means may be arranged in grooves in the
through-bore of the tool body to seal against the hydraulically
activated punch, and/or the abutment may be arranged in the
through-bore.
[0028] Such sealing means may be arranged in grooves in the
hydraulically activated punch, the punch base part and/or the
abutment to seal against the through-bore and the tool body.
[0029] In an embodiment, the tool may comprise a plurality of
punching units.
[0030] In another embodiment, the tool may comprise a plurality of
punching units and a plurality of abutments.
[0031] Furthermore, the piston may be movable in a hollow space
defined by the hydraulically activated punch or a base part of the
hydraulically activated punch, and the piston may be connected with
the abutment through a piston rod.
[0032] Additionally, the piston may be movable in a hollow space
defined by the abutment, and the piston may be connected with the
hydraulically activated punch through a piston rod.
[0033] Also, one of the hydraulically activated punch and the
abutment may be connected with the piston through a piston rod, and
the other of the hydraulically activated punch and the abutment may
have an end arranged inside the tool body, the end comprising a
flange, and a spring may be arranged between the piston and the
flange.
[0034] Further, a stop element may be arranged in connection with
the hydraulically activated punch and the abutment to avoid
separation of the hydraulically activated punch and the
abutment.
[0035] Also, the abutment may be fixedly connected with the tool
body.
[0036] The abutment may project radially from the tool body.
[0037] In an embodiment, the stop element may be arranged in
connection with the fluid inlet.
[0038] Furthermore, the fluid inlet may be connected with one or
more fluid channels being in fluid communication with a pressure
side of the piston.
[0039] A distance between the retracted and a projected position of
the punch may be 3 mm, preferably above 10 mm, most preferably
above 20 mm, and more preferably above 100 mm.
[0040] Moreover, the punch may comprise a pointed surface adapted
to rupture the metal casing during the movement of the
hydraulically activated punch from the retracted to the projected
position.
[0041] Additionally, the abutment may comprise a "curved" (convex)
face which is adapted to abut an inner surface of a tubular metal
casing during the punching.
[0042] Further, the abutment may comprise attachment elements so
that the face of the abutment can be changed in relation to the
inner surface of the metal casing.
[0043] In an embodiment, the tool may comprise an electrical motor
driving the pump.
[0044] In addition, the tool may comprise a fluid reservoir for
containing a fluid for being injected into the bore to move the
hydraulically activated punch into the projected position, a fluid
reservoir for containing a fluid for being injected into the
inflatable packers to inflate and expand the inflatable packers
from the tool body, and/or a fluid reservoir for containing a fluid
for being injected into the isolated section of the casing through
the one or more injection nozzles.
[0045] Moreover, the fluid reservoir may be one common fluid
reservoir.
[0046] Furthermore, the hydraulically activated punch may be a
punch adapted to provide a dimple in a metal casing.
[0047] Additionally, the hydraulically activated punch may be a
punch having rounded edges.
[0048] Also, the hydraulically activated punch may be a pin punch,
a centre punch, a taper punch, a flat chisel, a cape chisel, a
half-round nose chisel or a combination thereof.
[0049] Further, the hydraulically activated punch may be a punch
adapted to install a plug in an existing hole in the casing
downhole to seal the existing hole.
[0050] Hereby, if an annular barrier or packer bursts, an inlet to
such annular barrier or packer may be sealed off to avoid fluid
from flowing from the casing and into the formation through the
defect annular barrier or packer. Thus, by installing a plug in an
inlet of the defect annular barrier or packer, the remaining
annular barriers or packers may still be inflated by pressurising
the well from the top or by pressurising a section of the well
containing the defect annular barrier or packer.
[0051] Moreover, the punch may have a cavity in which the plug can
be arranged.
[0052] In an embodiment, the hydraulically activated punch may be
further adapted to hold on to the plug prior to installing the plug
in the existing hole, to place the plug in the existing hole when
the hydraulically activated punch is moved into a projected
position, and to deform the plug when the hydraulically activated
punch is moved into a fully projected position.
[0053] In addition, the cavity of the punch may have a
circumferential projection or a plurality of projections matching a
circumferential groove in the plug.
[0054] By having a projection matching the groove of the plug, the
plug can be held in place before being inserted, and when the hole
has been plugged, the plug is secured in the hole so that the force
securing the plug in the hole is greater than a force enabling
detachment of the plug from the punch. The plug is thus easily
detached from the punch when the plug has been punched in the
hole.
[0055] The present invention furthermore relates to a method for
providing a hole or a dimple in a metal casing downhole, comprising
the steps of:
[0056] providing a punching tool as described above in the metal
casing downhole,
[0057] positioning the punching unit of the punching tool at a
location where a hole or dimple is to be provided,
[0058] positioning the abutment arranged circumferentially opposite
the hydraulically activated punch around the tool body so that it
abuts a casing wall at a position circumferentially opposite the
hydraulically activated punch, and
[0059] moving the hydraulically activated punch radially from a
retracted position to a projected position so that a hole or dimple
is provided in the metal casing by the hydraulically activated
punch in its projected position.
[0060] Furthermore, the hydraulically activated punch may be moved
radially to provide a hole in the metal casing, the method further
comprising the steps of expanding the isolation devices from the
tool body in a radial direction, thereby providing zonal isolation
of a section of the casing downhole, and injecting a fluid into the
section of the casing being isolated by the isolation devices,
thereby forcing a fluid through the hole provided in the
casing.
[0061] Moreover, the hydraulically activated punch may be moved
radially to provide a dimple in the metal casing, the method
further comprising the step of arranging an electronic device in
the dimple or hole, the electronic device comprising a
radio-frequency identification (RFID) chip, a radio-frequency tag
(RFT) and/or one or more sensors, such as a temperature sensor.
[0062] Finally, the present invention relates to a method for
installing a plug, such as a Lee-plug, in an existing hole in the
casing downhole, the method comprising the steps of:
[0063] providing a punching tool as described above in the casing
downhole,
[0064] positioning the punching unit of the punching tool at a
location opposite the existing hole,
[0065] positioning the abutment arranged circumferentially opposite
the hydraulically activated punch around the tool body so that it
abuts a casing wall at a position circumferentially opposite the
hydraulically activated punch,
[0066] moving the hydraulically activated punch radially from a
retracted position to a projected position to place the plug in the
existing hole, and
[0067] moving the hydraulically activated punch to a fully
projected position, thereby deforming the plug to secure the plug
and seal the existing hole.
[0068] In one embodiment, part of the plug may be plastically
deformed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0069] The invention and its many advantages will be described in
more detail below with reference to the accompanying schematic
drawings, which for the purpose of illustration show some
non-limiting embodiments and in which
[0070] FIG. 1 shows a punching tool in a casing,
[0071] FIG. 2 shows a partly cross-sectional view of the punching
tool,
[0072] FIG. 3 shows a partly cross-sectional view of another
embodiment of the punching tool,
[0073] FIG. 4 shows another embodiment of the punching tool in a
casing,
[0074] FIG. 5 shows yet another embodiment of the punching tool in
a casing,
[0075] FIG. 6 shows yet another embodiment of the punching tool in
a casing,
[0076] FIG. 7 shows a partly cross-sectional view of another
embodiment of the punching tool along the axial extension of the
tool,
[0077] FIG. 8 shows a partly cross-sectional view of another
embodiment of the punching tool along a radial extension of the
tool perpendicular to the axial extension of the tool,
[0078] FIG. 9 shows a partly cross-sectional view of a punching
tool for providing a dimple in a casing downhole,
[0079] FIG. 10 shows a cross-sectional view of a casing in which an
electronic device has been secured in a dimple,
[0080] FIG. 11 shows a partly cross-sectional view of the punching
tool comprising isolation devices for providing zonal isolation of
a section of the casing,
[0081] FIG. 12 shows a partly cross-sectional view of the punching
tool comprising an injection nozzle for injecting a fluid into the
isolated section of the casing, and
[0082] FIG. 13 shows a partly cross-sectional view of a punching
tool comprising a hydraulically activated punch adapted to install
a plug in an existing hole in a casing downhole.
[0083] All the figures are highly schematic and not necessarily to
scale, and they show only those parts which are necessary in order
to elucidate the invention, other parts being omitted or merely
suggested.
DETAILED DESCRIPTION OF THE INVENTION
[0084] FIG. 1 shows a punching tool 1 having just punched a hole 2a
in a casing 3 in a borehole 4. The punching tool 1 comprises a tool
body 5 having an axial extension 6, a punching unit 11 comprising a
bore 27a provided in the tool body, and a hydraulically activated
punch 9 which is movable between a retracted and a projected
position to be able to punch out a piece 12 of a wall 13 of the
casing 3 or to provide a dimple in a wall 13 of the casing 3. The
hydraulically activated punch may also be used for applying a force
to an object, such as a plug, downhole, e.g. to plug a hole in the
casing. The hydraulically activated punch 9 is arranged in a bore
27a extending in a direction substantially radial in relation to
the axial extension of the tool body, and a fluid inlet 26 in fluid
communication with the bore is provided to enable injection of a
fluid into the bore to activate the hydraulically activated punch.
The punching unit further comprises an abutment 10 arranged
circumferentially opposite the hydraulically activated punch around
the tool body to abut the wall of the casing so that the force
generated by injection of the fluid into the bore is applied to the
hydraulically activated punch and exploited to move the
hydraulically activated punch in the radial direction. The abutment
is fixedly connected with the tool body.
[0085] In one embodiment, the punching tool further comprises two
isolation devices 70 for providing zonal isolation of a section 75
of the casing and a plurality of injection nozzles 80 for injecting
a fluid into the isolated section of the casing, as shown in FIGS.
11-12. The isolation devices 70 circumferent the tool body and are
positioned along the tool body on opposite sides of the punching
unit, and are expandable from the tool body in a radial direction.
When the isolation devices 70 are expanded, they isolate a section
75 of the casing, thereby providing zonal isolation. The isolation
devices 70 may be constituted by inflatable packers, swellable
packers, compression or cup packers, other downhole packers,
retrieval packers, combinations thereof or any other means known to
the skilled person for providing a seal between the inner wall of
the casing and the tool body. The injection nozzles 80 are arranged
between the isolation devices 70, allowing a fluid to be injected
into the isolated section 75 of the casing through the injection
nozzles.
[0086] The punching tool 1 is submerged into the well and is
powered through a wireline 14 and connected with the tool through a
cable head 15. The punching tool 1 comprises a motor 17 connected
with the cable head 15 through an electronic section 16 and a pump
18 driven by the motor, which pump supplies a fluid under pressure
to the bore 27a via the fluid inlet 26 to activate the
hydraulically activated punch 9. In one embodiment, the pump is
further in fluid communication with the isolation devices 70
constituted by inflatable packers. Accordingly, the inflatable
packers are inflated and expanded from the tool body by the pump
supplying a fluid to the inflatable packers. In a further
embodiment, the pump is in fluid communication with the injection
nozzle 80 via a conduit 83 extending in the axial extension of the
punching tool, as indicated by the dotted lines in FIG. 11. The
pump is further fluidly connected to an inlet 81 provided in the
punching tool, whereby fluid may be drawn in by the pump from an
annulus 82 surrounding the punching tool. The fluid drawn in from
the annulus may subsequently be supplied to the injections nozzles
80 via the conduit 83 and injected into the isolated section of the
casing. When a hole 2a is provided in the wall of the isolated
section of the casing and fluid is continuously injected into that
section, the fluid in the section will be displaced through the
hole 2a, as shown in FIG. 12. The hole 2a, 2c may be an existing
hole 2c or a hole 2a provided by the punching tool, and the casing
may also have a plurality of holes through which the fluid can be
injected.
[0087] In FIG. 2, the hydraulically activated punch 9 defines a
hollow space 19a in which a piston 20 is arranged, enabling the
hydraulically activated punch 9 to move from its retracted position
to its projected position, thus functioning as a hydraulic punch
cylinder. The hydraulically activated punch 9 moves inside an
expandable space 31 primarily defined by the bore 27a. In one end,
the hydraulically activated punch 9 has a punching edge 21a for
providing a hole in a metal casing, and in the opposite end, a
flange 22 extending towards a piston rod 23 of the piston is
provided. Between the flange 22 and the piston, a spring 24 is
arranged which is compressed when the hydraulically activated punch
is in its projected position. In another embodiment, the end of the
hydraulically activated punch extending from the tool body may
alternatively be adapted to provide a dimple in a metal casing, as
illustrated in FIG. 9. The hydraulically activated punch for
providing a dimple in the metal casing may have a shape
substantially similar to that of a pin punch, a centre punch, a
taper punch, a flat chisel, a cape chisel, a half-round nose
chisel, a combination thereof, or any other shape for providing a
dimple known to the skilled person.
[0088] Further, in another embodiment, the hydraulically activated
punch is adapted to install a plug 61 in an existing hole 2c in the
casing, as shown in FIG. 13. The hydraulically activated punch is
adapted to hold on to the plug prior to installation and to place
the plug in the existing hole by moving the hydraulically activated
punch into a projected position. After having placed the plug in
the hole 2c, the plug may be deformed by further moving the
hydraulically activated punch into a fully projected position,
whereby the plug is secured in the hole and the hole is sealed. The
plug may be any kind of plug suitable for sealing a hole in a
casing downhole, such as a plug sold under the trade name Lee Plug
by The Lee Company. What is special about the Lee Plug is that only
a radial force is required to install the plug, and such a plug may
thus be installed by the punching tool according to the present
invention.
[0089] After having plugged the hole, the hydraulically activated
punch may be moved further radially from the tool body in an even
further projected position, forcing the plug further outwards and
deforming the casing wall so that the plug does not diminish the
inner diameter of the casing. In this way, the plug plugs the hole
and is used to provide a dimple in the casing wall.
[0090] The pump 18 illustrated by dotted lines in FIG. 2 provides
fluid through fluid channels 25 into the expandable space 31
through inlets 26 in order to force the hydraulically activated
punch radially outwards from the tool body 5. When the punching
process is completed, the pump stops pumping fluid into the
expandable space 31, and the fluid is forced back into the fluid
channel 25 by the decompressing force of the spring 24. Sealing
means 28 is arranged in grooves 29 in the bore 27a of the tool body
to seal against the hydraulically activated punch 9.
[0091] By having a hydraulically activated punching tool, the
punching force can be substantially increased compared to prior art
mechanically operated solutions. Furthermore, tests have shown that
the hole in the casing can be made with a higher degree of accuracy
and that this cut is cleaner, leaving almost no burrs on the edges.
The prior art solutions leave substantial burrs on the edges,
hindering the insertion of a valve in the hole in a subsequent
process. If the hole is made to open the casing to an inflow of
well fluid, such as hydrocarbons, also called oil and/or gas, the
burrs hinder an optimal inflow, causing a more turbulent flow
before the hole at the burring side.
[0092] In FIG. 3, also the abutment 10 projects radially from the
tool body 5, and it is therefore slideably arranged in a second
bore 32 provided in the tool body. The abutment 10 is activated by
injecting a fluid into the second bore 32, whereby the abutment 10
moves radially in relation to the axial extension. The abutment has
a hollow space 33 in which a second piston 34 moves, thereby
compressing a second spring 35 between the piston and a second
flange 36 provided in one end of the abutment opposite an outer
face of the abutment abutting the inner wall of the casing. The
fluid is injected into the second bore 32 by the pump pumping a
fluid into the expandable space 38 via second fluid channels 37 and
through second inlets 39. One pump may thus supply fluid to move
both the hydraulically activated punch 9 and the abutment 10, and
the fluid channels 25, 37 supplying fluid to the hydraulically
activated punch 9 and the abutment 10 may be one channel.
[0093] The punching tool 1 may comprise several punching units 11
punching holes in the casing in a predetermined pattern, as shown
in FIG. 4. Thus, the punching tool can be used instead of a
perforation gun, thereby avoiding the risky detonations downhole.
As can be seen in FIG. 5, the punching tool 1 comprises second
punching units 11b also arranged circumferentially opposite the
first punching units 7 around the tool body 5. The second punching
units have the same design as the first punching units 7 and
function as abutments in relation to the first punching units 7.
Similarly, the first punching units function as abutments to the
second punching units 11b. The punching units shown in FIG. 5 are
arranged with an angular spacing of 180.degree..
[0094] As shown in FIG. 6, the punching tool 1 may further comprise
third punching units 11c and fourth punching units (not shown)
arranged opposite each other and between the first and second
punching units. The third and fourth punching units have a design
similar to that of the previously described punching units and
function as abutments in relation to one another. Each of the
punching units is thus arranged with an angular displacement of
90.degree. along the circumference of the punching tool. Further,
the third and fourth punching units are displaced in an axial
direction of the punching tool in relation to the first and second
punching units. The punching tool shown in FIG. 5 thus comprises 10
punching units spaced apart to optimise the tool length, and all
the punching units may be supplied with fluid from the same pump
through the same channel or through several channels.
[0095] In another embodiment shown in FIG. 7, the hydraulically
activated punch and the abutment are arranged in a through-bore
27b. As shown, the abutment 10 and the hydraulically activated
punch 9 engage one another, forming two common fluidly connected
expandable spaces 31. The radial movement of the abutment and the
hydraulically activated punch thus occurs by the abutment and the
hydraulically activated punch moving radially away from each other.
A piston 20 provided on a piston rod 23 is arranged in each of the
expandable spaces 31, and the piston rods 23 are connected with the
abutment 10 by screws 41. The hydraulically activated punch 9 is
connected with a punch base part 42 defining part of each of the
expandable spaces 31, and the punch base part 42 is again
threadedly connected with two inserts 40. The pistons are movable
within each of the expandable spaces 31. The inserts 40 each have a
flange 22 which together with the piston compresses a spring 24
when the hydraulically activated punch and the abutment are
projected from the tool body. The hydraulically activated punch 9
and the abutment 10 are forced away from each other by means of
fluid pumped into the expandable space 31 through fluid channels 25
and is led into the expandable space through a circumferential
groove 43 leading the fluid in through the inlet 26 and into a
cylinder bore 44. Sealing means 28 are arranged in grooves 29 in
the through-bore 27b in which the hydraulically activated punch and
the abutment are arranged, preventing the fluid from escaping into
the annulus 82 surrounding the tool.
[0096] In order to fasten the hydraulically activated punch 9 and
the abutment 10 to each other, a hollow rod 45 functioning as a
stop element is arranged penetrating both the hydraulically
activated punch and the abutment. Both comprise an elongated
opening allowing the hydraulically activated punch 9 and the
abutment 10 to move in relation to the rod and each other. The rod
is hollow to be able to lead the fluid and has openings for the
fluid to enter, thus leading the fluid into the expandable space
31. The fluid inlet 26 is thus positioned in the centre of the
punching unit.
[0097] In another embodiment shown in FIG. 8, the punching unit 11
is rotated 90 degrees compared to the punching unit shown in FIG.
8. Otherwise, the punching unit shown in FIG. 8 has substantially
the same design as the punching unit of FIG. 7. In FIG. 8, the
punching unit, however, has a fluid channel 46 in the punch base
part 42 to lead the fluid from the hollow rod 45 to one end of each
of the expandable spaces 31 so that the fluid is injected into the
expandable spaces acting directly on the pistons. Hereby, the
initial movement of the hydraulically activated punch 9 and the
abutment 10 requires less fluid power.
[0098] In FIGS. 7 and 8, part of the hydraulically activated punch
9 engages part of the abutment 10 to control the radial movement
between the retracted and the projected position of the
hydraulically activated punch 9. The abutment 10 has radially
extending guide elements 50 engaging radially extending tracks 51
of the hydraulically activated punch 9. Hereby, the hydraulically
activated punch 9 engages the abutment 10 on an outside thereof or
vice versa so as to control the radial movement between the
retracted and the projected position of the hydraulically activated
punch 9. In FIG. 8, the sealing means 28 are arranged in grooves in
the punch base part 42 and in the abutment to seal against the
through-bore 27b and the tool body 5.
[0099] The punching tool 1 is designed so that the distance between
the retracted and the projected position of the hydraulically
activated punch is above 5 mm, preferably above 10 mm, more
preferably above 20 mm, and most preferably above 50 mm. However,
this depends on the completion and the restrictions already present
in the completion.
[0100] The punching tool may be used to punch only a small hole
having a diameter smaller than that of the hydraulically activated
punch, and thus, the hole is made by the tip of the hydraulically
activated punch. When having a double-cased casing and when the
inner casing is blocked in the bottom, it may be necessary to make
small relief holes and even pump gas down through the outer casing
in through the inner casing to force the fluid upwards. Such relief
holes may also be necessary to even out the pressure between the
casing and the annulus. When making relief holes, the piece of the
casing is not separate from the rest of the casing and does not
flow freely in the annulus.
[0101] The punching tool may have several abutments and one
hydraulically activated punch, all of which are hydraulically
activated so that the abutments are positioned on both sides of the
hydraulically activated punch and are projected radially until the
hydraulically activated punch presses against the inner wall of the
casing. Subsequently, the hydraulically activated punch is
activated and cuts its way into the casing wall without having to
travel a certain length before reaching the inner casing wall. In
this way, the hydraulically activated punch is capable of
penetrating thicker casings than if it had to travel a certain
length before reaching the inner casing wall.
[0102] The hydraulically activated punch may be any kind of punch,
e.g. a punch comprising a pointed surface adapted to rupture the
metal casing during the movement of the hydraulically activated
punch from the retracted to the projected position.
[0103] As shown, the abutment has a curved and convex face which is
adapted to abut an inner surface of a tubular metal casing during
the punching. The abutment may comprise attachment elements so that
the face of the abutment can be changed in relation to the inner
surface of the metal casing. The abutment face may then change to a
teethed surface or a similar design to better be able to fasten the
tool while punching the hole.
[0104] The pump of the tool takes fluid in from the well through a
filter, but the tool may instead comprise a fluid reservoir, or the
fluid may be led from the surface through the wireline which is
thus also a supply line.
[0105] In the following, the use of the punching tool will be
described in further detail. In FIG. 9, the punching tool comprises
a hydraulically activated punch 9 for providing a dimple 2b in the
casing downhole. When the punching tool has been inserted into the
casing and the punching unit has been positioned at a location
where a dimple is to be provided, the abutment 10 arranged
circumferentially opposite the hydraulically activated punch is
positioned so that it abuts the casing. Subsequently, the
hydraulically activated punch is moved radially from the retracted
position to the projected position so that a dimple is provided in
the metal casing. When the dimple has been provided, the
hydraulically activated punch is retracted into the tool body, and
an electronic device 60 is secured in the dimple, as shown in FIG.
10. The electronic device may have various functionalities and may
comprise a radio-frequency identification (RFID) chip, a
radio-frequency tag (RFT), and/or one or more sensors, such as a
temperature sensor.
[0106] In FIG. 11, the punching tool comprises a hydraulically
activated punch 9 for providing a hole 2a in the casing downhole.
When the punching tool has been inserted into the casing and the
punching unit has been positioned at a location where a hole is to
be provided, the abutment 10 arranged circumferentially opposite
the hydraulically activated punch is positioned so that it abuts
the casing. The isolation devices 70 are also expanded from the
tool body, thereby sealing off a section 75 of the casing.
Subsequently, the hydraulically activated punch is moved radially
from the retracted position to the projected position so that a
hole 2a is provided in the metal casing. When the hole has been
provided, the hydraulically activated punch is retracted into the
tool body by the force exerted by the spring shown in the
previously mentioned figures. The isolation devices 70 may also be
expanded when the hole has been punched in the casing to seal off
the section 75 of the casing. When the hole has been punched and
the section of the casing has been isolated, a fluid is injected
into the section of the casing being isolated by the isolation
devices, as shown in FIG. 12. Thereby, the fluid present in the
isolated section is forced through the hole 2a in the casing and
into an annular barrier 90. The punching tool may thus be used for
expanding the annular barrier or stimulating the pressure in the
annular barrier, e.g. to expand the annular barrier even further.
The punching tool may also be used for other injection purposes
envisaged by the skilled person, such for inflating inflatable
packers or other types of annular barriers, for flushing the
annulus after insertion of the casing, for acid treatment of a
formation outside a casing or for fracking purposes.
[0107] In FIG. 13, the punching tool comprises a hydraulically
activated punch 9 for installing a plug 61 in an existing hole 2c
in the casing. This functionality may be relevant if an annular
barrier forming part of a series of annular barriers is defect. An
annular barrier may be defect if for example the annular barrier
have burst during inflation as shown in FIG. 13, or if the annular
barrier is leaking for other reasons, and fluid injected into the
well to inflate the series of annular barriers will thus flow
through the defect annular barrier into the formation. Hereby, the
series of annular barriers cannot be inflated as the required
pressure cannot be reached by pressurising the well from the top or
by pressurising a section of the well containing the defect annular
barrier. However, by installing the plug 61 in the existing hole 2c
constituting an inlet to the defect annular barrier, the defect
annular barrier is sealed off and the remaining annular barriers
may still be inflated.
[0108] In order to be able to install a plug in an existing hole
2c, the exact position of the existing hole must be known and the
operator must be able to position the punching tool in the correct
position to install the punch. To facilitate positioning of the
punching tool, the casing in the vicinity of the annular barrier
and the punching tool may be provided with associated marker tags
91 and marker tag identifications means 92. The marker tag 91 may
be arranged on the casing and the marker tag identification means
92 may be arranged on the punching tool, or the other way around.
The marker tag 91 may be a radio-frequency identification (RFID)
chip, a radio-frequency tag (RFT) or any other device adapted to
send or receive a signal known to the skilled person, and the
marker tag identification means 92 may be any kind of sensor or
receiver known to the skilled person for detecting the position of
the marker tag 91 in relation to the punching tool. In one
embodiment, the marker tag 91 and the marker tag identification
means 92 may be replaced by mechanical positioning means, whereby
the punching tool may latch onto the casing to ensure the correct
position of the punching tool in relation to the existing hole
2c.
[0109] When the punching tool has been inserted into the casing and
the punching unit has been positioned with the piston opposite the
existing hole to be sealed, the abutment 10 arranged
circumferentially opposite the hydraulically activated punch is
positioned so that it abuts the casing. Subsequently, the
hydraulically activated punch is moved radially from the retracted
position to the projected position so that the plug is placed in
the hole and the hole is sealed. The installation of the plug may
require that a further radial force is applied to the plug, e.g. to
plastically deform part of the plug. To apply a further radial
force to the plug, the hydraulically activated punch may be moved
to a fully projected position, thereby deforming the plug.
[0110] After having installed the plug in the existing hole 2c
constituting the inlet to the defect annular barrier, the defect
annular barrier is sealed off. Hereby the well may once again be
pressurised to inflate the remaining annular barriers as the
injected fluid does not escape through the defect annular
barrier.
[0111] In another embodiment, the punching tool may comprise
multiple punching units, wherein one or more punching units
comprises a hydraulically activated punch adapted to provide a hole
in the casing and one or more other punching units comprises a
hydraulic activated punch adapted to install a plug. The punching
tool may thus install a plug in an existing hole to seal off that
hole as described above and provide a new hole adjacent to the hole
sealed off. Alternatively, the punching tool may provide a new
hole, enlarge an existing hole or trim a fracture in order to allow
installation of a plug to seal off the existing hole or
fracture.
[0112] By fluid or well fluid is meant any kind of fluid that may
be present in oil or gas wells downhole, such as natural gas, oil,
oil mud, crude oil, water, etc. By gas is meant any kind of gas
composition present in a well, completion, or open hole, and by oil
is meant any kind of oil composition, such as crude oil, an
oil-containing fluid, etc. Gas, oil, and water fluids may thus all
comprise other elements or substances than gas, oil, and/or water,
respectively.
[0113] By a casing is meant any kind of pipe, tubing, tubular,
liner, string etc. used downhole in relation to oil or natural gas
production.
[0114] In the event that the tools are not submergible all the way
into the casing, a downhole tractor can be used to push the tools
all the way into position in the well. A downhole tractor is any
kind of driving tool capable of pushing or pulling tools in a well
downhole, such as a Well Tractor.RTM..
[0115] Although the invention has been described in the above in
connection with preferred embodiments of the invention, it will be
evident for a person skilled in the art that several modifications
are conceivable without departing from the invention as defined by
the following claims.
* * * * *