The invention relates generally to downhole cutting mills and methods for operation of such cutting mills.
Milling tools, or mills, are used to perform cutting tasks within a subterranean wellbore. As opposed to drill bits, which tunnel through the earth, mills are often employed to cut away discrete objects within or associated with a wellbore. For example, a cutting mill is used to cut through a plug or other obstruction which is located within the bore of a well. A casing exit mill is used to cut a window in metallic wellbore casing.
The present invention relates to cutting mill assemblies which are adjustable in at least one of several ways to alter the cutting ability or nature of the cutting mill during operation. The invention features methods for operating a cutting mill assembly wherein one or more milling operating parameters are sensed or measured and, in response, a milling operating feature associated with the cutting mill or its operation is adjusted.
Exemplary milling operating parameters which can be sensed include torque experienced by the milling bottom hole assembly, weight-on-bit, flow rate at surface, flow rate proximate the bottom hole assembly, temperature, pressure and vibration. In preferred embodiments, suitable sensors are provided within the cutting mill assembly to detect and measure these milling operating parameters and to provide generated signals indicative of each.
In described embodiments, the milling operating features which are adjusted include movement of, including the amount of protrusion of, a cutter from the cutting mill body, diameter of the cutting mill body and fluid flow through a nozzle on the cutting mill body. Other adjustable milling operating features include vibration imparted to the cutting mill bottom hole assembly and the rate of fluid flow provided to the cutting mill bottom hole assembly.
In described embodiments, a controller is provided which is capable of receiving signals representative of the sensed milling operating parameters as well as providing control commands to adjust a milling operating feature. In certain embodiments, the controller senses one or more milling parameters and adjusts one or more milling operating features autonomously.
In described embodiments, an adjustable cutting mill features a mill body with a plurality of cutters, at least one or more of which are moveable with respect to the mill body. Movement of the one or more cutters is a milling operating feature which can be adjusted in response to sensed milling parameters. The one or more cutters are adjustable by movement to cause the cutter(s) to protrude outwardly from the mill body to a greater extent or lesser extent. In described embodiments, mechanisms are provided for moving the cutters with respect to the mill body. In preferred embodiments, the cutters can be remotely adjusted with respect to the mill body. In still other embodiments, the cutter(s) are autonomously adjusted with respect to the mill body by a controller based upon sensed downhole and/or uphole milling operating parameters.
In certain embodiments, an adjustable cutting mill is provided which includes a mill body having an adjustable diameter. In particular, wedge portions of the mill body can be moved to alter the diameter of the mill body. The diameter of the mill body is a milling operating feature which can be adjusted in response to sensed milling parameters. The diameter of the mill body might be reduced in response to detection of sensed milling parameters which indicate a restriction in the wellbore and wherein reduction of the mill body diameter would permit the mill body to pass through the restriction.
In other aspects, the cutting mill assembly includes nozzles or flow ports that are adjustable in flow area. Flow area can be adjusted to allow greater flow of fluid or lesser flow of fluid. This would also affect the pressure at which fluid exits the nozzle or flow port. Nozzle flow area is also a milling operating feature which can be adjusted or controlled in response to one or more sensed milling operating parameters.
In certain embodiments, the cutting mill assembly includes an extended reach tool which imparts vibration to the tool string to improve cutting ability at desired depth of the well. In described embodiments, the extended reach tool is operably associated with the controller so that vibrational energy can be created by the extended reach tool to increase the cutting effectiveness of the milling bottom hole assembly. Vibration created by the extended reach tool is a milling operating feature which can be adjusted or controlled in response to sensed milling operating parameters.
In described embodiments, the cutting mill assembly includes a circulation tool that includes lateral ports which can be opened to adjust fluid flow to the milling bottom hole assembly. Fluid flow to the milling bottom hole assembly is a milling operating feature which can be adjusted in response to sensed milling operating parameters.
In particular embodiments, a cutting mill assembly is provided which includes an adjustable cutting mill which is carried by a bottom hole assembly having a sensing and control unit. The sensing and control unit includes one or more sensors which are configured to detect one or more downhole milling parameters. In currently preferred embodiments, the downhole milling parameters include weight on bit (WOB), torque and temperature. Measured surface milling parameters include pump rate or fluid flow rate and surface weight of the entire cutting mill assembly.
The sensing and control unit preferably includes a controller which receives signals from the sensors which are representative of the one or more milling operating parameters and is configured to determine whether an adjustment of one or more milling operating features of the cutting mill assembly is desired. The controller is operably associated with the cutting mill assembly so that the controller can adjust one or more of these features to alter the milling operation. The controller is preferably a programmable processor with associated memory.
In a described embodiment, the bottom hole assembly of the cutting mill assembly includes a communications module which permits communication of data and commands between the downhole controller and the surface. The communication module will permit data representative of sensed milling operating parameters to be displayed to an operator at surface. An operator would be able to command the controller to control or adjust one or more milling operating features.
The invention provides methods for adjusting or controlling at least one milling operating feature of a cutting mill assembly within a wellbore. In accordance with described methods, one or more milling operating parameters are sensed and, in response, one or more milling operating features are adjusted or controlled.
For a thorough understanding of the present invention, reference is made to the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings, wherein like reference numerals designate like or similar elements throughout the several figures of the drawings and wherein:
A cutting mill assembly 20 is disposed within the wellbore 10, having been run in from the surface 14. The cutting mill assembly 20 is being used to cut away the plug 18. Generally, the cutting mill assembly 20 includes a running string 22 and a milling bottom hole assembly 24 which is carried by the running string 22. The running string 22 is typically coiled tubing. However, the running string 22 might also be composed of conventional drill pipe sections which are interconnected in end-to-end fashion, as is known in the art. A central flow bore 26 is defined within the running string 22 and permits flow of fluid, such as drilling mud through the running string 22 to the milling bottom hole assembly 24.
In preferred embodiments, the running string 22 incorporates an extended reach tool 28 and/or a circulation tool 30. The extended reach tool 28 may be an EasyReach Extended Reach Tool which is available commercially from Baker Hughes, a GE company, LLC of Houston, Tex. The extended reach tool 28 uses water hammer effect to generate traction forces which help to pull the running string 22 into the wellbore 10. The extended reach tool 28 is capable of imparting vibration to the milling bottom hole assembly 24, thereby increasing its rate of penetration and effectiveness.
The circulation tool 30 is a tool which enables mid-running string circulation from the flow bore 26 into the annulus 32, which is defined radially between the cutting mill assembly 22 and the casing 16. The circulation tool 30 generally includes a generally cylindrical housing 34 which defines a central flow passage 36 within. A plurality of lateral flow ports 38 are formed within the housing 34 permitting fluid flow between the annulus 32 and the flow passage 36. An interior sleeve 40 is retained with in the housing 34 and can be axially shifted within the body 34 selectively block or unblock the ports 38. The lateral flow ports 38 of the circulation tool 30 can therefore be opened, to reduce fluid flow to the milling bottom hole assembly 24 through the running string 22, or closed, to increase fluid flow to the milling bottom hole assembly 24 through the running string 22. The circulating tool 30 is preferably provided with a suitable solenoid valve (not shown) which is connected with a flow channel and will enable sleeve 40 to be shifted via fluid pressure so that the solenoid valve, under control of a controller, will open or close the flow ports 38.
A surface weight scale, of a type known in the art, is shown schematically at 42 in
Now also referring to
It is noted that the milling tool which is being described is a cutting mill that is used to cut away a plug or obstruction within a wellbore. It should be understood, however, that other forms of milling tools can be used as well. For example, the milling tool could be a casing exit mill which is used to cut an opening within the wellbore casing 16.
The milling bottom hole assembly 24 also includes a sensing and control module 58, which is illustrated in greater detail in
The controller 66 may be in the form of one or more printed circuit boards which contain a programmable processor, data storage and the necessary computer programming to receive signals from the sensors 60 which are indicative of sensed downhole milling operating parameters and calculate desired adjustments for adjustable milling operating features. Data connections 68 transmit signals from the sensors 60 to the controller 66. As shown in
The controller 66 is also operably interconnected with certain adjustable milling operating features of the cutting mill assembly 20 in order to control those milling operating features. Control line 72 extends from the controller 66 to the milling bit 44. The control line 72 carries actuation commands from the controller 66 to adjust the extension of mill bit cutters 48 or flow rate through nozzles 50, as will be described.
Referring once again to
The milling bit 44 includes an actuator, generally indicated at 82, for extending or retracting cutter 48 from recess 80. The actuator 82 includes a motorized fluid pump 84 which is operably interconnected with the control line 72 so that the pump 84 can be actuated by the controller 66. The actuator 82 also includes a piston chamber 86 which is in fluid communication with the pump 84. Piston 88 resides within the piston chamber 86 and is moveable within the chamber 86. Rod 90 secures the piston 88 to cutter 48. The actuator 82 can move the cutter 48 between a retracted position, wherein the cutter 48 is fully contained within the recess 80 and an alternate, extended position indicated at 48a. When the controller 66 commands the pump 84 to flow fluid to the chamber 86, the piston 88 is moved to the alternate, extended position 48a. When the controller 66 commands the pump 84 to flow fluid out of the chamber 86, the cutter 48 is returned to the retracted position within the recess 80. Other techniques and mechanisms for extending and retracting cutters are described in U.S. Pat. Publication No. 2015/0053551 which is owned by the applicant and is herein incorporated by reference in its entirety.
The controller 66 is also operably interconnected with various features within the cutting mill assembly 20 which enable it to adjust or control milling operating features. In particular embodiments, the controller 66 is operably interconnected with fluid pump 84 via control line 72 for control of extension of cutters 48. Preferably, the controller 66 is also operably interconnected via the control line 72 with linear actuator 92 in order to control or adjust flow through nozzle 50. Preferably also, the controller 66 is operably associated with the motor/pump 102 in order to control or adjust the diameter of the mill bit body 46′.
As
In some embodiments, the controller 66 will determine what, if any, adjustments of the milling operating features need to be made. In other embodiments, decisions about adjustment of milling operating features are made at surface 14 by human operators. Communications module 110 (
In operation, the cutting mill assembly 20 is run into the wellbore 10 until the milling bottom hole assembly 24 is proximate the plug 18 to be removed. Drilling fluid is flowed down through the cutting mill assembly 20 and out through the nozzles 50 of the milling bit 44. The milling bit 44 is rotated to mill away the plug 18. During milling, the sensors 60 detect downhole milling operating parameters, including torque, weight-on-bit, pressure, temperature, vibration and flow rate of fluid received proximate the milling bottom hole assembly 24. Signals indicative of the sensed milling operating parameters are transmitted from the sensors 60 to the controller 66. Other sensed milling parameters, such as pump flow rate and surface weight are transmitted to the controller 66 from weight scale 42 and flow meter 56 at the surface 14. The controller 66 then controls the adjustable milling operating features to respond to the sensed milling operating parameters.
If the controller 66 (or individual at surface 14) determines that the flow rate and the weight-on-bit are acceptable (branch 146), the decision is made to adjust mill aggressiveness (step 148). The controller 66/individual at surface 14 then determines whether the interaction between the mill bit 44 and the plug 18 is excessive or not (step 150). If yes, one or more of the cutters 48 on the lower cutting face 78 of the mill bit 46 are retracted to in step 152 in order to reduce frictional cutting contact between the mill bit 46 and the plug 18. Conversely, if the interaction between the mill bit 46 and plug 18 is too low, one or more cutters 48 are extended from the lower cutting face 78 of the mill bit 46 to compensate.
The controller 66 (or individual at surface 14) can also determine whether interaction between the mill body 46′ and the surrounding wellbore 10 is too great, which would indicate a need to reduce the diameter of the milling bit 46′. One technique for determining whether interaction between the mill body 46′ and surrounding wellbore 10 is too great is to move the tool string up and down in the wellbore 10 and monitor weight transfer. In step 154, it is determined that contact between the mill body 46′ and the surrounding wellbore 10 is excessive. In response, the controller (or individual at surface 14) controls the milling bit 44′ to retract the lateral cutting portions 94 (step 156).
In accordance with the exemplary control process 120, the controller 66 or individual at surface 14 can determine whether it is necessary to adjust flow rate through the nozzles 50 of the milling bit 44. In step 158, it is determined that there is excessive debris around the milling bit 44. Ultrasonic imaging technology could be used to detect the amount of debris. In response, the flow area through nozzle(s) 50 is adjusted to increase flow through the nozzle 50 (step 160). These actions should result in good torque response.