The present disclosure generally relates to downhole milling tools and methods, more particularly, tools and methods for milling tubular components in a wellbore or casing.
Drilling, operating, and maintaining wellbores includes placing tubular members within the wellbore. For example, production tools, packers, and other tubular components can be used in a wellbore and can become stuck, permanently fixed, abandoned, or otherwise left in the wellbore. Milling tools are used to mill and remove components in a wellbore.
This disclosure describes well tools for milling tubular components in a wellbore.
Some aspects of the disclosure encompass a well tool for milling a tubular. The well tool includes a well tubing configured to be disposed in a wellbore, the well tubing including a circulation fluid pathway through an interior of the well tubing, a first milling tool coupled to the well tubing at a first longitudinal end of the well tubing, a second milling tool coupled to the well tubing at a location longitudinally uphole from the first milling tool, and a third milling tool coupled to the well tubing at a location longitudinally uphole from the second milling tool. The first milling tool includes a first mill bit and a first circulation sub fluidly connected to the circulation fluid pathway, and the first milling tool is configured to mill a first portion of the tubular. The second milling tool includes a second mill bit and a second circulation sub fluidly connected to the circulation fluid pathway, and the second milling tool is configured to mill a second portion of the tubular. The third milling tool includes a third mill bit and a third circulation sub fluidly connected to the circulation fluid pathway, and the third milling tool is configured to mill a third portion of the tubular.
This, and other aspects, can include one or more of the following features. The first mill bit can include a first milling surface having a first outer diameter, the second mill bit can include a second milling surface with a second outer diameter, and the third mill bit can include a third milling surface with a third outer diameter. The first outer diameter, second outer diameter, and third outer diameter can be the same. At least one of the first mill bit, the second mill bit, or the third mill bit can include a pilot-type mill bit. The first mill bit can include a flat-bottom milling surface, and at least one of the second mill bit or the third mill bit can include the pilot-type mill bit. The first circulation sub can include a first circulation port to fluidly couple the circulation fluid pathway to an annulus of the wellbore downhole of the first mill bit. The second circulation sub can include a second circulation port through an exterior wall of the second circulation sub downhole of the second mill bit, where the second circulation port fluidly couples the circulation fluid pathway to the annulus downhole of the second mill bit, and the third circulation sub can include a third circulation port through an exterior wall of the third circulation sub downhole of the third mill bit, where the third circulation port fluidly couples the circulation fluid pathway to the annulus downhole of the third mill bit. The first circulation sub can include a first cylindrical body and a first plug seat to receive a first dropped plug and plug the first circulation port. The second circulation sub can include a first cylindrical body and a first sleeve valve within the first cylindrical body, where the first sleeve valve includes a first plug seat to receive a first dropped plug and selectively open the second circulation port. The third circulation sub can include a second cylindrical body and a second sleeve valve within the cylindrical body, the second sleeve valve including a second plug seat to receive a second dropped plug and selectively open the third circulation port. A first bore diameter of the first plug seat can be less than a second bore diameter of the second plug seat.
Some aspects of the disclosure encompass a method for milling a tubular in a wellbore. The method includes disposing a well tool in a wellbore, where the well tool includes a well tubing having a circulation fluid pathway through the well tubing, and milling the tubular in the wellbore with a first mill bit of the well tool until the first mill bit is at least partially consumed. The first mill bit is coupled to the well tubing proximate to a first longitudinal end of the well tubing. After milling the tubular until the first mill bit is at least partially consumed, the method includes lowering the well tool into the wellbore to dispose the first mill bit within the tubular, and after lowering the well tool, milling the tubular in the wellbore with a second mill bit of the well tool. The second mill bit is coupled to the well tubing at a location longitudinally uphole of the first mill bit.
This, and other aspects, can include one or more of the following features. Milling the tubular with the first mill bit can include flowing a circulation fluid to the first mill bit through a first circulation port in a first circulation sub at the first mill bit, the first circulation port fluidly connecting the circulation fluid pathway to an annulus of the wellbore, and the method can further include, after milling the tubular with the first mill bit until the first mill bit is at least partially consumed, plugging flow to the first circulation port with a first dropped plug. The first circulation sub can include a first cylindrical body and a first sleeve valve including a first plug seat, and plugging flow to the first circulation port with the first dropped plug can include engaging the first plug seat with the first dropped plug and sliding the first sleeve valve from a first, open position to a second, closed position of the first sleeve valve to plug the first circulation port. Milling the tubular with the second mill bit can include flowing the circulation fluid to the second mill bit through a second circulation port in a second circulation sub at the second mill bit, the second circulation port located downhole of the second mill bit and configured to flow the circulation fluid from within the second circulation sub to the annulus of the wellbore proximate to the second mill bit. The second circulation sub can include a sleeve valve having a plug seat, and plugging flow to the first circulation port with a first dropped plug can include receiving the first dropped plug in the plug seat of the sleeve valve of the second circulation sub, and moving the sleeve valve from a first position to a second position to open the second circulation port to the flow of circulation fluid. Milling the tubular with the second mill bit can include milling the tubular until the second mill bit is at least partially consumed, and the method can further include, after milling the tubular until the second mill bit is at least partially consumed, lowering the well tool into the wellbore to dispose the second mill bit within the tubular, and after lowering the well tool, milling the tubular in the wellbore with a third mill bit of the well tool, the third mill bit being coupled to the well tubing at a location longitudinally uphole from the second mill bit. The method can further include, after milling the tubular with the second mill bit until the second mill bit is at least partially consumed, plugging the second circulation port with a second dropped plug, and milling the tubular with the third mill bit can include flowing the circulation fluid to the third mill bit through a third circulation port in a third circulation sub at the third mill bit, the third circulation port located downhole of the third mill bit and configured to flow the circulation fluid from within the third circulation sub to the annulus of the wellbore proximate to the third mill bit. The third circulation sub can include a second sleeve valve having a second plug seat, and plugging the second circulation port with the second dropped plug can include receiving the second dropped plug in the second plug seat of the second sleeve valve of the third circulation sub, and moving the sleeve valve from a first position to a second position to open the third circulation port to the flow of circulation fluid. When the second mill bit mills the tubular in the wellbore, the first mill bit has been consumed, and the third mill bit is outside of the tubular. When the first mill bit mills the tubular in the wellbore, the second mill bit is outside of the tubular.
In certain aspects, a well tool for milling a tubular includes a drill pipe configured to be disposed in a wellbore, where the drill pipe includes a circulation fluid pathway through an interior of the drill pipe, a first milling tool coupled to the drill pipe at a first longitudinal end of the drill pipe, and a second milling tool coupled to the drill pipe at a location longitudinally uphole from the first milling tool. The first milling tool includes a first mill bit and a first circulation sub fluidly connected to the circulation fluid pathway, and the second milling tool includes a second mill bit and a second circulation sub fluidly connected to the circulation fluid pathway.
This, and other aspects, can include one or more of the following features. The first mill bit can include a first milling surface having a first outer diameter, the second mill bit can include a second milling surface with a second outer diameter, and the first outer diameter can be the same as the second outer diameter. The first circulation sub can include a first circulation port to fluidly couple the circulation fluid pathway to an annulus of the wellbore downhole of the first mill bit, and the second circulation sub can include a second circulation port through an exterior wall of the second circulation sub downhole of the second mill bit, where the second circulation port fluidly couples the circulation fluid pathway to the annulus downhole of the second mill bit. The second circulation sub can include a cylindrical body and a sleeve valve within the cylindrical body, where the sleeve valve includes a plug seat to receive a dropped plug and selectively open the second circulation port.
The details of one or more implementations of the subject matter described in this disclosure are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.
Like reference numbers and designations in the various drawings indicate like elements.
This disclosure describes a downhole well tool for milling and workover operations. The well tool includes a well tubing, such as a drill pipe, carrying multiple mills, and each mill includes a mill bit and a respective circulation sub through which fluid flows from the surface to the respective mill bit, for example, to cool the surface being milled, to cool the milling surface of the respective mill bit, to carry milled parts toward the surface through the wellbore (for example, through an annulus of the wellbore that exists between an exterior surface of the well tubing and an inner wall of the wellbore), or a combination of these. The multiple mill bits are longitudinally stacked in series along the well tubing, and adjacent mill bits are separated by one of the respective circulation subs. In some examples, each circulation sub is positioned within or just downhole of a respective mill, and each circulation sub can be ball activated to selectively close circulation ports at the respective circulation sub. A circulation port (or set of circulation ports) can be closed directly using a dropped ball (or other type of dropped plug) that seats in the circulation port, or the circulation port can be closed by moving a ball-activated sliding sleeve from a first position to a second, closed position that covers and plugs the circulation port (or set of circulation ports). For example, a dropped ball (or other type of dropped plug) can travel to and set on a plug seat on the sliding sleeve, the well tubing can be pressured up to a pressure threshold that is sufficient to shear a shear pin or fuse that temporarily holds the sliding sleeve in the open position, and the sliding sleeve can slide within its respective circulation sub adjacent to the circulation port to cover and plug the circulation port from fluid flow.
In some implementations, operation of the milling tool includes lowering the well tool into a wellbore or casing to the top of a tubular profile that needs to be milled. A first mill bit at the downhole end of the drill pipe (or other well tubing) contacts the uphole end of the tubular to be milled. The drill pipe is rotated to perform a milling operation until the first mill bit at the downhole end of the drill pipe wears out, such that the radius of the first mill bit recedes due to wear. Since the worn out first mill bit has reduced in diameter, a drawworks or other operable component at a wellhead of the wellbore can lower the drill pipe further downhole such that the worn out first mill bit is lowered within the tubular. As the drill pipe is lowered, a second mill bit of the well tool contacts the tubular to perform a milling operation. The milling operation is repeated with the second mill bit, and in some instances, a third mill bit or more mill bits disposed on the drill pipe, until the tubular is completely milled. The well tool can also be used to mill multiple tubulars and other components in the wellbore in succession.
Conventional milling tools include a single mill bit on a drill pipe, and a milling tool is run then retried each time the mill bit is consumed. The milling well tool of the present disclosure includes multiple sets of mills stacked on a single drill string, and a milling operation can run the multiple sets of mills in one trip to maximize milling operations, provide for faster milling operations, save rig time, and mill away more material from a well in the single trip, among other benefits.
In the example well system 100 of
The downhole well tool 116 is shown in
In the example well system 100 of
The example well tool 200 includes a well tubing 210 supported from a wellhead (not shown) at the surface of the wellbore 204. In the example well tool 200 of
The respective mill bits (222, 232, 242) each include a milling surface (226, 236, 246, respectively) at a longitudinally downhole end of its respective milling tool (220, 230, 240), which can sequentially engage and mill away all or a portion of the tubular 206. The milling surfaces (226, 236, 246) each have a respective outer diameter, which can be the same or different among the milling tools 220, 230, 240. In the example well tool 200 of
The fist mill bit 222, second mill bit 232, and third mill bit 242 can take a variety of shapes and mill types, and each of the mill bits 222, 232, 242 can be the same mill bit type or different mill bit types. In the example well tool 200 of
The example well tool 200 of
In operation of the example well tool 200, the drill pipe 210 rotates about its central longitudinal axis A-A, and the first milling tool 220, second milling tool 230, and third milling tool 240 sequentially engage and mill down the tubular 206. The milling tools 220, 230, and 240 are longitudinally stacked along the drill pipe 210 in order to mill down the tubular 206 in sequential stages, starting with the first milling tool 220, moving to the second milling tool 230 after the first mill bit 222 is worn down and consumed (partially or completely), then moving to the third milling tool 240 after the second mill bit 232 is worn down and consumed (partially or completely).
In an example milling operation using the example well tool 200, as the first mill bit 222 wears down the tubular 206, the tubular 206 also wears down the first mill bit 222. As the first mill bit 222 wears down, the material of the first mill bit 222 breaks down. When the material of the first mill bit 222 wears down completely through a thickness of the first mill bit 222, the diameter of the first mill bit 222 is reduced. With the reduced diameter of the first mill bit 222, a drawworks (or other operable equipment at a surface of the well) lowers the first mill bit 222 into the bore 208 of the tubular 206, for example, so that the second mill bit 232 can proceed with continuing to mill the tubular 206 while the first mill bit 222 resides in the bore 208 of the tubular 206. This milling operation is repeated for each sequential mill bit that is coupled to the drill pipe 210 (or until the tubular 206 is completely milled away), for example, so that the tubular 206 can be milled using multiple mill bits and in a single running of the example well tool 200 (or in fewer runnings of well tools relative to multiple runnings of single-bit milling tools). In some implementations, the drawworks (or other component at the wellhead) determines when one of the milling tools tags, or contacts, the tubular 206 by sensing a resistance to downward movement of the example well tool 200. As a milling tool mills the tubular 206, the drawworks, top drive, or other component can sense a downward acceleration or other downward movement of the well tool 200, indicating that the respective milling tool is consumed and can be lowered into the tubular 206. For example, the top drive provides the rotational force to the example well tool 200 to drive the milling operation that mills the downhole tubular profiles, and the top drive can also longitudinally push and pull the example well tool 200 (for example, along axis A-A). The depths of the respective milling tools of the example well tool 200 is known, for example, since the depths are recorded as the example well tool 200 enters the wellbore at the surface of the well.
The first circulation sub 224, second circulation sub 234, and third circulation sub 244 each include a circulation port or set of circulation ports that fluidly connect and direct a flow of the circulation fluid from the circulation fluid pathway 212 of the drill pipe 210 to an annulus of the wellbore 102 proximate to the respective mill bits 222, 232, 242 during a milling operation of the respective mill bits 222, 232, 242. The circulation ports are selectively controllable, for example, so that the milling tool that is milling a tubular component receives the flow of circulation fluid, while a worn out milling tool that is not actively milling the component does not receive a flow of the circulation fluid.
The example circulation sub 400 includes a sleeve valve 406 that is movable between a first position and a second position. In the first position of the sleeve valve 406, the set of circulation ports 404 are open to allow circulation fluid flow out of the circulation sub 400. In
In some examples, the sleeve valve 406 couples to the cylindrical body 402 of the circulation sub 400 and is held in the first, open position with a shear pin 410 or fuse. When a ball, plug, or other matching component is dropped into the circulation fluid pathway and reaches the seat of the sleeve valve 406, the interior of the circulation sub 400 can be pressurized (for example, from the surface) to shear the shear pin 410 or fuse, and slide the sleeve valve 406 into the second, closed position. In the second position of the sleeve valve 406, the sleeve valve physically plugs the circulation port(s) in the cylindrical body 402. With the circulation port(s) closed, the flow of circulation fluid cannot pass through the circulation sub 400, and instead, the circulation fluid can flow through an open circulation port of an adjacent circulation sub uphole of the example circulation sub 400.
In
The example circulation sub 400 can be implemented in the first circulation sub 224, second circulation sub 234, third circulation sub 244, or a combination of these, of the example well tool 200 of
One or more or all of the circulation subs 224, 234, 244 of the example well tool 200 are operated with dropped balls to allow fluid flow through its respective circulation port(s) to a milling tool that is actively milling the tubular component 206, and to plug circulation fluid flow to a milling tool that is consumed and positioned within the bore 208 of the tubular component 206. Since the circulation subs 224, 234, 244 are oriented in series with each other along the drill pipe 210, a first ball seat of the first circulation sub 224 can have a first bore diameter, a second ball seat of the second circulation sub 234 can have a second bore diameter that is larger than the first bore diameter, and a third ball seat of the third circulation sub 244 can have a third bore diameter that is larger than the second bore diameter. In these instances, a first dropped ball, having a diameter greater than the first bore diameter and less than the second bore diameter, flows through the third ball seat and second ball seat and seats on the first ball seat to plug a first circulation port of the first circulation sub 224. A second dropped ball, having a diameter greater than the second bore diameter and less than the second bore diameter, flows through the third ball seat and seats on the second ball seat to plug a second circulation port of the second circulation sub 234. A third dropped ball, having a diameter greater than the third bore diameter and less than an internal diameter of the cylindrical body of the third circulation sub 244, seats on the third ball seat to plug a third circulation port of the third circulation sub 244. In some instances, during a milling operation of the example well tool 200, the first dropped ball is dropped after the first milling tool is partially or completely consumed, the second dropped ball is dropped after the second milling tool is partially or completely consumed, and the third dropped ball is dropped after the third milling tool is partially or completely consumed.
In some implementations, the first circulation sub 224 of the first milling tool 220 includes a cylindrical opening at a downhole end of the first milling tool 200, and does not include a plug seat or sleeve valve. The second circulation sub 234 and third circulation sub 244 each include a circulation port or set of circulation ports that fluidly connect and direct a flow of the circulation fluid from the circulation fluid pathway 212 of the drill pipe 210 to the annulus of the wellbore 102 proximate to the respective mill bits 232, 242 during a milling operation of the respective mill bits 232, 242. However, the second circulation sub 234 and third circulation sub 244 include sliding sleeves that initially plug the circulation port(s), and are activated with a dropped ball (or other plug) to open the respective circulation port(s) and also to plug the central bore from fluid flow to a tool downhole of the respective circulation sub. For example,
The circulation ports are selectively controllable, for example, so that the milling tool that is milling a tubular component receives the flow of circulation fluid, while a worn out milling tool that is not actively milling the component does not receive a flow of the circulation fluid. In
In the schematic view of
With respect to
In a similar operation, with respect to
The example second circulation sub 234′ is the same as the example circulation sub 400 of
The second circulation sub 234′ and third circulation sub 244′ of the example well tool 500 are operated with dropped balls to allow fluid flow through its respective circulation port(s) to a milling tool that is actively milling a tubular component, and to plug circulation fluid flow to a milling tool that is consumed and positioned within the bore of the tubular component. Since the circulation subs 234′ and 244′ are oriented in series with each other along the drill pipe 210, the ball seat of the second circulation sub 234′ can have a bore diameter that is smaller than the ball seat of the third circulation sub 244′. In these instances, the dropped ball 509 has a diameter greater than the bore diameter of the sleeve valve 516 of the third circulation sub 244′ and less than the bore diameter of the sleeve valve 506 of the second circulation sub 234′. Other dropped ball 519 has a diameter greater than the bore diameter of the sleeve valve 516 of the third circulation sub 244′, and seats on the sleeve valve 516 to plug the sleeve valve 516 and open the circulation ports 514 of the third circulation sub 244′.
Referring to
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure.
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