The present invention relates generally to a restriction element trap for use with an actuation element of a downhole apparatus and method of use thereof and, more particularly, to a trap sleeve in an actuation sleeve for conditionally exposing hydraulic fluid pressure to operational components of an expandable reamer apparatus for enlarging a subterranean borehole beneath a casing or liner.
Expandable reamers are typically employed for enlarging subterranean boreholes. Conventionally in drilling oil, gas, and geothermal wells, casing is installed and cemented to prevent the well bore walls from caving into the subterranean borehole while providing requisite shoring for subsequent drilling operations to achieve greater depths. Casing is also conventionally installed to isolate different formations, to prevent cross-flow of formation fluids, and to enable control of formation fluids and pressure as the borehole is drilled. To increase the depth of a previously drilled borehole, new casing is laid within and extended below the previous casing. While adding additional casing allows a borehole to reach greater depths, it has the disadvantage of narrowing the borehole. Narrowing the borehole restricts the diameter of any subsequent sections of the well because the drill bit and any further casing must pass through the existing casing. As reductions in the borehole diameter are undesirable because they limit the production flow rate of oil and gas through the borehole, it is often desirable to enlarge a subterranean borehole to provide a larger borehole diameter for installing additional casing beyond previously installed casing as well as to enable better production flow rates of hydrocarbons through the borehole.
A variety of approaches have been employed for enlarging a borehole diameter. One conventional approach, as generally described in U.S. Pat. No. 7,036,611 entitled “Expandable Reamer Apparatus for Enlarging Boreholes While Drilling and Methods of Use,” the entire disclosure of which is incorporated by reference herein, provides for displacing an actuation sleeve allowing hydraulic fluid pressure to be directed at actuating laterally movable blades for reaming a borehole. The actuation sleeve is releasably restrained within an inner bore of an expandable reamer apparatus by way of shear pins, interlocking members, frictional elements, or friable members, and includes a fluid flow path through a sleeve seat. The fluid flow path is interrupted when a restriction element, such as a so-called “drop ball,” is deployed upon the sleeve seat allowing hydraulic fluid pressure to build thereupon until the actuation sleeve is displaced. The restriction element is retained within the sleeve seat by gravity or while fluid pressure is maintained thereupon. However, conventional reamer designs do not provide positive retention of the restriction element.
A conventional gravel packing tool as generally described in U.S. Pat. No. 6,702,020 entitled “Crossover Tool,” the entire disclosure of which is incorporated by reference herein, provides a sleeve for trapping a ball. The ball is dropped into the tool and lands on a thin sleeve, which acts as the initial ball seat. Upon pressure buildup, the ball is forced past the thin sleeve and into sealing contact with a seat of a second sleeve, which is an extension of the thin sleeve and where both sleeves are retained in the tool. A shear pin holds the second sleeve in its initial position. A snap ring is mounted to the second sleeve and it is able to snap out of its recess allowing the second sleeve shifts as a result of applied fluid pressure upon the ball on the seat and when the fluid pressure is sufficient to shear the shear pins holding the second sleeve in its initial position. As a result of this movement, the internal diameter of the thin sleeve, through which the ball has already been forced, is further reduced as it is pulled through a reduced diameter of a surrounding body and locks the ball into the seat. The ball cannot be dislodged, particularly in the opposite direction, until a predetermined pressure is exceeded. Undesirably, dynamic motion required by the thin sleeve and the second sleeve in order to secure the ball only occurs after sufficient fluid pressure has been applied for shearing the shear pins and releasing the snap ring. Also, a sleeve for trapping a ball of a conventional gravel packing tool is undesirable for use with a downhole tool that includes an actuation sleeve, such as an expandable reamer apparatus, particularly where the actuation sleeve is selectively retained by fluid pressure and release of the actuation sleeve is desired only after the restriction elements is secured.
Furthermore, the shockwave or pressure build-up in order to secure the restriction element may likely initiate premature releasing of an actuation sleeve, rendering the captioning of the restriction element in an indeterminate or unknown state and possible premature tool activation.
Accordingly, it would be desirable to improve the performance of a downhole apparatus, such as an expandable reamer apparatus, by providing positive and robust retention of a restriction element. There is a further desire to provide determinate retention of a restriction element within an actuation element, such as the traveling sleeve of an expandable reamer apparatus. Moreover, there is a desire to provide verifiable retention of a restriction element prior to dynamic release of an actuation element. Lastly, there is a desire to provide positive retention of a restriction element without necessitating dynamically moving parts.
In order to provide positive and robust retention of a restriction element, a downhole apparatus is provided in at least one embodiment of the invention for engaging a borehole wall in a subterranean formation. The downhole apparatus includes a tubular body having a longitudinal axis and a first bore, an actuation element having a second bore and is positioned within the first bore of the tubular body, a drilling fluid flow path extending through the first and second bores, and a restriction element trap positioned within the second bore of the actuation element. The actuation element is configured to selectively retain an operable component of the downhole apparatus in an initial position and the restriction element trap is configured for retentively receiving a restriction element.
In other embodiments of the invention, a restriction element trap for use with an actuation element for retentively receiving a restriction element is provided. The restriction element trap provides determinate retention of a restriction element when used with, for example, a traveling sleeve of an expandable reamer apparatus.
In still other embodiments of the invention, an expandable reamer apparatus for enlarging a borehole in a subterranean formation is also provided. The expandable reamer apparatus is configured for positive retention of a restriction element with passive components.
Further, a method of using a downhole apparatus within a borehole of a subterranean formation is provided. The method provides verifiable retention of a restriction element within the downhole apparatus prior to dynamic release of an actuation element.
While the specification concludes with claims particularly pointing out and distinctly claiming that which is regarded as the invention various features and advantages of this invention may be more readily ascertained from the following description of the invention when read in conjunction with the accompanying drawings, in which:
The illustrations presented herein are, in some instances, not actual views of any particular downhole apparatus, restriction element trap in an actuation element, or other feature of a downhole apparatus, such as an expandable reamer apparatus, but are merely idealized representations that are employed to describe the present invention. Additionally, elements common between figures may retain the same numerical designation.
An expandable reamer apparatus 100 comprising a restriction element trap (reference numeral 200 shown in
Three sliding cutter blocks or blades 101 are positionally retained in circumferentially spaced relationship in the tubular body 108 as further described below and may be provided at a position along the expandable reamer apparatus 100 intermediate the first lower end 190 and the second upper end 191. The blades 101 may be comprised of steel, tungsten carbide, a particle-matrix composite material (e.g., hard particles dispersed throughout a metal matrix material), or other suitable materials as known in the art. The blades 101 are retained in an initial, retracted position within the tubular body 108 of the expandable reamer apparatus 100 as illustrated in
As shown in
The expandable reamer apparatus 100 may be configured such that the outermost radial or lateral extent of each of the blades 101 is recessed within the tubular body 108 when in the initial or retracted positions so it may not extend beyond the greatest extent of outer diameter of the tubular body 108. Such an arrangement may protect the blades 101 as the expandable reamer apparatus 100 is disposed within a casing of a borehole, and may allow the expandable reamer apparatus 100 to pass through such casing within a borehole. In other embodiments, the outermost radial extent of the blades 101 may coincide with or slightly extend beyond the outer diameter of the tubular body 108. As illustrated in
With continued reference to
The expandable reamer apparatus 100 includes a shear assembly 150 for retaining the expandable reamer apparatus 100 in the initial position by securing the traveling sleeve 128 toward the upper end 191 thereof. Reference may also be made to
With reference to
Shock absorbing member 125 may comprise a flexible or compliant material, such as, for instance, an elastomer or other polymer. In one embodiment, shock absorbing member 125 may comprise a nitrile rubber. Utilizing a shock absorbing member 125 between the traveling sleeve 128 and seal sleeve 126 may reduce or prevent deformation of at least one of the traveling sleeve 128 and seal sleeve 126 that may otherwise occur due to impact therebetween.
It should be noted that any sealing elements or shock absorbing members disclosed herein that are included within expandable reamer apparatus 100 may comprise any suitable material as known in the art, such as, for instance, a polymer or elastomer. Optionally, a material comprising a sealing element may be selected for relatively high temperature (e.g., about 400° Fahrenheit or greater) use. For instance, seals may be comprised of TEFLON®, polyetheretherketone (“PEEK™”) material, a polymer material, or an elastomer, or may comprise a metal-to-metal seal suitable for expected borehole conditions. Specifically, any sealing element or shock absorbing member disclosed herein, such as shock absorbing member 125 and sealing elements 134 and 135, discussed hereinabove, or sealing elements, such as seal 136 discussed herein below, or other sealing elements included by an expandable reamer apparatus of the invention may comprise a material configured for relatively high temperature use, as well as for use in highly corrosive borehole environments.
The seal sleeve 126 includes an O-ring seal 136 sealing it between the inner bore 151 of the tubular body 108, and a T-seal seal 137 sealing it between the outer bore 162 of the traveling sleeve 128, which completes fluid sealing between the traveling sleeve 128 and the nozzle intake port 164. Furthermore, the seal sleeve 126 axially aligns, guides and supports the traveling sleeve 128 within the tubular body 108. Moreover, the seal sleeve 126 seals 136 and 137 may also prevent drilling fluid from leaking from within the expandable reamer apparatus 100 to outside the expandable reamer apparatus 100 by way of the nozzle intake port 164 prior to the traveling sleeve 128 being released from its initial position.
A downhole end 165 of the traveling sleeve 128 (also see
The dogs 166 are positionally retained between an annular groove 167 in the inner bore 151 of the tubular body 108 and the seat stop sleeve 130. Each dog 166 of the lowlock sleeve 117 is a collet or locking dog latch having an expandable detent 168 that may engage the groove 167 of the tubular body 108 when compressively engaged by the seat stop sleeve 130. The dogs 166 hold the lowlock sleeve 117 in place and prevent the push sleeve 115 from moving in the uphole direction 159 until the “end” or seat stop sleeve 130, with its larger outer diameter 169, travels beyond the lowlock sleeve 117 allowing the dogs 166 to retract axially inward toward the smaller outer diameter 170 of the traveling sleeve 128. When the dogs 166 retract axially inward they may be disengaged from the groove 167 of the tubular body 108, allowing the push sleeve 115 to move responsive to hydraulic pressure primarily in the axial direction, i.e., in the uphole direction 159.
Advantageously, the lowlock sleeve 117 supports the weight of the traveling sleeve 128, minimizing the extent to which the shear assembly 150 is subjected to forces that potentially could weaken or cause premature failure of the shear elements, i.e., the shear screws 127. Thus, the shear assembly 150 requires an affirmative act, such as introducing a ball or other restriction element into the expandable reamer apparatus 100 to cause the pressure from hydraulic fluid flow to increase as a restriction element is captured in the restriction element trap 200 of the invention, before the shear screws 127 will shear or the shear assembly 150 will release the actuating, or traveling sleeve 128.
The restriction element trap 200 shown in
It is to be recognized that the restriction element, i.e., the ball 147, is sized and configured to engage the restriction element trap 200 at seat portion 195 complementarily sized and configured to substantially prevent the flow of drilling fluid through the traveling sleeve 128 and to cause displacement of the traveling sleeve 128 within the expandable reamer apparatus 100 to a position that allows communication between drilling fluid within the inner bore 151 and operational components, such as the actuating structure of the push sleeve 115.
Optionally, the ball 147 used to activate the expandable reamer apparatus 100 may engage the ball trap sleeve 129 and or the plug 131 of the restriction element trap 200 that include malleable characteristics, such that the ball 147 may swage therein as it seats in order to prevent the ball 147 from moving around and potentially causing problems or damage to the expandable reamer apparatus 100. In this regard, the ball trap sleeve 129 and the plug 131 may be made from a resilient malleable material, such as metal, elastomer, or other material having a deformable quality suitable for retentively receiving the ball 147 therein. In this embodiment, the annular portion 197 of the ball trap sleeve 129 is a thin-walled annular conduit made of relatively low yield-strength metal suitable for deforming into the recess of the enlarged bore 196 of the traveling sleeve 128 as the ball 147 is received therein. Optionally, the plug 131 is made of, or lined with, a resilient plastic material, such as tetrafluoroethylene (TFE), being suitable for capturing and stopping the ball 147 as it is trapped therein.
Also, in order to support the traveling sleeve 128 and mitigate vibration effects after the traveling sleeve 128 is axially retained, the seat stop sleeve 130 and the downhole end 165 of the traveling sleeve 128 are retained in a stabilizer sleeve 122. Reference may also be made to
After the traveling sleeve 128 travels sufficiently far enough to allow the duos 166 of the lowlock sleeve 117 to be disengaged from the groove 167 of the tubular body 108, the dogs 166 of the lowlock sleeve 117 being connected to the push sleeve 115 may all move in the uphole direction 159. Reference may also be made to
The push sleeve 115 includes at its uphole section 176 a yoke 114 coupled thereto as shown in
In order that the blades 101 may transition between the extended and retracted positions, they are each positionally coupled to one of the blade tracks 148 in the tubular body 108 as particularly shown in
In addition to the upper stabilizer block 105, the expandable reamer apparatus 100 also includes a mid stabilizer block 106 and a lower stabilizer block 107. The stabilizer blocks 105, 106, 107 help to center the expandable reamer apparatus 100 in the drill hole while being run into position through a casing or liner string and also while drilling and reaming the borehole. As mentioned above, the upper stabilizer block 105 may be used to stop or limit the forward motion of the blades 101, determining the extent to which the blades 101 may engage a borehole while drilling. The upper stabilizer block 105, in addition to providing a back stop for limiting the lateral extent of the blades 101, may provide for additional stability when the blades 101 are retracted and the expandable reamer apparatus 100 of a drill string is positioned within a borehole in an area where an expanded hole is not desired while the drill string is rotating.
Also, the expandable reamer apparatus 100 may include tungsten carbide nozzles not shown. The nozzles are provided to cool and clean the cutting elements 104 and clear debris from blades 101 during drilling. The nozzles may include an O-ring seal between each nozzle and the tubular body 108 to provide a seal between the two components. The nozzles are configured to direct drilling fluid towards the blades 101 in the down-hole direction 157, but may be configured to direct fluid laterally or in the uphole direction 159.
The downhole apparatus, or expandable reaming apparatus, 100 having a restriction element trap 200 is now described in terms of its operational aspects. Reference may be made to
Referring to
Thereafter, as illustrated in
In
As reaming takes place with the expandable reamer apparatus 100, the mid and lower hard face pads 106, 107 help to stabilize the tubular body 108 as the cutting elements 104 of the blades 101 ream a larger borehole and the upper hard face pads 105 also help to stabilize the top of the expandable reamer 100 when the blades 101 are in the retracted position.
After the traveling sleeve 128 with the ball 147 moves downward, it comes to a stop with the flow bypass or fluid ports 173 located above the ball 147 in the traveling sleeve 128 exiting against the inside wall 184 of the hard faced protect sleeve 121, which helps to prevent or minimize erosion damage from drilling fluid flow impinging thereupon. The drilling fluid flow may then continue down the bottomhole assembly, and the upper end of the traveling sleeve 128 becomes “trapped,” i.e., locked, between the ears 163 of the uplock sleeve 124 and the shock absorbing member 125 of the seal sleeve 126 and the lower end of the traveling sleeve 128 is laterally stabilized by the stabilizer sleeve 122.
When drilling fluid pressure is released, the spring 116 will help drive the lowlock sleeve 117 and the push sleeve 115 with the attached blades 101 back downwardly and inwardly substantially to their original or initial position into the retracted position, see
Whenever drilling fluid flow is re-established in the drill pipe and through the expandable reamer apparatus 100, the push sleeve 115 with the yoke 114 and blades 101 may move upward with the blades 101 following the ramps or tracks 148 to again cut/ream the prescribed larger diameter in a borehole. Whenever drilling fluid flow is stopped, i.e., the differential pressure falls below the restoring force of the spring 116, the blades 101 retract, as described above, via the spring 116.
In aspects of the invention, the restriction element trap 200 provides a positive and robust retention of a restriction element or ball 147 within a downhole tool such as an expandable reamer apparatus 100. Furthermore, the restriction element trap 200 provides for determinate retention of a ball 147 within an actuation element, such as the traveling sleeve 128, during or prior to its release within the downhole tool. Moreover, the restriction element trap 200 provides positive retention of a ball 147 without necessitating dynamically movable parts, which is felt by some, to potentially cause premature actuation or render captioning of the restriction element in an indeterminate or unknown state.
The expandable reamer apparatus 100 may include a lower saver sub 109 shown in
The shear screws 127 of the shear assembly 150, retaining the traveling sleeve 128 and the uplock sleeve 124 in the initial position, are used to provide or create a trigger, releasing when pressure builds to a predetermined value. The predetermined value at which the shear screws 127 shear under drilling fluid pressure within expandable reamer apparatus 100 may be 1000 psi, for example, or even 2000 psi. It is recognized that the pressure may range to a greater or lesser extent than presented herein to trigger the expandable reamer apparatus 100. Optionally, it is recognized that a greater pressure at which the shear screws 127 shears may be provided to allow the spring 116 to be conditionally configured and biased to a greater extent in order to further provide desired assurance of blade retraction upon release of hydraulic fluid. In this respect, the restriction element trap 200 may retentively receive a restriction element, such as a ball 147, with a pressure substantially less than pressure required for releasing the shear assembly 150 while conditionally providing retention of the restriction element to pressures greatly exceeding the pressure required for releasing the shear assembly 150. Furthermore, the restriction element trap 200 provides for retaining a restriction element under reverse pressure conditions. It is recognized the restriction element trap 200 may be configured for retentively receiving a restriction element for differing hydraulic pressure requirements, and may be configured to have retention characteristics chosen in relationship to a shear assembly 150 of an actuation element, such as a traveling sleeve 128.
In another aspect of the invention, the restriction element trap 200 within an actuation element may retentively receive a restriction element in order to cause activation of the actuation element by hydraulic fluid pressure in response to occlusion of a flow path therethrough, allowing the actuation element to be displaced in an axial downhole direction and thereafter exposing an operational component to a diverted hydraulic fluid in order to actuate the operational component in an axial upward direction, an axial downward direction, a laterally outward direction or other direction. In this respect, the actuation element may shield an operational component from hydraulic fluid pressure or premature operation until a restriction element is positively retained and the actuation element has been displaced.
While particular embodiments of the invention have been shown and described, numerous variations and other embodiments will occur to those skilled in the art. Accordingly, it is intended that the invention only be limited in terms of the appended claims and their legal equivalents.
The present application is also related to U.S. patent application Ser. No. 11/949,259, filed Dec. 3, 2007, entitled Expandable Reamers for Earth Boring Applications, now U.S. Pat. No. 7,900,717, issued Mar. 8, 2011, which is a non-provisional of U.S. Provisional Patent Application Serial No. 60/872,744, filed Dec. 4, 2006; U.S. patent application Ser. No. 12/058,384, filed Mar. 28, 2008, entitled Stabilizer and Reamer System Having Extensible Blades and Bearing Pads and Method of Using Same, now U.S. Pat. No. 7,882,905, issued Feb. 8, 2011; U.S. patent application Ser. No. 12/501,688, filed Jul. 13, 2009, entitled Stabilizer Ribs on Lower Side of Expandable Reamer Apparatus to Reduce Operating Vibration, now U.S. Pat. No. 8,297,381, issued Oct. 30, 2012; U.S. patent application Ser. No. 12/433,939, filed May 1, 2009, entitled Stabilizer and Reamer System Having Extensible Blades and Bearing Pads and Method of Using Same, now U.S. Pat. No. 8,205,689, issued Jun. 26, 2012, which is a non-provisional of U.S. Provisional Patent application Serial No. 61/049,617, filed May 1, 2008; and U.S. patent application Ser. No. 12/715,610, filed Mar. 2, 2010, entitled Chip Deflector on a Blade of a Downhole Reamer and Methods Therefore, now abandoned, which is a non-provisional of U.S. Provisional Patent Application Serial No. 61/156,936, filed Mar. 3, 2009; and U.S. patent application Ser. No. 13/662,862, filed Oct. 29, 2012, pending, each of which is assigned to the Assignee of the present application.
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