U.S. patent application number 15/416499 was filed with the patent office on 2017-07-20 for downhole tool, method and assembly.
The applicant listed for this patent is Deep Casing Tools, Ltd.. Invention is credited to Edward D. Scott.
Application Number | 20170204664 15/416499 |
Document ID | / |
Family ID | 51587620 |
Filed Date | 2017-07-20 |
United States Patent
Application |
20170204664 |
Kind Code |
A1 |
Scott; Edward D. |
July 20, 2017 |
DOWNHOLE TOOL, METHOD AND ASSEMBLY
Abstract
A tool assembly (10) comprises a casing section (12), and a
downhole tool (14) comprising a rotary drive (16) and a cutting
member (18). In use, the tool assembly (10) is disposed in a well
borehole (B) and the rotary drive (16) operated to drive rotation
of the cutting member (18) to cut the borehole (B). The downhole
tool (14) comprises a tubular housing (20) and a cartridge assembly
(36), the cartridge assembly (36) disposed within the housing (20)
of the downhole tool (14) and comprising the rotary drive (16) of
the downhole tool (14). A clutch (78) is provided to enable free
movement of the cutting member (18) during normal operation,
engagement of the clutch (78) preventing rotation of the cutting
member (18) and the housing (20).
Inventors: |
Scott; Edward D.; (Fife,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Deep Casing Tools, Ltd. |
Aberdeen |
|
GB |
|
|
Family ID: |
51587620 |
Appl. No.: |
15/416499 |
Filed: |
January 26, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/GB2015/052218 |
Jul 31, 2015 |
|
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15416499 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 4/02 20130101; E21B
7/20 20130101; E21B 7/203 20130101; E21B 4/003 20130101 |
International
Class: |
E21B 4/02 20060101
E21B004/02; E21B 7/20 20060101 E21B007/20; E21B 4/00 20060101
E21B004/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 1, 2014 |
GB |
1413693.1 |
Claims
1. A downhole tool comprising: a housing; and a cartridge assembly
configured for location within the housing, the cartridge assembly
comprising a rotary drive of the downhole tool.
2. The downhole tool of claim 1, wherein the cartridge assembly
comprises a housing and a shaft, the housing of the cartridge
assembly comprises a stator of the rotary drive and the shaft of
the cartridge assembly comprises a rotor of the rotary drive.
3. The downhole tool of claim 1, wherein the rotary drive comprises
a fluid driven rotary drive.
4. The downhole tool of claim 3, wherein the rotary drive comprises
one of: a positive displacement motor; a turbine; an axial flow
reaction turbine.
5. The downhole tool of claim 2, wherein the housing of the
cartridge assembly is coupled to a housing of the downhole tool,
the housing of the cartridge assembly secured to the housing of the
downhole tool by at least one retainer, the retainer preventing
axial and rotational movement of the housing of the cartridge
assembly relative to the housing of the downhole tool.
6. The downhole tool of claim 1, wherein all or substantially all
of the cartridge assembly is disposed within a drill through
diameter of the downhole tool such that the cartridge assembly is
removable in a drill through operation.
7. The downhole tool of claim 1, further comprising a cutting
member configured for rotation relative to a housing of the
downhole tool by the rotary drive of the cartridge assembly.
8. The downhole tool of claim 1, comprising a bearing.
9. The downhole tool of claim 8, wherein the bearing is fluid
lubricated by fluid from the rotary drive.
10. The downhole tool of claim 9, wherein the bearing is disposed
outside a drill through diameter of the downhole tool such that the
bearing is retained in a drill through operation.
11. The downhole tool of claim 1, comprising a clutch.
12. The downhole tool of claim 11, wherein the clutch is a cone
clutch.
13. A cartridge assembly for a downhole tool, the cartridge
assembly comprising a rotary drive of the downhole tool.
14. A downhole tool assembly comprising: a tubular component; a
downhole tool; and the cartridge assembly comprising a rotary drive
of the downhole tool assembly.
15. A method of running a tubular string into a borehole,
comprising: running a downhole tool into a borehole, the downhole
tool comprising; a housing, and a cartridge assembly configured for
location within the housing, the cartridge assembly comprising a
rotary drive of the downhole tool, or the downhole tool comprising;
a tubular component, a downhole tool, and a cartridge assembly, the
cartridge assembly comprising at least one of, a housing and a
shaft, the housing of the cartridge assembly comprising a stator of
the rotary drive and the shaft of the cartridge assembly comprising
a rotor of the rotary drive, the rotary drive comprising at least
one of (i) a fluid driven rotary drive, and (ii) a positive
displacement motor; and directing fluid through the rotary drive to
operate the downhole tool.
16. A clutch for a downhole tool, the clutch comprising: a male
cone provided on one of a rotor of a downhole tool and a stator of
the downhole tool; a female cone provided on the other of the rotor
of the downhole tool and the stator of the downhole tool and being
operatively associated with the male cone, the male cone and the
female cone configured to engage to rotationally fix the rotor of
the downhole tool and the stator of the downhole tool, wherein at
least one of the male cone and the female cone comprises at least
one axial slot extending at least partially along the length of the
male cone and/or the female cone.
17. A downhole tool comprising a clutch, the clutch comprising: a
male cone provided on one of a rotor of a downhole tool and a
stator of the downhole tool; a female cone provided on the other of
the rotor of the downhole tool and the stator of the downhole tool
and being operatively associated with the male cone, the male cone
and the female cone configured to engage to rotationally fix the
rotor of the downhole tool and the stator of the downhole tool,
wherein at least one of the male cone and the female cone comprises
at least one axial slot extending at least partially along the
length of the male cone and/or the female cone.
18. A downhole tool assembly comprising: a tubular component; a
downhole tool; and a clutch comprising a male cone provided on one
of a rotor of a downhole tool and a stator of the downhole tool and
a female cone provided on the other of the rotor of the downhole
tool and the stator of the downhole tool and being operatively
associated with the male cone, the male cone and the female cone
configured to engage to rotationally fix the rotor of the downhole
tool and the stator of the downhole tool, wherein at least one of
the male cone and the female cone comprises at least one axial slot
extending at least partially along the length of the male cone
and/or the female cone.
19. The downhole tool of assembly of claim 18, wherein the clutch
comprises a male cone and a female cone, wherein at least one of
the male cone and the female cone comprises at least one axial slot
extending at least partially along the length of the male cone
and/or the female cone.
20. A method of running a tubular string into a borehole, the
method comprising: running a downhole tool into a borehole, the
downhole tool comprising; a tubular component, a downhole tool, and
a male cone provided on one of a rotor of a downhole tool and a
stator of the downhole tool and a female cone provided on the other
of the rotor of the downhole tool and the stator of the downhole
tool and being operatively associated with the male cone, the male
cone and the female cone configured to engage to rotationally fix
the rotor of the downhole tool and the stator of the downhole tool,
wherein at least one of the male cone and the female cone comprises
at least one axial slot extending at least partially along the
length of the male cone and/or the female cone; and directing
fluid, such as drill fluid, through the rotary drive to operate the
downhole tool.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of International Application No.
PCT/GB2015/052218 filed on Jul. 31, 2015. Priority is claimed from
British Patent Application No. 1413693.1 filed on Aug. 1, 2014.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
BACKGROUND
[0004] The present disclosure relates to a downhole tool and
assembly. More particularly, but not exclusively, the present
disclosure relates to a cartridge assembly for a downhole tool and
assembly.
[0005] In the oil & gas exploration and production industry, in
order to access hydrocarbons from a formation, a well borehole is
typically drilled from surface and the borehole lined with sections
of metal tubular, known as casing. The casing is then typically
cemented in place to secure and support the casing within the
borehole.
[0006] It will be recognised that conventional drilling and casing
techniques involve a number of separate steps or trips into the
borehole. As a result, techniques for drilling with casing have
been developed, whereby the drill bit is connected to the lowermost
end of the casing and the casing--together with connected drill
bit--is then rotated from surface, such as from the rig floor. In
drilling with casing operations, weight is applied to the casing
from surface as it rotates, the borehole being formed as the drill
bit progresses through the rock strata until the required depth or
target location is reached.
[0007] However, there are a number of limitations with conventional
drilling with casing techniques. For example, casings are generally
provided in a number of different sizes/diameters and larger casing
sizes are more difficult to rotate due to the larger mass.
Moreover, boreholes are often now drilled for significant distances
horizontally or at a high angle from vertical which makes
manipulation of the casing string problematic or impossible.
SUMMARY
[0008] Aspects of the present disclosure relate to the use of a
downhole rotary drive in the drilling, reaming or cutting of a
borehole.
[0009] According to a first aspect of the present disclosure, there
is provided a cartridge assembly for a downhole tool.
[0010] The cartridge assembly may comprise a rotary drive of the
downhole tool.
[0011] In use, the cartridge assembly may be secured to and run
into the borehole with the downhole tool and operable to drive
rotation of a cutting member, cutting structure or the like of the
downhole tool. Beneficially, providing a rotary drive in the form
of a cartridge assembly amongst other things facilitates efficient
drill through of the rotary drive of the downhole tool without
impacting on the surrounding components of the string where it is
desired to extend and/or ream the borehole.
[0012] The rotary drive may be of any suitable form and
construction.
[0013] The rotary drive may comprise a fluid driven rotary drive.
The rotary drive may comprise a motor. In particular embodiments,
the rotary drive may comprise a positive displacement motor. In
other embodiments, the rotary drive may comprise a turbine. In
embodiments where the rotary drive comprises a turbine, the turbine
may comprise an axial flow reaction turbine.
[0014] A body or stator of the rotary drive may be coupled to, or
form part of, a housing of the cartridge assembly.
[0015] A shaft or rotor of the rotary drive may be disposed within
the body or stator and configured for rotation relative to the body
or stator. The shaft may comprise a throughbore. The shaft may be
hollow.
[0016] A fluid flow passage may be defined between the stator and
the rotor for driving rotation of the rotor relative to the
stator.
[0017] A cutting member of the downhole tool may be coupled to, or
form part of, the cartridge assembly. In use, the cutting member
may be rotated by the rotary drive.
[0018] Beneficially, the cutting member of the downhole tool may be
rotated at high speed relative to the casing. As such, rotation of
the casing can be reduced or the string run into the borehole
without rotation.
[0019] The cutting member may be of any suitable form and
construction.
[0020] In some embodiments, the cutting member may comprise a
reaming bit.
[0021] In some embodiments, the cutting member may comprise a drill
bit.
[0022] In some embodiments, the cutting member may comprise a
coring or sampling tool.
[0023] The cartridge assembly may be disposed within the housing of
the downhole tool.
[0024] The cartridge assembly, in particular but not exclusively,
the housing of the cartridge assembly, may be coupled to the
housing of the downhole tool.
[0025] The coupling between the cartridge assembly and the downhole
tool may be configured to prevent relative rotation between the
cartridge assembly and the downhole tool. The coupling may comprise
or form a rotary lock.
[0026] The coupling may be of any suitable form and
construction.
[0027] The cartridge assembly may, for example, be secured to the
downhole tool by at least one retainer. The retainer may comprise a
pin; a dowel, a grub screw or the like, or a combination of these.
The retainer may be radially disposed between the housing of the
cartridge assembly and the housing of the downhole tool. For
example, axially aligned grooves may be formed in the cartridge
assembly housing and the downhole tool housing for receiving the
retainer. In some embodiments, the retainer may be breakable. For
example, in some embodiments the retainer may comprise one or more
shear screw. The retainer may comprise or form part of the rotary
lock.
[0028] A bore-lining tubular or bore-lining tubular string may be
provided. The bore-lining tubular or bore-lining tubular string may
comprise a casing or casing string, a completion string or other
tubular component or string for deployment into the borehole. The
cartridge assembly may be coupled to the bore-lining tubular or
bore-lining tubular string. The cartridge assembly may be directly
coupled to the bore-lining tubular or bore-lining tubular string.
However, in particular embodiments the cartridge assembly may be
indirectly coupled to the bore-lining tubular or bore-lining
tubular string via the housing of the downhole tool.
[0029] Beneficially, in embodiments of the present invention the
bore-lining tubular string may be deployed/run into the borehole
without or substantially without rotation (from surface).
[0030] The housing of the downhole tool may be configured to be
coupled to the casing.
[0031] The housing of the downhole tool may be directly coupled to
the casing. In particular embodiments, the housing of the downhole
tool may be indirectly coupled to the casing via a connector sub or
the like.
[0032] In particular embodiments, the cartridge assembly housing
may be coupled to the downhole tool housing which in turn is
coupled to the casing via the connector sub.
[0033] A coupling may secure the housing of the downhole tool to
the casing or connector sub. In particular embodiments, the
coupling may comprise a threaded coupling. Alternatively, the
coupling between the downhole tool and the casing or connector sub
may comprise a quick connector, push connector, weld or the
like.
[0034] A seal may be provided between the housing of the downhole
tool and the cartridge assembly. In use, the seal may prevent fluid
leakage between the cartridge assembly and the housing of the
downhole tool. The seal may be interposed between the inside of the
housing of the downhole tool and the outside of the cartridge
assembly housing. The seal may be disposed in a groove or recess
provided in at least one of downhole tool housing and the cartridge
assembly housing.
[0035] The seal may be of any suitable form and construction. The
seal may comprise an o-ring, for example.
[0036] The cartridge assembly may comprise or may be operatively
associated with a bearing.
[0037] The cartridge assembly may comprise a modular bearing. For
example, the bearing may comprise a bearing pack comprising a
plurality of bearings. The bearing may comprise or be provided at a
bearing sub coupled to the housing of the downhole tool. The
bearing sub may, for example, be coupled to the housing of the
downhole tool via a threaded connector or the like.
[0038] The bearing may be disposed between the cutting member and
the housing of the downhole tool. The bearing may be of any
suitable form and construction.
[0039] The bearing may comprise at least one thrust bearing.
[0040] The bearing may comprise at least one radial bearing.
[0041] The bearing, or in embodiments where there are more than one
bearing at least one of the bearings, may be fluid lubricated.
[0042] The bearing may be sealed.
[0043] The bearing may be lubricated by fluid from the fluid
passage.
[0044] Part or all of the cartridge assembly and/or the downhole
tool may be configured to facilitate drill through.
[0045] Part or all of the cartridge assembly may be constructed
from a readily drillable material. The rotary drive may be
constructed from aluminium.
[0046] In particular embodiments, all or substantially all of the
cartridge assembly may be disposed within a drill through diameter
of the downhole tool. As such, all of the cartridge assembly may be
removable, such as by a further tool, further drill bit, further
reaming bit or the like.
[0047] The bearing, or in embodiments where there are more than one
bearing at least one of the bearings, may be disposed outside a
drill through diameter of the downhole tool. In particular
embodiments, a ball bearing may be provided and disposed outside
the drill through diameter. Beneficially, providing a bearing
outside the drill through diameter may facilitate more rapid drill
through operations to be carried out. Alternatively, or
additionally, providing a bearing outside the drill through
diameter may permit the integrity of the bearing to be retained,
preventing obstructions from being formed which may otherwise
inhibit passage of tools through the cartridge assembly and/or the
downhole tool.
[0048] A clutch may be provided. The clutch may be configured to
rotationally fix the rotor to the stator. The clutch may be
configured to prevent rotation of the cutting member with respect
to a tubular component, such as the bore-lining tubular string.
[0049] The clutch may be provided or formed between the cutting
member and the rotary drive. The clutch may be provided or formed
between the cutting member and the housing. The clutch may be
provided or formed between the cutting member and the bearing or
bearing sub.
[0050] The clutch may of any suitable form and construction.
[0051] In particular embodiments, the clutch may comprise a cone
clutch, such as that described in US Patent Application Publication
No. 2013/0319769, the contents of which are incorporated herein in
their entirety.
[0052] In particular embodiments, the clutch may comprise a cone
clutch. The clutch may comprise a male cone. The clutch may
comprise a female cone. The male cone may be located within the
female cone. In use, the male cone may engage or mate with the
female cone to engage the clutch. The male cone and the female cone
may be configured to be selectively engaged to rotationally fit the
rotor to the housing.
[0053] The internal taper angle of the female cone and the external
taper angle of the male cone may be matched. The female cone and
the male cone may have a self-locking taper angle. For example, the
self-locking taper angle may be from 0.1 to 10.0 degrees or
more.
[0054] The male cone may be integral with, or coupled to, the
rotor. The female cone may be integral with, or coupled to, the
housing of the rotary drive, or vice-versa.
[0055] The male cone and the female cone may be configured to be
engaged by application of axial force to the housing of the rotary
drive.
[0056] One or more axial restraint may be operatively associated
with the clutch. The axial restraint may be configured to permit
the clutch to be engaged when a selected minimum axial force is
applied, that is where the axial force reaches or exceeds a
predetermined force threshold. The axial restraint may be
configured to be sheared through. The axial restraint may take any
suitable form, shape or construction. In particular embodiments,
the axial restraint--or in embodiments comprising more than one
axial restraint at least one of them--may comprise a shear pin,
shear ring or the like.
[0057] The clutch may comprise an anti-rotation clutch or lock. In
such embodiments, the clutch or lock may be configured to allow
free rotation of the rotor--and the connected cutting
member--relative to the stator during normal operations of the
rotary drive.
[0058] The clutch may be configured to permit fluid, such as
drilling fluid, to flow over the lock during normal operation. The
clutch may comprise an axial slot or slots The axial slot or slots
may extend along--or partially along--the length of the male cone.
The axial slot or slots may extend along--or partially along--the
length of the female cone. In use, the axial slot or slots may be
configured to trap debris carried in the drilling fluid. The axial
slot or slots may be configured to receive debris and retain it
away from the clutch. The axial slot or slots may be dimensioned to
receive an predetermined amount of debris. For example, the axial
slot or slots may be configured to drive debris away from the
clutch. Beneficially, the axial slots may allow the clutch to
operate as designed, unaffected by the presence of any debris that
may have been driven into the downhole tool during its
operation.
[0059] The clutch may be engaged on demand by any suitable method.
The clutch may be engaged by applying axial force on the rotor.
Axial force applied to the rotor may shear through the one or more
axial restraint and permit the clutch to engage. The clutch may be
engaged by increasing the rate of fluid flow rate through the
rotary drive, increasing the pressure drop in the rotary drive
until a predetermined pressure drop is reached. This pressure drop
acting on the upper area of the rotor may effect the axial force on
the one or more axial restraint, the one or more axial restraint
shearing where said axial force reaches or exceeds the required
force threshold. Beneficially, this arrangement permits embodiments
of the invention to resist forces experienced in normal operation,
such as torque forces transmitted from the rotary drive and/or the
cutting member, and facilitates selective engagement of the
clutch.
[0060] The clutch may be configured to be fully engaged on demand
by downwards axial movement. The clutch may comprise an axial
clearance gap. The axial clearance gap may be an engagement
allowance distance. The axial clearance gap may provide axial
allowance to engage the clutch. The axial clearance gap may be any
suitable distance. For example, the axial clearance gap may be 15
mm. Beneficially, the axial allowance may aid in determining the
included angle of the male and female locking cones.
[0061] According to a second aspect of the present disclosure,
there is provided a downhole tool comprising a cartridge assembly
according to the first aspect.
[0062] According to a third aspect of the present disclosure, there
is provided a downhole tool assembly comprising:
[0063] a tubular component;
[0064] a downhole tool; and
[0065] a cartridge assembly according to the first aspect.
[0066] The tubular component may be of any suitable form or
construction.
[0067] The tubular component may comprise a bore-lining tubular or
tubular string. In particular embodiments, the bore-lining tubular
may comprise a casing or casing string. Alternatively, the
bore-lining tubular may comprise a completion string, running
string, workover string or the like.
[0068] The downhole tool may comprise a borehole cutting tool, such
as a drilling tool and/or reaming tool.
[0069] According to a fourth aspect of the present disclosure there
is provided a method of running a tubular string into a borehole,
the method comprising:
[0070] running a downhole tool according to the second aspect or a
downhole tool assembly according to the third aspect into a
borehole; and
[0071] directing fluid, such as drill fluid, through the rotary
drive to operate the downhole tool.
[0072] The method may comprise inserting the tubular string with
the attached apparatus into the borehole to a selected depth.
[0073] The method may comprise inserting the tubular string with
the attached apparatus into the wellbore to a selected depth while
causing the shaft to rotate.
[0074] The method may comprise stopping rotation of the shaft when
reaching a selected depth.
[0075] The method may comprise locking the shaft to the motor
housing when reaching a selected depth. Locking the shaft to the
motor housing may comprise engaging a lock. Locking the shaft to
the motor housing may comprise engaging the male cone and the
female cone.
[0076] The method may comprise engaging a lock by applying axial
force to the motor housing. Applying axial force may comprise at
least one of applying axial force to hold up the tubular string and
applying fluid flow to the motor to cause pressure drop in the
motor above a selected threshold.
[0077] The method may comprise inserting a second cutting structure
into the tubular string. The second cutting structure may be
disposed at the end of a pipe string.
[0078] The second cutting structure may be configured to drill
through at least part of the first cutting structure. The second
cutting structure may comprise a drill bit.
[0079] According to a fifth aspect of the present disclosure there
is provided a clutch for a downhole tool, the clutch
comprising:
[0080] a male cone provided on one of a rotor of a downhole tool
and a stator of the downhole tool;
[0081] a female cone provided on the other of the rotor of the
downhole tool and the stator of the downhole tool and being
operatively associated with the male cone, the male cone and the
female cone configured to engage to rotationally fix the rotor of
the downhole tool and the stator of the downhole tool, wherein at
least one of the male cone and the female cone comprises at least
one axial slot extending at least partially along the length of the
male cone and/or the female cone.
[0082] The clutch may be configured to permit fluid, such as
drilling fluid, to flow over the lock during normal operation. The
axial slot or slots may extend along--or partially along--the
length of the male cone. The axial slot or slots may extend
along--or partially along--the length of the female cone. In use,
the axial slot or slots may be configured to trap debris carried in
the drilling fluid. The axial slot or slots may be configured to
receive debris and retain it away from the clutch. The axial slot
or slots may be dimensioned to receive a predetermined amount of
debris. For example, the slot or slots may be configured to drive
debris away from the clutch. Beneficially, the axial slots may
allow the clutch to operate as designed, unaffected by the presence
of any debris that may have been driven into the downhole tool
during its operation.
[0083] The clutch may be engaged on demand by any suitable method.
The clutch may be engaged by applying axial force on the rotor.
Axial force applied to the rotor may shear through the one or more
axial restraint and permit the clutch to engage. Alternatively, or
additionally, the clutch may be engaged by increasing the rate of
fluid flow rate through the rotary drive, increasing the pressure
drop in the rotary drive until a predetermined pressure drop is
reached. This pressure drop acting on the upper area of the rotor
may effect the axial force on the one or more axial restraint, the
one or more axial restraint shearing where said axial force reaches
or exceeds the required force threshold. Beneficially, this
arrangement permits embodiments of the invention to resist forces
experienced in normal operation, such as torque forces transmitted
from the rotary drive and/or the cutting member, and facilitates
selective engagement of the clutch.
[0084] The clutch may be configured to be fully engaged on demand
by downwards axial movement. The clutch may comprise an axial
clearance gap. The axial clearance gap may be an engagement
allowance distance. The axial clearance gap may provide axial
allowance to engage the clutch. The axial clearance gap may be any
suitable distance. For example, the axial clearance gap may be 15
mm. Beneficially, the axial allowance may aid in determining the
included angle of the male and female locking cones.
[0085] The clutch may be configured to rotationally fix the rotor
to the stator. The clutch may be configured to prevent rotation of
the cutting member with respect to a tubular component, such as the
bore-lining tubular string.
[0086] The clutch may be provided or formed between the cutting
member and the rotary drive. The clutch may be provided or formed
between the cutting member and the housing. The clutch may be
provided or formed between the cutting member and the bearing or
bearing sub.
[0087] The clutch may of any suitable form and construction.
[0088] In particular embodiments, the clutch may comprise a cone
clutch, such as that described in US Patent Application Publication
No. 2013/0319769, the contents of which are incorporated herein in
their entirety.
[0089] In particular embodiments, the clutch may comprise a cone
clutch. The clutch may comprise a male cone. The clutch may
comprise a female cone. The male cone may be located within the
female cone. In use, the male cone may engage or mate with the
female cone to engage the clutch. The male cone and the female cone
may be configured to be selectively engaged to rotationally fit the
rotor to the housing.
[0090] The internal taper angle of the female cone and the external
taper angle of the male cone may be matched. The female cone and
the male cone may have a self-locking taper angle. For example, the
self-locking taper angle may be from 0.1 to 10.0 degrees or
more.
[0091] The male cone may be integral with, or coupled to, the
rotor. The female cone may be integral with, or coupled to, the
housing of the rotary drive, or vice-versa.
[0092] The male cone and the female cone may be configured to be
engaged by application of axial force to the housing of the rotary
drive.
[0093] One or more axial restraint may be operatively associated
with the clutch. The axial restraint may be configured to permit
the clutch to be engaged when a selected minimum axial force is
applied, that is where the axial force reaches or exceeds a
predetermined force threshold. The axial restraint may be
configured to be sheared through. The axial restraint may take any
suitable form, shape or construction. In particular embodiments,
the axial restraint--or in embodiments comprising more than one
axial restraint at least one of them--may comprise a shear pin,
shear ring or the like.
[0094] The clutch may comprise an anti-rotation clutch or lock. In
such embodiments, the clutch or lock may be configured to allow
free rotation of the rotor--and the connected cutting
member--relative to the stator during normal operations of the
rotary drive.
[0095] According to a sixth aspect of the present disclosure, there
is provided a downhole tool comprising a clutch according to the
fourth aspect.
[0096] According to a seventh aspect of the present disclosure,
there is provided an assembly comprising:
[0097] a tubular component;
[0098] a downhole tool; and
[0099] a clutch according to the fourth aspect.
[0100] The downhole tool may comprise a borehole cutting tool, such
as a drilling tool and/or reaming tool.
[0101] The downhole tool may comprise a rotary drive. In some
embodiments, the rotary drive may be provided on a cartridge as
outlined above.
[0102] The downhole tool may comprise a housing. The housing may be
configured to be coupled to a leading end of a bore-lining
tubular.
[0103] The rotary drive may be disposed in the housing.
[0104] The rotary drive may comprise a rotor. The rotary drive may
comprise a stator. In some embodiments, the rotor may be disposed
around the stator. In other embodiments, the stator may be disposed
around the rotor.
[0105] The stator may be connected to a leading end of the tubular
component. The stator may comprise a flared portion. The flared
portion may be locked to the interior surface of the tubular
component. The flared portion may be locked to the interior surface
of the tubular component by a lock arrangement.
[0106] The stator may be concentric with the rotor. The stator may
locate around the rotor. The rotor may locate around the
stator.
[0107] The rotor and stator may define a void. The void may be
located parallel to the axis of rotation. The void may be
configured to receive fluid pumped through the fluid inlet and
allow the fluid to travel through the void.
[0108] The stator may be hollow. The stator may be tubular in
shape. The stator may be radially spaced from the rotational axis
of the rotor. The stator may comprise a bore. The bore may extend
along the length of the rotary drive. The bore may be coaxial with
the axis of rotation of the shaft.
[0109] The stator may not extend across the rotor. The rotor may be
rotatably mounted on the stator. The rotor may be rotatably mounted
on the stator by means of a bearing.
[0110] The stator may comprise a fluid inlet. The fluid inlet may
be located between an external stator and an internal rotor. The
fluid inlet may be radially outwardly spaced from the axis of
rotation of the rotor.
[0111] The rotor may not extend across the stator. The stator may
be rotatably mounted on the rotor. The stator may be rotatably
mounted on the rotor by means of a bearing.
[0112] The rotor and the stator may be spaced radially outwardly of
the rotational axis of the rotor. The rotor and the stator may
define an access bore. The access bore may be configured to allow
unobstructed access of additional components through the rotary
drive.
[0113] The downhole tool may comprise a shaft. The shaft may be an
output shaft. The shaft may be rotationally coupled to the rotary
drive. In some embodiments, the shaft may define the rotor. In
other embodiments, the shaft may define the stator.
[0114] The shaft may be a tubular shaft. The shaft may comprise a
bore. The bore may extend along the length of the rotary drive. The
bore may be coaxial with the axis of rotation of the shaft. The
bore may be parallel but not coaxial with the axis of rotation of
the shaft.
[0115] The bore may be configured to receive a further object. The
further object may be located adjacent the cutting structure. The
further object may comprise a second cutting member, a second
cutting structure or the like. The further object may comprise a
sensing device. The further object may be run into the downhole
tool.
[0116] The downhole tool may comprise a cutting member, a cutting
structure or the like. The cutting member or cutting structure may
be coupled to the shaft. The cutting member or cutting structure
may be coupled to the shaft by any suitable means, for example
threads. The cutting member or cutting structure may be coupled at
one end of the shaft. The cutting member or cutting structure may
be integral with the shaft. The cutting member or cutting structure
may be configured to rotate upon rotation of the shaft. The cutting
member or cutting structure may be configured to rotate upon
rotation of the tubular component locked to the shaft.
[0117] The rotary drive may comprise a motor. The rotary drive may
comprise a positive displacement motor, or the like.
[0118] In particular embodiments, the rotary drive may comprise a
turbine arrangement. The turbine arrangement may comprise an axial
flow reaction turbine. The rotor may comprise turbine blades. The
turbine blades may be arranged to deflect fluid pumped between the
rotor and the stator. The turbine blades may be arranged to convert
some of the energy of the fluid into rotation of the rotor.
[0119] The cutting member or cutting structure may be of any
suitable form or construction. For example, the cutting member or
cutting structure may comprise a reamer shoe, a drill bit or a
coring tool.
[0120] The cutting member or cutting structure may comprise a
sacrificial cutting structure. The cutting member or cutting
structure may be configured to be sacrificed upon completion of the
installation of the tubular component into the borehole.
[0121] The cutting member or cutting structure may comprise jetting
apertures. The jetting apertures may be configured to allow fluid
pumped through the void to exit the first cutting structure. The
fluid may be configured to act as a lubricant of the first cutting
structure. The fluid may be drilling mud slurry.
[0122] The downhole tool may comprise a flow diverter. The flow
diverter may be located adjacent the fluid inlet. The flow diverter
may be configured to divert fluid pumped down the tubular component
radially outwardly so as to flow into the fluid inlet.
[0123] The downhole tool may comprise one or more bearing between
the rotor and the stator. The bearing or bearings may comprise
thrust bearings configured to limit the axial movement between the
rotor and the stator while allowing relative rotation of these
components. The thrust bearing or bearings may be arranged to allow
limited axial movement. The bearings may be positioned in any
suitable location.
[0124] The downhole tool may comprise a seal. The seal may be
configured to resist fluid leakage between the rotor and an end of
the tubular component. The seal may take any suitable form or
shape. For example, the seal may be a rotating elastomeric
seal.
[0125] The downhole tool may comprise a second cutting structure.
The second cutting structure may be coupled to a tubular string.
The second cutting structure may be a drill bit or a reamer shoe.
The second cutting structure may have a narrower diameter than the
(first) cutting structure. The second cutting structure may be
configured to be run into the tubular component of the reaming
tool. The second cutting structure may be configured to be run into
the access bore of the shaft. The second cutting structure may be
configured to be run into the access bore of the stator.
Beneficially, this allows the second cutting structure to pass
through the interior of the motor, the motor components not
obstructing the passage of the second cutting structure. The second
cutting structure may be configured to cut through the first
cutting structure. The second cutting structure may be configured
to drill a subsequent section of wellbore.
[0126] The reaming tool may comprise a position sensing device. The
reaming tool may comprise any suitable inspection or testing
device. The device may be configured to be fed through the motor
bore defined by the rotor and the stator.
[0127] According to an eighth aspect of the present disclosure,
there is provided a downhole tool assembly comprising:
[0128] a bore-lining tubular;
[0129] a downhole tool; and
[0130] a clutch according to the fourth aspect.
[0131] According to a ninth aspect of the present invention, there
is provided a method of running a tubular string into a borehole,
the method comprising:
[0132] running a downhole tool according to the seventh aspect or a
downhole tool assembly according to the eighth aspect into a
borehole; and
[0133] directing fluid, such as drill fluid, through the rotary
drive to operate the downhole tool.
[0134] It should be understood that the features defined above in
accordance with any aspect of the present invention or below in
relation to any specific embodiment of the invention may be
utilised, either alone or in combination with any other defined
feature, in any other aspect or embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0135] These and other aspects of the present invention will now be
described, by way of example only, with reference to the
accompanying drawings, in which:
[0136] FIG. 1 shows a diagrammatic view of a downhole tool assembly
according to an embodiment of the present invention;
[0137] FIG. 2 shows a longitudinal half section view of an upper
portion of a downhole tool and cartridge assembly according to an
embodiment of the present invention;
[0138] FIG. 3 shows a longitudinal half section view of a
mid-section of the downhole tool and cartridge assembly;
[0139] FIG. 4 shows an enlarged cross-sectional view of the rotary
drive shown in FIGS. 2 and 3; and
[0140] FIGS. 5 and 6 show longitudinal half section views of a
lower portion of the downhole tool and cartridge assembly, showing
the bearings.
[0141] FIG. 7 shows a clutch as shown in FIG. 5;
[0142] FIG. 8 shows an alternative clutch for use in embodiments of
the invention; and
[0143] FIG. 9 shows the axial slot shown in FIG. 8.
DETAILED DESCRIPTION
[0144] Referring first to FIG. 1, there is shown a diagrammatic
view of a downhole tool assembly 10 according to an embodiment of
the present invention. As shown in FIG. 1, the assembly 10
comprises a bore-lining tubular in the form of a casing section or
casing string 12, and a downhole tool 14 comprising a rotary drive
16 and a cutting member 18. In use, the assembly 10 is disposed in
a well borehole (shown schematically as B) and the rotary drive 16
operated to drive rotation of the cutting member 18 to cut the
borehole B.
[0145] Beneficially, the provision of a downhole rotary drive 16
facilitates cutting, such as reaming or drilling, of the borehole B
without the requirement to rotate the casing or casing string
12.
[0146] In some embodiments, the cutting member 18 comprises a drill
bit, the tool assembly 10 being utilised to perform a drilling with
casing operation in the borehole B. In other embodiments, the
cutting member 18 comprises a reaming bit, the tool assembly 10
being utilised to perform a reaming with casing operation in the
borehole B.
[0147] Referring now to FIGS. 2 to 7 of the accompanying drawings,
there is shown an exemplary downhole tool 14 according to an
embodiment of the present invention. As shown in FIG. 2, the
downhole tool 14 comprises a tubular housing 20. An upper end
portion 22 of the housing 20 is coupled to a lower end portion 24
of a tubular connector sub 26 via a threaded connection 28, the
upper end portion 22 of the housing 20 defining a recess 30 for
receiving the lower end portion 24 of the connector sub 26. An
upper end portion 32 of the connector sub 26 defines a threaded box
connector 34 for coupling the connector sub 26 to the lower end of
a casing section, such as casing string 12 shown in FIG. 1. While
in the illustrated embodiment, the downhole tool 14 is indirectly
coupled to the casing section/casing string 12 it will be
recognised that the housing 20 of the downhole tool 14 may
alternatively be directly coupled to the casing section/casing
string 12.
[0148] A cartridge assembly 36 is disposed within the housing 20 of
the downhole tool 14, an upper part of which is shown in FIG. 2.
The cartridge assembly 36 comprises a tubular housing 38 (referred
to below as the cartridge assembly housing 38) which is disposed
within, and which is coupled to, the housing 20 of the downhole
tool 14. In use, the cartridge assembly housing 38 defines a stator
of the rotary drive 16.
[0149] An upper end portion 40 of the cartridge assembly housing 38
comprises a recess or groove 42 for receiving a seal element 44. In
the illustrated embodiment, the seal element 44 comprises an o-ring
and in use prevents fluid leakage between the cartridge assembly
housing 38 and the housing 20 of the downhole tool 14.
[0150] The cartridge assembly 36 is secured to the housing 20 by
one or more--and in the illustrated embodiment a plurality of
circumferentially arranged--retainers 46 disposed between the
cartridge assembly housing 38 and the housing 20. In the
illustrated embodiment, the retainer 46 prevents axial and
rotational movement of the cartridge assembly 36 relative to the
housing 20.
[0151] The cartridge assembly 36 further comprises a shaft 48, the
shaft 48 in use defining a rotor of the rotary drive 16. As shown
in the illustrated embodiment, the shaft 48 is hollow, the shaft 48
comprising a throughbore 50 (see FIG. 4).
[0152] Referring now also to FIGS. 3 and 4 of the accompanying
drawings, which shows a mid-section of the downhole tool 14 and
cartridge assembly 36 shown in FIG. 2, the rotary drive 16 formed
by the cartridge assembly housing 38 and the shaft 48 comprises a
positive displacement motor with a fluid passage 52 defined between
the outside of the shaft 48 and the inside of the cartridge
assembly housing 38. In use, passage of fluid, such as drill fluid,
mud or the like, through the fluid passage 52 drives rotation of
the shaft 48 at high speed relative to the cartridge assembly
housing 38--and thus relative to the casing section/casing string
12.
[0153] As shown in FIG. 3, a u-joint 54 is disposed between the
lower end of the rotary drive 16 and the upper end of the cutting
member 18, an upper end portion 56 of the u-joint coupled to a
lower end portion 58 of the cartridge assembly housing 38 and a
lower end portion 60 of the u-joint 54 coupled to an upper end
portion 62 of the cutting member 18.
[0154] Referring now in particular to FIG. 3 and also to FIGS. 5
and 6 of the accompanying drawings, fluid exiting the rotary drive
16 passes into a fluid flow annulus 64 before passing into cutting
member 18 via port 66 (see FIGS. 5 and 6). Although not
specifically shown in the drawings, the cutting member 18 may be
provided with jetting nozzles or outlet ports for directing the
fluid into an annulus between the downhole tool 12 and the borehole
B for return to surface.
[0155] As shown in FIGS. 5 and 6, the cutting member 18--which in
the illustrated embodiment takes the form of a reaming
member--comprises a generally tubular body 68 coupled to the
u-joint 54 and a nose 70.
[0156] A sub 72 comprising a ball bearing package 74 is coupled to
the housing 20 as shown in FIG. 5. As shown in FIG. 5, the ball
bearing package 74 is disposed outside a drill through diameter D,
such that drilling through can be achieved without the requirement
to remove the ball bearing package 74.
[0157] A thrust bearing package 76 is disposed around the outside
of the cutting member upper portion 62.
[0158] A clutch in the form of a cone clutch 78 is disposed between
the outside of the cutting member 18 and the housing 20.
Beneficially, the cone clutch 78 facilitates mill out or drill
through operations to be carried out.
[0159] An exemplary arrangement for the clutch 78 is shown in FIG.
7 of the accompanying drawings.
[0160] In use, the clutch 78 is designed to enable free rotation of
the cutting member 18 during normal operation and may be engaged or
activated on demand by any suitable method. Beneficially, the
clutch 78 prevents or at least mitigates unwanted rotation of the
cutting member 18 upon drilling thereof, which may otherwise hinder
rotation of the cutting member 18.
[0161] In the illustrated embodiment, the clutch 78 takes the form
of a cone clutch having a female cone 80 and a male cone 82. In
this embodiment, the male cone 82 is integral with output shaft 84
of the rotary drive 16 and the female cone 80 is integral with
housing 20. However, it will be recognised that the male cone 82
and/or the female cone 80 may alternatively comprise a separate
component and may be coupled to the output shaft 84 and housing 20,
respectively. As shown in FIG. 7, the rotary drive 16 is coupled to
the output shaft 84 by a thread connection 86.
[0162] As described above, the housing 20 is coupled to a tubular
connector sub 26, the connector sub 26 in turn being couplable to a
tubular component, which in the illustrated embodiment comprises a
casing string 12 (shown diagrammatically in FIG. 7). Lock-up of the
output shaft 84 to the housing 20 permits rotation of the cutting
member 18 directly by rotation of the casing string 12.
[0163] When the clutch 78 is engaged, the male cone 82 is locked
into the female cone 80. As shown in FIG. 7, taper angle .alpha.1
of the female cone 80 and taper angle .alpha.2 of the male cone 82
match and in the illustrated embodiment, the taper angles .alpha.1,
.alpha.2 self-lock.
[0164] Axial restraints in the form of shear pins 88 (two of which
are shown in FIG. 7) are operatively associated with the clutch 78.
In use, the shear pins 88 are configured to permit the clutch 78 to
be engaged when a selected minimum axial force is applied, that is
where the axial force reaches or exceeds a predetermined force
threshold.
[0165] In some embodiments, the clutch 78 is engaged by applying
axial force onto the output shaft 84 or via axial movement of
components of the rotary drive 16. Reaching or exceeding a selected
force threshold causes the shear pins 88 to shear and allow the
female cone 80 and the male cone 82 of the clutch 78 to engage.
[0166] However, in the illustrated embodiment, the clutch 78 is
engaged by increasing the fluid flow rate through the rotary drive
16. Increasing the fluid flow rate through the rotary drive 16
increases the pressure drop of the rotary drive 16 until a
predetermined pressure drop--corresponding to an axial force
sufficient to shear the shear pins 88--is reached.
[0167] Referring now to FIGS. 8 and 9 of the accompanying drawings,
there is shown an alternative clutch 178 according to another
embodiment of the present invention.
[0168] The clutch 178 is similar to the clutch 78 described above
and like numerals are represented by like reference signs
incremented by 100.
[0169] As in the clutch 78, the clutch 178 takes the form of a cone
clutch having a female cone 180 and a male cone 182. In this
embodiment, the male cone 182 is integral with output shaft 184 of
the rotary drive 116 and the female cone 180 is integral with
housing 120. However, as in the clutch 78 it will be recognised
that the male cone 182 and/or the female cone 180 of the clutch 178
may alternatively comprise a separate component and may be coupled
to the output shaft 184 and housing 120, respectively. The rotary
drive 116 is coupled to the output shaft 184 by a thread connection
186.
[0170] The housing 120 is coupled to a tubular connector sub 126,
the connector sub 126 in turn being couplable to a tubular
component, which in the illustrated embodiment comprises a casing
string 112 (shown diagrammatically in FIG. 8). Lock-up of the
output shaft 184 to the housing 120 permits rotation of the cutting
member 118 directly by rotation of the casing string 112.
[0171] When the clutch 178 is engaged, the male cone 182 is locked
into the female cone 180. As shown in FIG. 8, taper angle .alpha.3
of the female cone 180 and taper angle .alpha.4 of the male cone
182 match and in the illustrated embodiment, the taper angles
.alpha.3, .alpha.4 self-lock.
[0172] Axial restraints in the form of shear pins 188 (two of which
are shown in FIG. 8) are operatively associated with the clutch
178. In use, the shear pins 188 are configured to permit the clutch
178 to be engaged when a selected minimum axial force is applied,
that is where the axial force reaches or exceeds a predetermined
force threshold.
[0173] As shown in FIG. 9, in this second embodiment the clutch 178
comprises an axial slot 90 configured to trap between the female
cone 180 and the male cone 182 any debris carried along with
drilling fluid. A single slot 90 is shown in FIG. 9. However, more
than one slot 90 may be provided. The axial slot 90 is configured
to receive debris and retain it away from the female and male cones
180, 182 of the clutch 178. The axial slot 90 is dimensioned to
receive an expected amount of debris. For example, the slot 90 is
configured to drive debris away from the clutch 178. Beneficially,
the axial slot 90 may thus allow the clutch 178 to operate as
designed, unaffected by the presence of any debris that may have
been driven into the downhole tool during its operation.
[0174] As shown in FIG. 8, the clutch 178 also has axial clearance
gap 92. In use, the clearance gap 92 may provide axial allowance to
engage the clutch 178. The axial clearance gap 92 may be any
suitable distance, but in the illustrated embodiment is 15 mm.
[0175] In use, the clutch 178 is designed to enable free rotation
of the cutting member 118 during normal operation and may be
engaged or activated on demand by any suitable method.
Beneficially, the clutch 178 prevents or at least mitigates
unwanted rotation of the cutting member 118 upon drilling thereof,
which may otherwise hinder rotation of the cutting member 118.
[0176] It should be understood that the embodiments described
herein are merely exemplary and that various modifications may be
made thereto without departing from the scope of the invention.
[0177] For example, it will be recognised that the clutches 78, 178
are not limited in use to the downhole tool and assemblies
described above and may be used in a variety of downhole tools,
such as for example the tools shown and described in European
Patent 1989390, in European Patent 2334890 or the completion system
shown and described in International Patent Publication WO
2011/048368, the contents of which are incorporated by
reference.
[0178] It should be understood that the embodiments described
herein are merely examples and that various modifications may be
made thereto without departing from the scope of the invention. The
scope of the invention shall be limited only by the claims appended
hereto.
* * * * *