The present invention relates, generally, to an apparatus and methods for cutting or severing a conduit located in a borehole formed in the earth. In particular, the invention relates to a radial cutting apparatus for cutting, perforating or severing a conduit.
During drilling operations of an oilfield well, a drill pipe may become stuck in the borehole of the well. In such a case, remedial action is required to remove an upper portion of the drill pipe, so that the lower portion of the drill pipe can be drilled out.
Existing cutting and severing apparatus have experienced problems with the clogging of the apertures of the nozzles or the lack of uniformity of the cutting or severing procedure. To avoid these problems, separate mixing chambers and other structural features have been added to the cutting and severing apparatus, which creates complexity in the operation of the apparatus and adds significant weight to the apparatus when operating downhole.
A need exists for apparatus and methods for cutting or severing a conduit, located downhole in a borehole formed in the earth, which eliminate any clogging of the nozzles and lack of uniformity in the cutting and severing procedures, as well as provides a more simple operation of the cutting and severing apparatus.
The present invention meets these needs.
One object of the present disclosure is to provide a new and useful apparatus for cutting, perforating or severing a conduit, wherein the conduit can be located within a borehole formed in the earth. The conduit may be a drill pipe, production tubing, coiled tubing, casing, or other tubular. The apparatus of the present disclosure comprises a non-explosive fuel type for use in cutting or severing at least one conduit and, therefore, provides a non-explosive solution to the pipe recovery process.
In an embodiment, the apparatus may comprise a main body section comprising a central axis, an upper portion, a lower portion, and an intermediate portion between the upper portion and the lower portion, and the main body section can be adapted to be inserted into the conduit. A combustible charge is located in the intermediate portion. An ignition mechanism can be coupled to the upper portion for igniting the combustible charge, which can comprise a pyrotechnic charge or a plurality of pyrotechnic charges. The lower portion of the main body can comprise an internal no-go shoulder. A nozzle head can be located in the lower portion and adjacent the combustible charge. The nozzle head can comprise an internal cavity and a nozzle portion, including a plurality of apertures at spaced apart positions located around the central axis for providing passages from the internal cavity to outside of the nozzle head. In an embodiment, the nozzle head can comprise at least one seal around a perimeter of the nozzle head. Further, the nozzle portion can include any numbers of apertures, including in an embodiment, three or more apertures forming a plurality of apertures. In an embodiment, each of the plurality of apertures can be elongated in a direction perpendicular to the central axis. The apparatus further includes an ignition mechanism, which can be configured to ignite the combustible charge to create a flame and combustion products, as well as pressure in the internal cavity, for moving the nozzle head relative to the lower portion so that the nozzle portion protrudes out of the lower portion for passage of the flame and hot combustion products out of the plurality of apertures, to sever the conduit.
In an embodiment, the nozzle head can comprise an outer shoulder that can be configured to contact the internal no-go shoulder, of the lower portion, after the ignition mechanism ignites the combustible charge to move the nozzle head relative to the lower portion of the main body section. Further, in an embodiment, the outer shoulder can be located on a radially protruding portion of the nozzle head, and the at least one seal can be located on the radially protruding portion of the nozzle head, as well.
In another embodiment, a method for severing a conduit includes inserting a severing apparatus into the conduit, wherein the severing apparatus can comprise a combustible charge, an ignition mechanism for igniting the combustible charge, and a nozzle head located within a distal end portion of the severing apparatus. The combustible charge can be formed of one or more charges (e.g., pyrotechnic charge such as thermite) for producing an exothermic reaction, which are installed within the severing apparatus. The nozzle head can comprise a plurality of apertures for projection of combustion products. In an embodiment, a first nozzle head, usable for discharging a flame and hot combustion products, can be replaced by a second nozzle head after the first nozzle head has discharged the flame and the hot combustion products from the plurality of apertures of the first nozzle head. The second nozzle head can include the same or a different arrangement of nozzles as compared to the plurality of nozzles of the first nozzle head. The steps of the method can continue by igniting the combustible charge via the ignition mechanism to create the flame and the combustion products, as well as to create pressure in an internal cavity of the nozzle head to move the nozzle head at least partially out of the distal end of the severing apparatus, so that the plurality of apertures are exposed to the conduit. The steps of the method can further include discharging the flame and hot combustion products out of the plurality of apertures to sever the conduit.
In an embodiment, the distal end portion of the severing apparatus can comprise an internal no-go shoulder, and the nozzle head can comprise an outer shoulder, and the method steps can include preventing the nozzle head from completely exiting the distal end portion by contacting the internal no-go shoulder with the outer shoulder of the nozzle head, after the nozzle head is moved a predetermined distance relative to the distal end portion. In an embodiment, the method steps can include sealing the nozzle head in the distal end portion of the severing apparatus via at least one seal around the perimeter of the nozzle head.
Before describing selected embodiments of the present disclosure in detail, it is to be understood that the present invention is not limited to the particular embodiments described herein. The disclosure and description herein is illustrative and explanatory of one or more presently preferred embodiments and variations thereof, and it will be appreciated by those skilled in the art that various changes in the design, organization, means of operation, structures and location, methodology, and use of mechanical equivalents may be made without departing from the spirit of the invention.
As well, it should be understood that the drawings are intended to illustrate and plainly disclose presently preferred embodiments to one of skill in the art, but are not intended to be manufacturing level drawings or renditions of final products and may include simplified conceptual views to facilitate understanding or explanation. As well, the relative size and arrangement of the components may differ from that shown and still operate within the spirit of the invention.
Moreover, it will be understood that various directions such as “upper”, “lower”, “bottom”, “top”, “left”, “right”, “uphole”, “downhole”, and so forth are made only with respect to explanation in conjunction with the drawings, and that components may be oriented differently, for instance, during transportation and manufacturing as well as operation. Because many varying and different embodiments may be made within the scope of the concept(s) herein taught, and because many modifications may be made in the embodiments described herein, it is to be understood that the details herein are to be interpreted as illustrative and non-limiting.
Referring now to the Figures, the apparatus, for cutting and severing conduit, of the invention is identified by reference numeral 10. It is shown located in metal drill pipe 12 located in a borehole 14 extending into the earth 16 from the surface 18. One of the purposes of the apparatus 10 is to cut or sever the drill pipe 12 in the event it becomes stuck in the borehole 14 to allow remedial action to take place. The drill pipe 12 is just one example of a conduit that may be cut or severed by the apparatus discussed herein. Other conduits that may be cut or severed by the disclosed apparatus include, but are not limited to, production tubing, coiled tubing, and casing.
The apparatus 10 comprises an annular metal wall 20 formed by annular metal sections 20A and 20B, and an ignition subassembly 30, which can comprise members 32 and 34 that can be screwed together as shown to form a chamber 35. The ignition subassembly 30 can comprise a lower portion 36L, an intermediate portion 361, and an upper portion 36U. The lower portion 36L includes a nozzle head 38 therein. The nozzle head 38 is provided with an internal cavity 40 that can be lined with a heat resistant liner 42 (See
As shown in
Located in the intermediate portion 361 of the ignition subassembly 30 and supported by the nozzle head 38 is a fuel load. The fuel may in some embodiments be combustible material in the form of a solid, a liquid, or a gel. The combustible material may be non-explosive fuels such as thermites, modified thermites (containing gasification agents) or thermite mixtures containing binders, low explosives such as propellants and pyrotechnic compositions or modified liquid or gelled fuels with metal and/or metal oxide additives. In some embodiments, the non-explosive combustible fuels may be in the form of a single or multiple stacked combustible charges 78, e.g., thermite pellets. The pelletized fuel may be installed within the assembly prior to shipping. In other embodiments, the pelletized fuel may be installed in the assembly at the work site so that the mass of fuel can be adjusted to suit the specific well conditions, constraints, and operational requirements such as hydrostatic pressure or changes to the cutting requirements. Each of the combustible charges 78 may have a cylindrical outer surface and a central aperture 78A extending therethrough, and may be compressed into donut shaped pellets, as shown in
In an embodiment, loosely packed combustible material 80, which can be of the same material used in forming the combustible charges 78, can be located within the apertures 78A of the combustible charges 78, such that each combustible charge 78 is ignited from the loosely packed combustible material 80 upon ignition by an ignition mechanism 58.
Referring back to
Ignition subassembly member 32 may be coupled to a cable head assembly 68. A wireline cable 70 can be coupled to the upper end of the cable head assembly 68 and can extend to the surface 18 and a lifting apparatus 72. The lifting apparatus 72 may include a reel employed for unwinding and winding the wireline cable 70 to lower and raise the cutting apparatus 10. As shown schematically in
When the ignition mechanism 58 is energize by electrical current, it can generate enough heat to ignite the combustible material 80 and, hence the combustible charges 78, to generate a very high temperature flame with other hot combustion products and pressure in the internal cavity 40 that forces the nozzle head 38 downward from a first position within the lower portion 36L, as shown in
After the drill pipe 12 has been cut or severed, the apparatus 10 is removed from the borehole 14, allowing the upper portion of the drill pipe 12 to be removed, and the lower portion of the drill pipe 12 may then be drilled out in the event that the drill pipe 12 has become stuck in the borehole 14.
In one embodiment, the outside diameter of annular metal section 20B may be 1 inch, with two or more equally spaced apart apertures 44 around the central axis 46. The height of the apertures may be of about 0.060 to 0.100 inches. It is to be understood, however, that these specifications may vary.
The apparatus 10 also may be used to cut or sever conventional metal production tubing, metal coiled tubing, or metal casing in a borehole for remedial purposes. In
A method for severing the drill pipe 12 may include the step of inserting the apparatus 10 into the drill pipe 12. The apparatus 10 may be the one described herein, e.g., comprising at least one combustible charge 78, an ignition mechanism 58 for igniting the combustible charge 78, and a nozzle head 38 located within a lower portion 36L (distal end portion) of the apparatus 10 and comprising a plurality of apertures 44. The steps of the method can continue by igniting the combustible charge 78, via the ignition mechanism 58, to create a flame and combustion products, and pressure in an internal cavity 40 of the nozzle head 38, to move the nozzle head 38 at least partially out of the lower portion 36L of the apparatus 10 so that the plurality of apertures 44 are exposed to the drill pipe 12. The steps of the method can further include discharging the flame and hot combustion products out of the plurality of apertures 44 to sever the drill pipe 12.
After the cutting process is complete and the apparatus 10 is removed from the borehole 14, the lower portion 36L of the apparatus 10, including the nozzle head 38, may be detached from the apparatus 10 and replaced with another lower portion 36L having another nozzle head. That is, the lower portion 36L may be detachably attached, e.g., by a threaded connection, to the intermediate portion 361, so that the lower portion 36L may be easily detached from the intermediate portion 361. The other nozzle head may be different than the original nozzle head 38 by having a different arrangement or pattern of nozzles. This process may be conducted at the well site or other locations. In other embodiments, the lower portion 36L may be detachably attached from the intermediate portion 361 in order to replace or modify the fuel load, i.e., the charges 78 and/or the combustible material 80. Replacing the lower portion 36L so that the apparatus 10 has a different nozzle head may be advantageous if the different nozzle head is more suited to a particular cutting operation. Similarly, detaching the lower portion 36L to replace or modify the fuel load may be advantageous if the different fuel load is more suited to a particular cutting operation. For instance, more donut shaped pellets (see charges 78 in
In another embodiment shown in
In a further embodiment, a slickline percussion firing system may be employed in lieu of the electric line firing system to ignite the charges 78. This system may comprise a slickline cable head connection for supporting the modified apparatus 10 and which is connected to a pressure firing subassembly. The pressure firing subassembly comprises a cylinder having the piston and spring described in connection with the battery firing system. Ports are formed through the cylinder wall above the piston. Fluid pressure is increased, to force the piston rod (firing pin) against a lower percussion firing cap which ignites upon impact to ignite the charges 78.
In addition, a percussion firing system that is run via coiled tubing, production tubing, or drill pipe may be employed in lieu of the electric firing system to ignite the charges 78. This system may comprise coiled tubing for supporting the modified apparatus 10, which is connected to a connector subassembly that connects to a pressure firing head, which comprises a hollow cylinder with a piston located therein and supported by shear pins. The coiled tubing is coupled to the interior of the cylinder at its upper end. The piston has a central flow path extending axially downward from its upper end and then radially outward through the cylinder wall. A firing pin extends from the lower end of the piston. The flow path allows the coiled tubing to fill with water as the assembly is lowered downhole and also allows for circulation of fluid in running of the assembly. When the apparatus is at the desired cutting depth, a ball is dropped into the tubing which passes to the piston, plugging the flow path and allowing an increase in fluid pressure to be achieved in the tubing and upper end of the cylinder, which shears the shear pins and drives the firing pin into the percussion cap to ignite the charges 78.
While various embodiments usable within the scope of the present disclosure have been described with emphasis, it should be understood that within the scope of the appended claims, the present invention can be practiced other than as specifically described herein.
The present application is a continuation patent application that claims priority to a U.S. Non-provisional patent application Ser. No. 17/840,356, having the title of “Radial Cutting Apparatus for Cutting a Downhole Conduit,” filed on Jun. 14, 2022, which claims priority to U.S. Provisional Patent Application No. 63/210,834, having the title of “Radial Cutting Apparatus for Cutting a Downhole Conduit,” filed on Jun. 15, 2021. The disclosures of the prior applications are hereby incorporated by reference herein in their entireties.
Number | Date | Country | |
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63210834 | Jun 2021 | US |
Number | Date | Country | |
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Parent | 17840356 | Jun 2022 | US |
Child | 18424110 | US |