U.S. patent application number 15/788112 was filed with the patent office on 2019-04-25 for modular window mill assembly and method.
This patent application is currently assigned to Baker Hughes, a GE company, LLC. The applicant listed for this patent is Ewoud Hulsewe. Invention is credited to Ewoud Hulsewe.
Application Number | 20190120005 15/788112 |
Document ID | / |
Family ID | 66169198 |
Filed Date | 2019-04-25 |
United States Patent
Application |
20190120005 |
Kind Code |
A1 |
Hulsewe; Ewoud |
April 25, 2019 |
MODULAR WINDOW MILL ASSEMBLY AND METHOD
Abstract
A modular window mill assembly includes a mill body having a
first connection feature and a second connection feature; a mill
head having a cutting structure and an engagement feature, the
engagement feature configured to matingly engage with the first
connection feature of the mill body to replaceably secure the mill
head to the mill body; and, a blade having a cutting structure and
a coupling feature, the coupling feature of each blade respectively
matingly coupled to the second connection feature to replaceably
secure the blade to the mill body. The mill body, mill head, and
the blade are formed separately from each other prior to assemblage
together to form the window mill assembly.
Inventors: |
Hulsewe; Ewoud; (Woodlands,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hulsewe; Ewoud |
Woodlands |
TX |
US |
|
|
Assignee: |
Baker Hughes, a GE company,
LLC
Houston
TX
|
Family ID: |
66169198 |
Appl. No.: |
15/788112 |
Filed: |
October 19, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 29/06 20130101;
E21B 29/005 20130101; E21B 17/02 20130101 |
International
Class: |
E21B 29/06 20060101
E21B029/06; E21B 29/00 20060101 E21B029/00; E21B 17/02 20060101
E21B017/02 |
Claims
1. A modular window mill assembly comprising: a mill body having a
first connection feature and a second connection feature; a mill
head having a cutting structure and an engagement feature, the
engagement feature configured to matingly engage with the first
connection feature of the mill body to replaceably secure the mill
head to the mill body; and a blade having a cutting structure and a
coupling feature, the coupling feature of each blade respectively
matingly coupled to the second connection feature to replaceably
secure the blade to the mill body; wherein the mill body, mill
head, and the blade are formed separately from each other prior to
assemblage together to form the window mill assembly.
2. The modular window mill assembly of claim 1, wherein the mill
body includes a longitudinal axis, a first end and a longitudinally
spaced second end, the mill head disposed at the first end of the
mill body, and the blade longitudinally trapped by the mill head
and a shoulder between the first and second ends of the mill
body.
3. The modular window mill assembly of claim 1, wherein the first
connection feature is threadably engaged with the engagement
feature.
4. The modular window mill assembly of claim 1, wherein the
engagement feature includes a male portion receivable within a
female portion of the first connection feature.
5. The modular window mill assembly of claim 1, wherein the second
connection feature includes circumferentially spaced slots
extending from a first longitudinal end of the mill body.
6. The modular window mill assembly of claim 5, wherein a radial
outermost end of the slots are narrower than a radial interior
portion of the slots.
7. The modular window mill assembly of claim 5, wherein the slots
are dove-tail shaped or T-shaped.
8. The modular window mill assembly of claim 5, wherein the mill
body has a shoulder wall disposed between the first end of the mill
body and a second end of the mill body, the slots extending from
the first end of the mill body to the shoulder wall.
9. The modular window mill assembly of claim 1, wherein the mill
head is secured to the first end of the mill body through weldless
engagement between the engagement feature and the first connection
feature, and the blade is secured to the mill body through weldless
coupling between the coupling feature of the blade and the second
connection feature.
10. The modular window mill assembly of claim 1, wherein the
cutting structure of the mill head and the blade includes carbide
and/or polycrystalline diamond compact inserts.
11. The modular window mill assembly of claim 1, wherein the mill
head includes a plurality of rows of cutting structures, each row
aligned with cutting structures on a plurality of the blades when
the blades and the mill head are secured to the mill body.
12. The modular window mill assembly of claim 1, further comprising
a fluid flow path extending along a longitudinal axis of the mill
body.
13. A system comprising: the modular window mill assembly of claim
1; a string, the window mill assembly attached to an end of the
string; and, a tubular structure, the string and window mill
assembly passable through an interior of the tubular structure and
the window mill assembly rotatable by the string within the tubular
structure.
14. The system of claim 13, further comprising a whipstock within
the tubular structure, the whipstock having a guide surface, and
the window mill assembly configured to slide along the guide
surface to cut an opening in the tubular structure.
15. A method of assembling a modular window mill assembly, the
method comprising: utilizing a mill body having a first connection
feature and a second connection feature; matingly coupling the
blade having a cutting structure with the second connection feature
of the mill body; and matingly engaging a mill head having a
cutting structure with the first connection feature.
16. The method of claim 15, wherein coupling the blade with the
second connection feature of the mill body includes sliding the
blade within a slot in the mill body.
17. The method of claim 16, wherein engaging the mill head with the
first connection feature occurs subsequent to sliding the blade
within the respective slot in the mill body, and longitudinally
trapping the blade between the mill head and a shoulder wall of the
mill body.
18. The method of claim 15, wherein the mill body includes a first
end, the first connection feature includes a female portion
indented from the first end, and the mill head includes a male
portion received within the female portion.
19. The method of claim 15, wherein the mill head is threadably
engaged to the first connection feature.
20. The method of claim 15, further comprising attaching the window
mill head assembly to a string, the string configured to rotate the
window mill assembly.
Description
BACKGROUND
[0001] In the resource recovery industry, resources (such as
hydrocarbons, steam, minerals, water, metals, etc.) are often
recovered from boreholes in formations containing the targeted
resource. It is sometimes desired to cut a window in a downhole
well casing, for the purpose of exiting the casing, to drill a
lateral well bore off of the main bore. A window mill carried on,
and rotated by, a work string is used to cut the window by
penetrating the casing wall as it is guided therethrough by a guide
surface of a whipstock. During use, the cutting surfaces of the
window mill experience vibration and impact against the casing
which can lead to their deterioration during this process. To
reduce deterioration, materials that exhibit wear resistance while
cutting through metal have been incorporated into the window
mills.
[0002] The art would be receptive to improved and/or alternative
window mills and methods for manufacturing improved and/or
alternative window mills.
SUMMARY
[0003] A modular window mill assembly includes a mill body having a
first connection feature and a second connection feature; a mill
head having a cutting structure and an engagement feature, the
engagement feature configured to matingly engage with the first
connection feature of the mill body to replaceably secure the mill
head to the mill body; and, a blade having a cutting structure and
a coupling feature, the coupling feature of each blade respectively
matingly coupled to the second connection feature to replaceably
secure the blade to the mill body. The mill body, mill head, and
the blade are formed separately from each other prior to assemblage
together to form the window mill assembly.
[0004] A method of assembling a modular window mill assembly
includes utilizing a mill body having a first connection feature
and a second connection feature; matingly coupling the blade having
a cutting structure with the second connection feature of the mill
body; and, matingly engaging a mill head having a cutting structure
with the first connection feature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The following descriptions should not be considered limiting
in any way. With reference to the accompanying drawings, like
elements are numbered alike:
[0006] FIG. 1 depicts a side view of an embodiment of a modular
window mill assembly;
[0007] FIG. 2 depicts a side view of an embodiment of a mill body
for the window mill assembly of FIG. 1;
[0008] FIG. 3 depicts a side view of an embodiment of a replaceable
blade for the window mill assembly of FIG. 1;
[0009] FIG. 4 depicts a side view of an embodiment of a replaceable
mill head for the window mill assembly of FIG. 1;
[0010] FIG. 5 depicts a cross-sectional view of an embodiment of
the millbody of FIG. 2;
[0011] FIG. 6 depicts a cross-sectional view of another embodiment
of the mill body of FIGS. 2; and
[0012] FIG. 7 depicts a schematic view of the modular window mill
assembly of FIG. 1 within a casing.
DETAILED DESCRIPTION
[0013] A detailed description of one or more embodiments of the
disclosed apparatus and method are presented herein by way of
exemplification and not limitation with reference to the
Figures.
[0014] With reference now to FIGS. 1-6, a modular window mill
assembly 10 is illustrated according to some embodiments. The
window mill assembly 10 is a modular device and includes a mill
body 12, a plurality of replaceable blades 14, and a replaceable
mill head 16. At least the blades 14 and the mill head 16 include
and can be pre-manufactured with a plurality of cutting structures
18 made of very hard material such as, but not limited to, one or
more of polycrystalline diamond compact structure, carbide,
inserts, and/or dressed with fixed cutters. The cutting structures
18 are provided on outer surfaces of each blade and oriented to cut
through a casing 104 (FIG. 7) as the window mill assembly 10 is
rotated by a work string 102 (FIG. 7). The outermost edges of the
cutting structures 18 together establish a contour which is
radially outside the outer contour of the blades 14 and the mill
head 16 themselves.
[0015] With reference to FIGS. 1 and 2, the mill body 12 includes a
longitudinal axis 20 which also defines an axis of rotation for the
window mill assembly 10. In some embodiments, a flow path 22 may be
provided along the longitudinal axis 20. The flow path 22 may be in
fluidic communication with ports (not shown) on the exterior
surface of the mill body 12, the mill head 16, and/or the blades 14
so that fluid can be pumped to the exterior of the window mill
assembly 10. The mill body 12 further includes a first connection
feature 24 which is configured to secure the mill head 16 to the
mill body 12. The first connection feature 24 is provided at a
first end 26 of the mill body 12, which corresponds to a downhole
end of the mill body 12 during use. The mill head 16, shown
separately in FIG. 4, includes an engagement feature 28 configured
to mate with the first connection feature 24 of the mill body 12.
The mill head 16 is dressed with cutting structures 18 for milling
purposes. In the illustrated embodiment, the first connection
feature 24 includes a female portion 30 indented into the first end
26 of the mill body 12, and the engagement feature 28 includes a
male portion 32. The female portion 30 is sized to receive and
retain the male portion 32. The female portion 30 may include
interior threads 34, which threadingly receive the exterior threads
36 of the male portion 32 of the mill head 16. Thus, in the
illustrated embodiment the mill head 16 is a mushroom-shaped cap
retainer that can be threaded in the mill body 12 to secure the
assembly 10. In alternate embodiments, the mill body 12 may include
a male portion receivable within a female portion of the mill head
16. Alternate mechanical connections between the mill body 12 and
the mill head 16 may be included that can removably retain the mill
head 16 onto the first end 26 of the mill body 12, such as, but not
limited to, bolted connections or one or more additional separate
connection features utilized to connect the first connection
feature 24 of the mill body 12 to the engagement feature 28 of the
mill head 16.
[0016] The mill body 12 includes a second end 40 longitudinally
spaced from the first end 26. The second end 40 of the mill body 12
is configured for attached to a string 102 (FIG. 7), as will be
further described below. A blade receiving section 42 extends from
the first end 26 of the mill body 12. With further reference to
FIGS. 5 and 6, an outer circumference 44 of the mill body 12
includes a plurality of second connection features 46 which are
configured to removably secure the plurality of blades 14,
respectively, to the mill body 12. Each blade, as shown in FIG. 3,
includes a coupling feature 48 located at the radially inward side
50 of the blade 14, substantially opposite a radially outermost
side 57 of the blade 14. The coupling feature 48 is sized and
configured to be retained within the second connection feature 46
during rotation of the window mill assembly 10. In the illustrated
embodiments, the second connection feature 46 includes a slot 52
forming a pocket that extends from the first end 26 and ending at a
shoulder wall 54 disposed between the first and second ends 26, 40
of the mill body 12. FIG. 5 depicts one embodiment of the slots 52
having a dovetail shape, and FIG. 6 depicts another embodiment of
the slots 52 having a T-shape. The radial outermost side 56 of the
slots 52 is narrower than a radially interior portion 58 of the
slots 52 so as to retain the coupling features 48 of the blades 14
within the slots 52 during rotation of the window mill assembly 10
through use of adjacent pairs of circumferential slot ends 60 at
the radial outermost side 56. The coupling features 48 of the
blades 14 includes a corresponding T-shaped or dovetail shape, or
other corresponding shape receivable within the slots 52 and
conducive for blade retention during rotation. The number of blades
14 and corresponding slots 52 may be changed depending on
application and size of the window mill assembly 10. For
illustrative purposes only, five slots 52 are shown in FIG. 5 for
receipt of five blades 14, and four slots 52 are shown in FIG. 6
for receipt of four blades 14. Also, while the slots 52 are shown
extending substantially in parallel with the longitudinal axis 20
of the mill body 12, the slots 52 could instead be angled with
respect to the longitudinal axis 20.
[0017] Insertion of the blades 14 within the slots 52 is by sliding
the coupling features 48 into the slots 52 at the first end 26 of
the mill body 12, and sliding the blades 14 towards the second end
40 of the mill body 12 until a second end 62 of the blade 14
contacts the shoulder wall 54. A longitudinal length of the
coupling features 48 of the blades 14 may be substantially the same
as a longitudinal length of the slots 52 so as to prevent
longitudinal shifting of the blades 14 relative to the mill body
12. In such an embodiment, a first end 64 of the blades 14 is
substantially aligned with the first end 26 of the mill body 12.
After the blades 14 are inserted within the slots 52, the mill head
16 is secured to the first end 26 of the mill body 12 through the
use of the first connection feature 24 of the mill body 12 and the
engagement feature 28 of the mill head 16, As in the illustrated
embodiment, after the blades 14 are slid into the slots 52 of the
mill body 12, the mill head 16 is screwed into the mill body 12.
The blades 14 are then longitudinally trapped within the mill body
12 between the shoulder wall 54 and the mill head 16. The blades 14
are radially trapped within the mill body 12 by the adjacent pairs
of circumferential slot ends 60. Thus, the blades 14 are prohibited
from moving radially and longitudinally with respect to the mill
body 12 and mill head 16 when assembled together. In some
embodiments, once the mill assembly 10 is assembled, respective
rows of cutting structures 18 on the mill head 16 are aligned with
cutting structures 18 on a respective blade 14.
[0018] Referring to FIG. 7, one embodiment for utilizing the window
mill assembly 10 within a downhole system 100 is shown. For
clarity, the cutting structures 18 are not illustrated in FIG. 7.
The window mill assembly 10 is attached to a work string 102 and
run through an interior of a tubular structure, such as a casing
104. A whipstock 106 is seated within the casing 104 and includes a
guide surface 108 which is azimuthally oriented in the desired
direction for guiding the mill assembly 10 to exit the casing 104.
The guide surface 108 is angled at a first acute angle relative to
a longitudinal axis of the casing 104. The longitudinal axis 20 of
the mill body 12 may be initially parallel to the longitudinal axis
of the casing 104, but will be angled relative to the longitudinal
axis 20 of the casing 104 when the window mill assembly 10 is
guided by the guide surface 108 of the whipstock 106 towards the
casing 104. The cutting structures 18 on the mill head 16 and
replaceable blades 14 are angled away from the hard guide surface
108 of the whipstock 106. As the window mill assembly 10 is rotated
by the work string 102, the mill head 16 of the window mill
assembly 10 moves in the downhole direction 110 (opposite an uphole
direction 112) along the guide surface 108, causing the cutting
structures 18 on the blades 14 to contact and mill through a wall
114 of the casing 104 to form window 116. Eventually, the cutting
structures 18 on the mill head 16 also contact and mill through the
casing 104.
[0019] The window mill assembly 10 and its cutting structures 18
can include materials that require strict welding procedures, and
therefore maintaining and fixing window mills at a wellsite without
the removable blades 14 and mill head 16 would require onsite
specialty welding and local expertise. However, the window mill
assembly 10 described herein has interchangeable blades 14 and mill
head 16 so that the requirements for local welding can be reduced,
and controls for welding procedures can be more strictly enforced
at manufacturing facilities where the replaceable blades 14 and
mill head 16 are pre-manufactured. The assembly of the blades 14
and mill head 16 to the mill body 12 to form the window mill
assembly 10 can be assembled on-site, or pre-assembled and
delivered to the site. Upon completion of a milling procedure, the
mill head 16 and blades 14 can be replaced or discarded as needed
at a lesser expense as compared to replacing an entire mill
assembly 10.
[0020] Set forth below are some embodiments of the foregoing
disclosure:
[0021] Embodiment 1: A modular window mill assembly including a
mill body having a first connection feature and a second connection
feature; a mill head having a cutting structure and an engagement
feature, the engagement feature configured to matingly engage with
the first connection feature of the mill body to replaceably secure
the mill head to the mill body; and, a blade having a cutting
structure and a coupling feature, the coupling feature of each
blade respectively matingly coupled to the second connection
feature to replaceably secure the blade to the mill body; wherein
the mill body, mill head, and the blade are formed separately from
each other prior to assemblage together to form the window mill
assembly.
[0022] Embodiment 2: The modular window mill assembly as in any
prior embodiment or combination of embodiments, wherein the mill
body includes a longitudinal axis, a first end and a longitudinally
spaced second end, the mill head disposed at the first end of the
mill body, and the blade longitudinally trapped by the mill head
and a shoulder between the first and second ends of the mill
body.
[0023] Embodiment 3: The modular window mill assembly as in any
prior embodiment or combination of embodiments, wherein the first
connection feature is threadably engaged with the engagement
feature.
[0024] Embodiment 4: The modular window mill assembly as in any
prior embodiment or combination of embodiments, wherein the
engagement feature includes a male portion receivable within a
female portion of the first connection feature.
[0025] Embodiment 5: The modular window mill assembly as in any
prior embodiment or combination of embodiments, wherein the second
connection feature includes circumferentially spaced slots
extending from a first longitudinal end of the mill body.
[0026] Embodiment 6: The modular window mill assembly as in any
prior embodiment or combination of embodiments, wherein a radial
outermost end of the slots are narrower than a radial interior
portion of the slots.
[0027] Embodiment 7: The modular window mill assembly as in any
prior embodiment or combination of embodiments, wherein the slots
are dove-tail shaped or T-shaped.
[0028] Embodiment 8: The modular window mill assembly as in any
prior embodiment or combination of embodiments, wherein the mill
body has a shoulder wall disposed between the first end of the mill
body and a second end of the mill body, the slots extending from
the first end of the mill body to the shoulder wall.
[0029] Embodiment 9: The modular window mill assembly as in any
prior embodiment or combination of embodiments, wherein the mill
head is secured to the first end of the mill body through weldless
engagement between the engagement feature and the first connection
feature, and the blade is secured to the mill body through weldless
coupling between the coupling feature of the blade and the second
connection feature.
[0030] Embodiment 10: The modular window mill assembly as in any
prior embodiment or combination of embodiments, wherein the cutting
structure of the mill head and the blade includes carbide and/or
polycrystalline diamond compact inserts.
[0031] Embodiment 11: The modular window mill assembly as in any
prior embodiment or combination of embodiments, wherein the mill
head includes a plurality of rows of cutting structures, each row
aligned with cutting structures on a plurality of the blades when
the blades and the mill head are secured to the mill body.
[0032] Embodiment 12: The modular window mill assembly as in any
prior embodiment or combination of embodiments, further comprising
a fluid flow path extending along a longitudinal axis of the mill
body.
[0033] Embodiment 13: A system including: the modular window mill
assembly as in any prior embodiment or combination of embodiments;
a string, the window mill assembly attached to an end of the
string; and, a tubular structure, the string and window mill
assembly passable through an interior of the tubular structure and
the window mill assembly rotatable by the string within the tubular
structure.
[0034] Embodiment 14: The system as in any prior embodiment or
combination of embodiments, further including a whipstock within
the tubular structure, the whipstock having a guide surface, and
the window mill assembly configured to slide along the guide
surface to cut an opening in the tubular structure.
[0035] Embodiment 15: A method of assembling a modular window mill
assembly, the method including: utilizing a mill body having a
first connection feature and a second connection feature; matingly
coupling the blade having a cutting structure with the second
connection feature of the mill body; and, matingly engaging a mill
head having a cutting structure with the first connection
feature.
[0036] Embodiment 16: The method as in any prior embodiment or
combination of embodiments, wherein coupling the blade with the
second connection feature of the mill body includes sliding the
blade within a slot in the mill body.
[0037] Embodiment 17: The method as in any prior embodiment or
combination of embodiments, wherein engaging the mill head with the
first connection feature occurs subsequent to sliding the blade
within the respective slot in the mill body, and longitudinally
trapping the blade between the mill head and a shoulder wall of the
mill body.
[0038] Embodiment 18: The method as in any prior embodiment or
combination of embodiments, wherein the mill body includes a first
end, the first connection feature includes a female portion
indented from the first end, and the mill head includes a male
portion received within the female portion.
[0039] Embodiment 19: The method as in any prior embodiment or
combination of embodiments, wherein the mill head is threadably
engaged to the first connection feature.
[0040] Embodiment 20: The method as in any prior embodiment or
combination of embodiments, further comprising attaching the window
mill head assembly to a string, the string configured to rotate the
window mill assembly.
[0041] The use of the terms "a" and "an" and "the" and similar
referents in the context of describing the invention (especially in
the context of the following claims) are to be construed to cover
both the singular and the plural, unless otherwise indicated herein
or clearly contradicted by context. Further, it should further be
noted that the terms "first," "second," and the like herein do not
denote any order, quantity, or importance, but rather are used to
distinguish one element from another. The modifier "about" used in
connection with a quantity is inclusive of the stated value and has
the meaning dictated by the context (e.g., it includes the degree
of error associated with measurement of the particular
quantity).
[0042] The teachings of the present disclosure may be used in a
variety of well operations. These operations may involve using one
or more treatment agents to treat a formation, the fluids resident
in a formation, a wellbore, and/or equipment in the wellbore, such
as production tubing. The treatment agents may be in the form of
liquids, gases, solids, semi-solids, and mixtures thereof.
Illustrative treatment agents include, but are not limited to,
fracturing fluids, acids, steam, water, brine, anti-corrosion
agents, cement, permeability modifiers, drilling muds, emulsifiers,
demulsifiers, tracers, flow improvers etc. Illustrative well
operations include, but are not limited to, hydraulic fracturing,
stimulation, tracer injection, cleaning, acidizing, steam
injection, water flooding, cementing, etc.
[0043] While the invention has been described with reference to an
exemplary embodiment or embodiments, it will be understood by those
skilled in the art that various changes may be made and equivalents
may be substituted for elements thereof without departing from the
scope of the invention. In addition, many modifications may be made
to adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this invention, but that the invention will include
all embodiments falling within the scope of the claims. Also, in
the drawings and the description, there have been disclosed
exemplary embodiments of the invention and, although specific terms
may have been employed, they are unless otherwise stated used in a
generic and descriptive sense only and not for purposes of
limitation, the scope of the invention therefore not being so
limited.
* * * * *