Retractable joint and cementing shoe for use in completing a wellbore

Abstract

An improved method and/or apparatus for completing a wellbore is provided. In one embodiment, a method of lining a pre-drilled wellbore is provided. The method includes the act of providing a casing assembly, the casing assembly including a string of casing; and a retractable joint comprising an inner tubular and an outer tubular. The method further includes the acts of running the casing assembly into the pre-drilled wellbore and actuating the retractable joint, thereby reducing the length of the casing assembly through movement between the inner and outer tubulars.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to apparatus and methods for completing a well. Particularly, the present invention relates to a retractable joint and/or a cementing shoe for use with conventional well completions and with drilling with casing applications.

2. Description of the Related Art

In the oil and gas producing industry, the process of cementing casing into the wellbore of an oil or gas well generally comprises several steps. For example, a section of a hole or wellbore is drilled with a drill bit which is slightly larger than the outside diameter of the casing which will be run into the well. Next, a string of casing is run into the wellbore to the required depth where the casing lands in and is supported by a well head.

Next, cement slurry is pumped into the casing to fill the annulus between the casing and the wellbore. The cement serves to secure the casing in position and prevent migration of fluids and gasses between formations through which the casing has passed. Once the cement hardens, a smaller drill bit is used to drill through the cement in the shoe joint and further into the formation.

Typically, when the casing string is suspended in a subsea casing hanger, the length of the casing string is shorter than the drilled open hole section, allowing the casing hanger to land into the wellhead prior to reaching the bottom of the open hole. Should the casing reach the bottom of the hole prior to landing the casing hanger, the casing hanger would fail to seal and the casing would have to be retrieved or remedial action taken.

In some instances, the area between the end of the casing (sometimes called the “shoe”) and the end of the drilled open hole can become eroded to an even larger diameter than the original open hole. A typical cementing operation fills the volume between the annulus and casing above the shoe with cement, but not the section below the shoe. When the next section of open hole is drilled and casing is run, this increased diameter below the previous casing string allows mud circulation velocity to decrease, leaving debris and cuttings in this hole. The debris and cuttings can lead to pack off problems and trouble logging the well.

One prior art solution is disclosed in U.S. Pat. No. 5,566,772 (Coone, et al., issued Oct. 22, 1996). This solution uses pressurized fluid to extend a tubular member to the bottom of the open hole section once the casing has been landed. Pressure and/or circulation is required to activate the system. In one embodiment, a plug must be dropped from the surface to seal the bore of the casing shoe. This wastes valuable rig time. If the plug is dropped prior to landing the casing, the potential exists to set the shoe prematurely or restrict circulation. In formations where this enlarged section exists, activating and extending the shoe with pressure is likely to surge and damage the formation leading to other problems such as loss of drilling fluid and cement into the formation.

Therefore, there exists a need in the art for an improved method and/or apparatus for completing a subsea wellbore.

SUMMARY OF THE INVENTION

An improved method and/or apparatus for completing a wellbore is provided. In one embodiment, a method of lining a pre-drilled wellbore is provided. The method includes the act of providing a casing assembly, the casing assembly including a string of casing; and a retractable joint comprising an inner tubular and an outer tubular. The method further includes the acts of running the casing assembly into the pre-drilled wellbore; and actuating the retractable joint, thereby reducing the length of the casing assembly through movement between the inner and outer tubulars.

In one aspect of the embodiment, the retractable joint comprises a shearable member coupling the inner and outer tubulars. The act of actuating the retractable joint may include setting at least some of the weight of the casing on the retractable joint, thereby breaking the shearable member. In another aspect of the embodiment, the casing assembly further includes a hanger and the method further comprises landing the hanger into a casinghead. In another aspect of the embodiment, the method further includes the act of injecting cement through the casing assembly and into an annulus between the casing assembly and the wellbore. In another aspect of the embodiment, the retractable joint is disposed at an end of the casing string distal from a surface of the wellbore. In another aspect of the embodiment, the casing assembly further includes a second retractable joint.

In another aspect of the embodiment, the retractable joint further includes an anti-rotation member coupling the inner and outer tubulars. The anti-rotation member may include a slip, a ball, a shearable member, or a spline. In another aspect of the embodiment, the outer tubular has a vane disposed on an outer surface thereof. In another aspect of the embodiment, the length of the casing assembly is greater than a depth of the wellbore. In another aspect of the embodiment, the casing assembly further comprises a guide shoe and the act of running comprises running the casing assembly into the pre-drilled wellbore until the guide shoe rests on the bottom of the wellbore.

In another aspect of the embodiment, the casing assembly further includes a guide shoe, the guide shoe including a body comprising an axial bore therethrough and at least one port through a wall thereof; a liner covering the port, the lining configured to rupture at a predetermined pressure; and a nose disposed on the body and made from a drillable material and having a bore therethrough. The nose may have a blade disposed on an outer surface thereof. The body may have a vane disposed on an outer surface thereof. The liner may be made from a drillable material. The body may further include a second port through the wall thereof. The second port may be covered by the liner or a second liner having a thickness substantially equal to the thickness of the liner. The first port may be axially disposed proximate to the nose. The second port may be axially disposed distal from the nose, and the diameter of the second port is less than the diameter of the first port. The body may further include a second port through the wall thereof. The second port may be covered by a second liner having a thickness greater than the thickness of the liner. The first port may be axially disposed proximate to the nose. The second port may be axially disposed distal from the nose. The diameter of the second port may be substantially equal to the diameter of the first port. The method may further include the act of injecting wellbore fluid through the casing assembly, wherein the pressure will increase inside the guide shoe, thereby rupturing the liner. The method may further include the act of drilling through the nose of the guide shoe.

In another aspect of the embodiment, the retractable joint is configured so that the inner tubular will slide into the outer tubular when the retractable joint is actuated. In another aspect of the embodiment, the retractable joint is configured so that the outer tubular will slide over the inner tubular when the retractable joint is actuated and the inner tubular is made from a drillable material.

In another embodiment, a guide shoe for use with a string of casing in a wellbore is provided. The guide shoe includes a body including an axial bore therethrough and at least one port through a wall thereof; a liner covering the port, the liner configured to rupture at a predetermined pressure; and a nose disposed on the body, made from a drillable material, and having a bore therethrough.

In one aspect of the embodiment, the nose has a blade disposed on an outer surface thereof. In another aspect of the embodiment, the body has a vane disposed on an outer surface thereof. In another aspect of the embodiment, the liner is made from a drillable material. In another aspect of the embodiment, the body further includes a second port through the wall thereof. The second port may be covered by the liner or a second liner having a thickness substantially equal to the thickness of the liner. The first port may be axially disposed proximate to the nose and the second port may be axially disposed distal from the nose. The diameter of the second port may be less than the diameter of the first port.

In another aspect of the embodiment, the body further includes a second port through the wall thereof. The second port may be covered by a second liner having a thickness greater than the thickness of the liner. The first port may be axially disposed proximate to the nose and the second port may be axially disposed distal from the nose. The diameter of the second port may be substantially equal to the diameter of the first port.

In another aspect of the embodiment, a method of using the shoe is provided. The method includes the acts of attaching the guide shoe to a string of casing; running the guide shoe into a wellbore; and injecting cement through the casing to the guide shoe, wherein the pressure will increase inside the guide shoe, thereby rupturing the liner. The method may further include drilling through the nose of the guide shoe.

In another embodiment, a retractable joint for use with a string of casing in a wellbore is provided. The retractable joint includes an outer tubular having an inside diameter for a substantial portion thereof; an inner tubular having an outside diameter for a substantial portion thereof, wherein the outside diameter is less than the inside diameter; and an axial coupling axially coupling the inner tubular to the outer tubular.

In another aspect of the embodiment, the axial coupling includes a shearable member. In another aspect of the embodiment, the axial coupling includes a slip. In another aspect of the embodiment, the retractable joint further includes a seal disposed between the inner and outer tubulars. In another aspect of the embodiment, an end of the inner tubular has a second outside diameter that is greater than the inside diameter. In another aspect of the embodiment, the retractable joint further includes an anti-rotation member coupling the inner and outer tubulars. In another aspect of the embodiment, the anti-rotation member includes a slip. In another aspect of the embodiment, the anti-rotation member includes a ball. In another aspect of the embodiment, the anti-rotation member includes a shearable member. In another aspect of the embodiment, the anti-rotation member includes a spline. In another aspect of the embodiment, the outer tubular has a vane disposed on an outer surface thereof.

In another embodiment, a method for manufacturing a retractable joint for shipment to a well-site is provided. The method includes the acts of manufacturing an outer sleeve, an outer casing, an inner sleeve, and a crossover; sliding the outer sleeve over the inner sleeve; attaching the outer casing to the outer sleeve; attaching the crossover to the inner sleeve; sliding the crossover into the outer casing; attaching the outer sleeve to the crossover with temporary retainers; and sending the retractable joint to the well-site.

In one aspect of the embodiment, the method further includes the acts of receiving the retractable joint at the well-site; removing the temporary retainers; extending the retractable joint; inserting shear members; and attaching the retractable joint to a string of casing.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

FIG. 1 is a partial section view and illustrates the formation of a subsea wellbore with a casing string having a drill bit or guide shoe disposed at a lower end thereof.

FIG. 2 is a cross-sectional view illustrating the string of casing prior to setting a casing hanger into a casing hanger of the subsea wellhead. FIG. 2A is an enlarged cross-sectional view illustrating a retractable apparatus of the casing string in a first position. FIG. 2A is an enlarged cross-sectional view illustrating the retractable joint and the guide shoe in an extended position. FIG. 2B is a sectional view taken along line 2B-2B of FIG. 2A. FIG. 2C is an enlarged view of a portion of FIG. 2B. FIG. 2D is an isometric view of the retractable joint. FIG. 2E is an isometric view of the guide shoe. FIG. 2F is a bottom end view of the guide shoe.

FIG. 3 is a cross-sectional view illustrating the casing assembly after the casing hanger is seated in the casing hanger. FIG. 3A is an enlarged cross-sectional view illustrating the retractable apparatus in a retracted position after the casing hanger is set into the casing hanger.

FIG. 4 is a cross-sectional view illustrating the casing assembly after the casing assembly has been cemented into the wellbore. FIG. 4A is an enlarged view of the retractable shoe joint and the guide shoe.

FIG. 5 is a cross-sectional view illustrating the casing assembly after the guide shoe has been drilled through. FIG. 5A is an enlarged view of the retractable shoe joint and the guide shoe.

FIGS. 6A-6D are cross sectional views of retractable joints, according to alternative embodiments of the present invention. FIG. 6E is a sectional view taken along line 6E-6E of FIG. 6D.

FIG. 7A is a cross sectional view of a guide shoe, according to an alternative embodiment of the present invention. FIG. 7B is an isometric view of the guide shoe.

DETAILED DESCRIPTION OF THE PERFERRED EMBODIMENT

All references to directions, i.e. upper and lower, are for embodiment(s) to be used in vertical wellbores. These references are not meant to limit the embodiment(s) in any way as they may also be used in deviated or horizontal wellbores as well where the references may lose their meaning. Unless otherwise specified and except for sealing members all components are typically constructed from a metal, such as steel. However, the components may also be constructed from a composite, such as fiberglass. Unless otherwise specified, sealing members are typically constructed from a polymer, such as an elastomer. However, metal-to-metal sealing members may also be employed.

FIG. 1 illustrates a run-in operation of a pre-drilled subsea wellbore 100 with a casing assembly 170 in accordance with one embodiment of the present invention. Although the illustrated embodiments are employed with the subsea wellbore 100, other embodiments include application to land based wellbores. Typically, offshore drilling in deep water is conducted from a floating vessel 105 that supports the drill rig and derrick and associated drilling equipment. A riser pipe 110 is normally used to interconnect the floating vessel 105 and a subsea wellhead 115. A run-in string 120 extends from the floating vessel 105 through the riser pipe 110. The riser pipe 110 serves to guide the run-in string 120 into the subsea wellhead 115 and to conduct returning drilling fluid back to the floating vessel 105 during the run-in operation through an annulus 125 created between the riser pipe 110 and the run-in string 120. The riser pipe 110 is illustrated larger than a standard riser pipe for clarity.

A running tool 130 is disposed at the lower end of the run-in string 120. Generally, the running tool 130 is used in the placement or setting of downhole equipment and may be retrieved after the operation or setting process. The running tool 130 is used to connect the run-in string 120 to the casing assembly 170 and subsequently release the casing assembly 170 after the casing assembly 170 is set.

The casing assembly 170 may include a casing hanger 135, a string of casing 150, a float or landing collar 152, a retractable joint 160, and a shoe, such as circulation guide shoe 140. The casing hanger 135 is disposed at the upper end of the string of casing 150. The casing hanger 135 is constructed and arranged to seal and secure the string of casing 150 in the subsea wellhead 115. As shown on FIG. 1, the retractable joint 160 is disposed at the bottom of the string of casing 150. However, it should be noted that the retractable joint 160 is not limited to the location illustrated on FIG. 1, but may be located at any point on the string of casing 150. Further, more than one retractable joint 160 may be disposed in the string of casing 160.

The guide shoe 140 is disposed at a lower end of the shoe joint 160 to guide the casing assembly 170 into the wellbore 100 and to remove any obstructions encountered in the wellbore 100. During run in, the casing assembly 170 may be rotated and urged downward using the guide shoe 140 to remove any obstructions. Typically, drilling fluid is pumped through the run-in string 120 and the string of casing 150 to the guide shoe 140. In this respect, the run-in string 120, the run-in tool 130, and the casing assembly 170 act as one rotationally locked unit to guide the casing assembly 170 into the wellbore 100.

In an alternative embodiment, a drill bit (not shown) may be disposed at the lower end of the shoe joint 160 instead of the guide shoe 140. In this alternative embodiment, the casing 150 and the drill bit would be used in a drilling with casing operation instead of being run in to the pre-drilled wellbore 100 (see FIGS. 1-4 along with the discussion thereof in the '186 Patent).

In another alternative embodiment, again to be used in a drilling with casing operation, a casing drilling shoe, as disclosed in Wardley, U.S. Pat. No. 6,443,247 which is incorporated herein in its entirety, may be disposed at the lower end of the shoe joint 160 instead of the guide shoe 140. Generally, the casing drilling shoe disclosed in the '247 Patent includes an outer drilling section constructed of a relatively hard material such as steel, and an inner section constructed of a readily drillable, preferably polycrystalline diamond compact (PDC) drillable, material such as aluminum. The drilling shoe further includes a device for controllably displacing the outer drilling section to enable the shoe to be drilled through using a standard drill bit and subsequently penetrated by a reduced diameter casing string or liner.

FIG. 2 is a cross-sectional view illustrating the casing assembly 170 prior to setting the casing hanger 135 into a casinghead 205. Preferably, the casing assembly 170 is run in until the guide shoe 140 is at the bottom of the wellbore 100 and the length of the casing assembly 170 is slightly longer than the depth of the wellbore so that the casing hanger 135 is proximate to, but not seated in, the casinghead 205. The rotation of the casing 150 is then stopped.

The casing hanger 135 and casinghead 205 may be conventional and as such are not shown in detail. One exemplary casing hanger 135 includes one or more elastomer seals 220 which may be actuated to expand one or more metal seal lips (not shown) into engagement with the casinghead 205. The resulting seal between the casing hanger 135 and the casinghead 205 is thus a metal-to-metal seal backed up by an elastomer seal 220. Such a casing hanger 135 and casinghead 205 is manufactured by Vetco Gray™ under the name SG-5 Subsea Wellhead System™. Other suitable subsea wellhead systems include MS-700 Subsea Wellhead System™ also manufactured Vetco Gray™ and other conventional wellhead systems manufactured by other providers. In land based embodiments, any conventional casing hanger may be used.

As shown in FIG. 2, the casinghead 205 is disposed in the subsea surface. Typically, the casinghead 205 is located and cemented in the subsea surface prior to drilling the wellbore 100. The casinghead 205 is typically constructed from steel. However, other types of materials may be employed so long as the material will permit an effective seal between the casing hanger 135 and the casinghead 205. The casinghead 205 includes a landing shoulder 210 formed at the lower end of the casinghead 205 to mate with the lower surface 215 formed on the lower end of the casing hanger 135.

FIG. 2A is an enlarged cross-sectional view illustrating the retractable joint 160 and the guide shoe 140 in an extended position. FIG. 2B is a sectional view taken along line 2B-2B of FIG. 2A. FIG. 2C is an enlarged view of a portion of FIG. 2B. FIG. 2D is an isometric view of the retractable joint 160. When actuated, the retractable joint 160 moves from an extended position to a retracted position allowing the overall length of the casing assembly 170 to be reduced. As the casing assembly 170 length is reduced, the casing hanger 135 may seat in the casinghead 205 sealing the subsea wellhead 115 without damaging the one or more seals 220. In doing so, the guide shoe 140 remains seated on the bottom of the wellbore 100. Placing the end of the outer casing at the bottom of the wellbore allows the entire length of open hole to be circulated and cemented, eliminating the risk that debris and cuttings will be trapped in the enlarged open hole section. Further, if an obstruction in the wellbore 100 is encountered during run in of the casing assembly 170 which cannot be bypassed or removed by the guide shoe 140, the retractable joint 160 may be actuated thereby reducing the axial length of the casing assembly 170 and allowing the casing hanger 135 to land in the casinghead 205 (provided the retraction length of the retractable joint 160 is sufficient to accommodate the length of casing 150 extending from the wellbore 100).

The retractable joint 160 may include a crossover sub 222, tubular inner sleeve 225, an outer tubular casing 230, a tubular outer sleeve 245, one or more shear members, such as shear screws 240, one or more anti-rotation members, such as gripping members 255, and one or more seals 235. The crossover 222 is coupled to the casing 150 at an upper end with a standard casing coupling (not shown) and is coupled to the inner sleeve 225 with a flush type threaded joint to clear the inner diameter of the outer sleeve 245. Alternatively, the crossover 222 may be omitted if casing 150 is flush jointed. The outer sleeve 245 is coupled to the outer casing 230 by a threaded or other type of connection. The outer diameter of the inner sleeve 225 tapers to form a stop shoulder 227. The stop shoulder 227 is configured to mate with a bottom edge of the outer sleeve 245 to prevent the retractable joint 160 from separating from the casing 150 after the shear screws 240 have been broken in case the retractable joint 160 must be removed from the wellbore 100 or in case the shear screws 240 fail prematurely, i.e., if an obstruction is encountered in the wellbore at a location where the retraction length of the retractable joint 160 is not sufficient to seat the casing hanger 135 in the casinghead 205. The seal 235 is disposed in a radial groove formed in an inner surface of the outer sleeve 245. The outer sleeve 245 is configured to receive the inner sleeve 225 (except for the larger diameter portion) and the crossover 222 therein. The outer casing 230 is configured to receive the inner sleeve 225 and the crossover 222 therein. The outer casing 230 and crossover 222 are constructed of a predetermined length to allow the casing hanger 135 to seat properly in the casinghead 205.

Alternatively, the retractable joint 160 may be constructed and arranged to permit the casing 150 to slide there-over to obtain a similar result. However, this alternative would reduce the size of a second string of casing that may be run through the retractable joint after cementing and drill through of the retractable joint. To alleviate this shortcoming, the inner casing could be made of a drillable material, such as a composite so that it may be drilled out before running the second string of casing or be made of an expandable metal material so that it may be expanded to the same or larger diameter as the casing 150.

A circumferential groove is formed in the outer surface of the inner sleeve 225 and one or more corresponding threaded holes are disposed through the outer sleeve 245 which together receive the shear screws 240. The shear screws 240 couple the inner sleeve 225 and the outer sleeve 245 together axially. Alternatively, the groove may instead be one or more depressions or slots so that the shear screws may also rotationally couple the inner sleeve 225 and the outer sleeve 245 together. Alternatively, the shear members may be wire, pins, rings, other shear-able retaining member(s), or may be a biasing member, such as a spring. The shear screws 240 are used to retain the outer casing 230 and the outer sleeve 245 in a fixed position until sufficient axial force is applied to cause the shear screws 240 to fail. Preferably, this axial force is applied by releasing some or all of the weight of the casing 150 supported from the floating vessel 105 on to the retractable joint 160. Alternatively, a setting tool (not shown) or hydraulic pressure may be employed to provide the axial force required to cause the locking mechanism 310 to fail. Once the shear screws 240 fail, casing 150 may then move axially downward to reduce the length of the casing assembly 170.

Formed on an inner surface of the outer sleeve 245 are grooves, each having an inclined surface. A gripping member, such as a slip 255, is disposed in each of the inclined grooves of the outer sleeve 245 and has an inclined outer surface formed thereon which mates with the inclined groove of the outer sleeve 245, thereby creating a wedge action when the slips are actuated. The slips 255 are axially retained in the inclined grooves by a cap 247, which is coupled to the outer sleeve by fasteners, such as cap screws or threads. A biasing member, such as spring 257 is disposed in each inclined groove to bias each slip 255 into an extended or actuated position in contact with the inner sleeve 225 (or the crossover 222 depending on the axial position of the retractable joint 160). The slip 255 has teeth 256 formed on an inner surface thereof. The teeth 256 may be hard, i.e. tungsten carbide, inserts disposed on the slips 255 or a hard coating or treatment applied to the slips 255. The teeth 256 penetrate or “bite into” an outer surface of the inner sleeve 225/crossover 222 when the slips 255 are actuated.

When the inner sleeve 225/crossover 222 is rotated clockwise (when viewed from the surface of the wellbore 100), the inner sleeve 225/crossover 222 will push the slips up the inclined surface and into the radial groove against the resistance of the spring 257. Other than overcoming the resistance of the spring, the inner sleeve 225/crossover 222 is allowed to rotate freely relative to the outer sleeve 245 in the clockwise direction. When the inner sleeve 225/crossover 222 is rotated in the counter-clockwise direction, the slips 255 will slide down the inclined surfaces of the outer sleeve 245 and out of the inclined grooves, thereby rotationally coupling the inner sleeve 225 to the outer sleeve 245. Alternatively, a second set of slips could be added to rotationally couple the inner sleeve 225/crossover 222 to the outer sleeve 245 in both directions or the slip-groove coupling could be inverted in orientation so that it locks in the clockwise direction.

Alternatively, a second set of shear screws disposed in axial grooves may be employed to transmit torque between the inner sleeve 225/crossover 222 and the outer sleeve 245. The shear screw assembly may be disengaged by axial movement of one member relative to the other member caused by applied weight of the casing string, thereby permitting rotational freedom of each member. Alternatively, a spline assembly may be employed to transmit the torque between the inner sleeve 225/crossover 222 and the outer sleeve 245. The spline assembly may be disengaged by axial movement of one member relative to the other member, thereby permitting rotational freedom of each member. Alternatively, a ratchet mechanism may be employed to transmit torque between the inner sleeve 225/crossover 222 and the outer sleeve 245. Alternatively, a clutch mechanism may be employed to transmit torque between the inner sleeve 225/crossover 222 and the outer sleeve 245. The clutch mechanism may be actuated hydraulically, by setting down the weight of the casing 150, or by a setting tool.

Formed In an outer surface of the outer sleeve 245 may be one or more vanes 248. The vanes 248 serve as reaming members during run in of the casing assembly 170, as centralizers, and as anti-rotation members after cementing. During cementing, the areas between the vanes 248 will be filled with cement, thereby rotationally coupling the outer sleeve 245 to the wellbore 100.

If the retractable joint 160 is assembled prior to shipping to the floating vessel 105, one or more temporary retaining members, such as a set screws (not shown), are disposed in holes 242 disposed through the outer sleeve 225. The temporary set screws couple the inner sleeve 225/crossover 222 to the outer sleeve 245 to retain the retractable joint 160 in a retracted position for shipping and handling. The set screws may then be removed from the retractable joint 160 upon delivery to the floating vessel. The retractable joint 160 may then be extended and the set screws installed prior to run-in of the retractable joint into the wellbore 100.

FIG. 2E is an isometric view of the guide shoe 140. FIG. 2F is a bottom end view of the guide shoe 140. The guide shoe 140 includes a body 270 and a nose 280. The body 270 is a tubular member and is coupled to a lower end of the retractable joint 160 by a threaded or welded connection. The body 270 has a main axial bore therethrough. Formed on the outside of the guide shoe 140 are one or more sets 290a,b of one or more vanes. The vanes 290a,b serve as reaming members during run in of the casing assembly 170, as centralizers, and as anti-rotation members after cementing and during drill through of the nose portion 280. During cementing, the areas between the vanes 290a,b will be filled with cement, thereby rotationally coupling the body 270 to the wellbore 100.

Coupled to a bottom end of the body 270 by a threaded connection is the nose 280. The nose 280 is a convex member made from a drillable material, usually a non-ferrous PDC drillable material, such as aluminum (preferred), cement, brass, or a composite material. The nose 280 has an axial bore therethrough which is in communication with a main port 286 through a bottom tip having a diameter D1. Disposed through a side of the nose are one or more jet ports 287. The jet ports 287 discharge drilling fluid during run-in of the casing assembly 170. Disposed on an outer surface of the nose are one or more blades 282. The blades 282 will serve to remove any obstacles encountered by the guide shoe 140 during circulation through the casing assembly 170.

Disposed through a wall of the body 270 are one or more sets 285a-c of one or more circulation ports having diameters D2-D4, respectively. The diameters decrease from D2 to D4 (D2>D3>D4). Lining an inner side of the body 270 and covering each set of circulation ports 285a-c is/are one or more frangible members, such as burst tubes 275a-c, respectively. Alternatively, the burst tubes 275a-c may be disposed on the outside of the body. Alternatively, the burst tubes 275a-c may be replaced by a single burst tube. The burst tubes are normally made from a PDC drillable material, such as a non-ferrous metal, a polymer, or a composite material. The thicknesses of the burst tubes 275a-c are equal or substantially equal. The burst pressure of each of the burst tubes 275a-c will be inversely proportional to the diameters (including higher order relations, i.e. burst pressure inversely proportional to diameter squared) D2-D4 of the circulation ports 285a-c.

After the casing assembly 170 has been landed and set into the casinghead 205, there exists a need to ensure that the well is circulated and cemented from the lowest possible location of the open hole section which is typically at the guide shoe 140. This allows maximum removal of cuttings and debris from the open hole section and cement to be placed beginning at in the lowest portion of the well. However, utilizing string weight to collapse the joint 160 increases the possibility of plugging the main port 286 and the jet ports 287, which could prevent circulation and cementing. In the event that the guide shoe 140 was to become plugged, pressure would be increased to rupture one or more of the burst tubes 275a-c, thereby activating one or more of the circulation ports 285a-c. Pressure increase inside the guide shoe 140 will cause the unsupported area of the burst tubes 275a-c covering the circulation ports 285a-c to fail. The burst tubes 275a-c will fail at the largest unsupported area first, allowing circulation to be initially established at the lowest set 285c of circulation ports.

Another method to allow alternate circulation paths is the use of rupture disks in the guide shoe instead of the burst tubes 275a-c. Rupture disks with higher pressures can be positioned at higher locations in the guide shoe 140 to ensure circulation and cementing is initiated from the lowest portion of the well.

FIG. 3 is a cross-sectional view illustrating the casing assembly 170 after the casing hanger 135 is seated in the casinghead 205. FIG. 3A is an enlarged view of the retractable joint 160 and the guide shoe 140. An axial force was applied to the crossover 222 causing the shear members 240 to fail and allow the crossover 222 to move axially downward and slide into the outer casing 230. The lower surface 215 of the casing hanger 135 has contacted the landing shoulder 210 of the casinghead 205, thereby seating the casing hanger 135 in the casinghead 205. As further illustrated, the one or more seals 220 on the casing hanger 135 are in contact with the casinghead 205, thereby creating a fluid tight seal between the casing hanger 135 in the casinghead 205 during the drilling and cementing operations. In this manner, the length of the casing assembly 170 is reduced allowing the casing hanger 135 to seat in the casinghead 205.

FIG. 4 is a cross-sectional view illustrating the casing assembly 170 after the casing assembly 170 has been cemented into the wellbore 100. FIG. 4A is an enlarged view of the retractable shoe joint 160 and the guide shoe 140. Once the casing hanger 135 has seated in the casinghead 205, cement 180 is pumped through the casing 150 to the guide shoe 140. The cement 180 may or may not be pumped behind circulation fluid, i.e. drilling mud. The cement exits the guide shoe 140 filling the well bore 100 in the region surrounding the guide shoe 140. Circulation fluid is then pumped through the casing 150 to force the cement out of the guide shoe 140. The casing hanger 135 is then actuated (i.e., by rotation of the casing assembly 170) to activate the metal-to-metal seal. Alternatively, for land based wellbores, the cementing step(s) are performed before landing the casing hanger and the casing hanger may not require an additional actuation step.

Assuming that the main port 286 through the nose 280 is plugged, pressure will increase, thereby bursting the burst tube 275c covering the circulation ports 285c. Depending on the diameter D2, the number of circulation ports 285c, and the injection rate of cement, burst tubes 285a,b may be ruptured as well. Depending on formation characteristics, circulation ports 285c may also be plugged leading to the rupture of burst tubes 275a,b. Once the desired amount of cement 180 has been discharged into the well bore 100, the cement is then allowed to harden thereby bonding the casing assembly 170 to the subsea formation surrounding the bottom of the well bore 100. Cement will also fill the areas between the vanes 290a,b of the guide shoe 140 and the vanes 248 of the retractable joint 160, thereby rotationally coupling the guide shoe 140 and the retractable joint 160 to the wellbore 100. In the event that the cement 180 does not adequately fill the areas between the vanes 290a,b of the guide shoe 140 and the vanes 248 of the retractable joint 160 to provide rotational coupling to the wellbore 100, the slips 255 will still provide rotational coupling between the retractable joint 160 (and the guide shoe 140) and the casing 150.

FIG. 5 is a cross-sectional view illustrating the casing assembly 170 after the guide shoe 140 has been drilled through. FIG. 5A is an enlarged view of the retractable shoe joint 160 and the guide shoe 140. After the cement 180 has hardened and the casing assembly 170 bonded in place, a drilling tool (not shown) is then lowered through the casing 150 to the float or landing collar 152. The drilling tool is used to drill through the float or landing collar 152, through any cement left inside the retractable joint 160 and the guide shoe 140, and through the PDC drillable portion of the guide shoe 140. After drilling through the guide shoe 140, the drilling tool then proceeds to drill the next section of the well bore 100 which is typically smaller in diameter than the previously drilled section.

FIGS. 6A-6D are cross sectional views of retractable joints 660a-d, according to alternative embodiments of the present invention. FIG. 6E is a sectional view taken along line 6E-6E of FIG. 6D.

Referring to FIG. 6A, the retractable joint 660a includes a tubular crossover 622, a tubular shear coupling 625a, outer casing 630a, a stop ring 645a, one or more shear members 640a, one or more seals 635a, and one or more temporary retaining members 642a. The shear coupling 625a is coupled to a lower end of the crossover 622 by a threaded connection. The stop ring 645a is coupled to the outer casing 630a by a threaded connection. The seal 635a is disposed in a circumferential groove formed in an inner surface of the stop ring 645a. The outer casing 630a is secured to the shear coupling 625a by the shear members 640a. The outer diameter of the shear coupling 625a is slightly greater than the outer diameter of the crossover 622 to form a stop shoulder. The stop shoulder will mate with a bottom tip of the stop ring 645a to prevent the retractable joint 660a from separating after the shear members 640a have been broken in case the retractable joint 660a must be removed from the wellbore 100 or in case the shear screws 240 fail prematurely, i.e., if an obstruction is encountered in the wellbore at a location where the retraction length of the retractable joint 160 is not sufficient to seat the casing hanger 135 in the casinghead 205. The seal 635a is disposed in a radial groove formed in an inner surface of the stop ring 645a. The stop ring 645a is configured to receive the crossover 622 therein. The outer casing 630a is configured to receive the shear coupling 625a and the crossover 622 therein. The outer casing 630a and crossover 622 are constructed of a predetermined length to allow the casing hanger 135 to seat properly in the casinghead 205.

Referring to FIG. 6B, the retractable joint 660b includes the crossover 622, a tubular shear coupling 625b, an outer casing 630b, a stop ring 645b, one or more shear members 640b, one or more seals 635b, and one or more temporary retaining members 642b. This embodiment is similar to that of FIG. 6A except that the temporary retaining members 642b are set screws and they are located on an opposite side of the seal 635b, thereby eliminating any leak paths due to the temporary retaining members 642b.

Referring to FIG. 6C, the retractable joint 660c includes the crossover 622, a tubular shear coupling 625c, outer casing 630c, a stop ring 645c, one or more shear members 640c, one or more seals 635c, and a plurality of axial gripping members, such as axial slips 655c. The stop ring 645c is coupled to an upper end of the shear coupling 625c by a threaded connection. The shear coupling 625c is coupled to an upper end of the outer casing 630c by a threaded connection. The seal 635c is disposed in a circumferential groove formed in an inner surface of the stop ring 645c. The shear coupling 625c is secured to the crossover 622 by the shear members 640c. The outer casing 630c and the crossover 622 are constructed of a predetermined length to allow the casing hanger 135 to seat properly in the casinghead 205.

Formed on an inner surface of the stop ring 645c is an annular groove having an inclined surface. The axial slips 655c are disposed in the annular groove of the stop ring 645 and each have an inclined outer surface formed thereon which mates with the inclined inner surface of the stop ring 645c, thereby creating a wedge action when the axial slips 655c are actuated. The axial slips 655 have teeth (not shown in visible scale) formed on an inner surface thereof. The slip-groove coupling will allow the stop ring 645c to move upward relative to the casing 150 but will restrain axial movement in the opposite direction. After the shear members 640 are broken, the slip-groove coupling will provide one-directional axial coupling to prevent the retractable joint 660c from separating after the shear members 640c have been broken in case the retractable joint 660c must be removed from the wellbore 100 or in case the shear members fail prematurely, i.e., if an obstruction is encountered in the wellbore at a location where the retraction length of the retractable joint 160 is not sufficient to seat the casing hanger 135 in the casinghead 205.

Referring to FIG. 6D, the retractable joint 660d includes the crossover 622, a tubular shear coupling 625d, outer casing 630d, a stop ring 645d, one or more shear members 640d, one or more seals 635d, one or more temporary torque members 642d, and one or more anti-rotation members, such as lugs or balls 655d. The shear coupling 625d is coupled to a lower end of the crossover 622 by a threaded connection. The stop ring 645d is coupled to an upper end of the outer casing 630 by a threaded connection. The outer diameter of the shear coupling 625d tapers outward slightly to form a stop shoulder. The stop shoulder will mate with a bottom tip of the stop ring 645d to prevent the retractable joint 660d from separating after the shear members 640d have been broken in case the retractable joint 660d must be removed from the wellbore 100 or in case the shear members fail prematurely, i.e., if an obstruction is encountered in the wellbore at a location where the retraction length of the retractable joint 160 is not sufficient to seat the casing hanger 135 in the casinghead 205. The seal 635d is disposed in a radial groove formed in an inner surface of the stop ring 645d. The stop ring 645d is secured to the shear coupling 625d by the shear members 640d. The outer casing 630d and the crossover 622 are constructed of a predetermined length to allow the casing hanger 135 to seat properly in the casinghead 205.

The stop ring 645d has one or more longitudinal grooves formed on an inner surface thereof and the shear coupling 625d has one or more corresponding longitudinal grooves formed on an outer surface thereof. An access hole 659d is disposed through the stop ring 645d for each pair of grooves and a ball 655d is disposed in each pair of grooves. The ball-groove coupling allows the shear coupling 625d to move longitudinally relative to the stop ring 645d while restraining rotational movement therebetween. When the retractable coupling is actuated and the stop ring 645d moves upward relative to the casing 150, each ball 655d will become aligned with the access hole 659d. Further axial movement will eject each ball 655d through a respective access hole 659d, thereby allowing continued actuation of the retractable joint 660d.

FIG. 7A is a cross sectional view of a guide shoe 740, according to an alternative embodiment of the present invention. FIG. 7B is an isometric view of the guide shoe 740. The guide shoe 740 includes a body 770 and a nose 780. The body 770 is a tubular member and has a main axial bore therethrough. Formed on the outside of the guide shoe 740 are one or more vanes 790. The vanes 790 serve as reaming members during run in of the casing assembly 170, as centralizers, and as anti-rotation members after cementing and during drill through of the nose portion 780. Cement will fill the areas between the vanes 790, thereby rotationally coupling the body 770 to the wellbore 100.

Formed integrally at a lower end of the body 770 is the nose 780. Alternatively, the nose 780 may be coupled to the body by a threaded connection or molded in place with a series of grooves or wickers formed into the body. The nose 780 is a convex member made from a PDC drillable material, usually a non-ferrous material, such as aluminum (preferred), cement, brass, or a composite material. The nose 780 has an axial bore therethrough which is in communication with a main port 786 through a bottom tip of the nose 780. Disposed through a side of the nose are one or more jet ports 787. Disposed on an outer surface of the nose 780 are one or more blades 782. The blades 782 will serve to remove any obstacles encountered by the guide shoe 740 during run in of the casing assembly 170.

Disposed through a wall of the body 770 are one or more sets 785a-c of one or more circulation ports having equal or substantially equal diameters. Lining an inner side of the body 770 and covering each set of circulation ports 785a-c are burst tubes 775a-c, respectively. The burst tubes are made from a PDC drillable material, such as a non-ferrous metal or a polymer. The thickness of the burst tube 775a is greater than the thickness of burst tube 775b which is greater than the thickness of burst tube 775c. The burst pressure of each of the burst tubes 775a-c will be proportional to the respective thickness (including higher order relations, i.e. burst pressure proportional to thickness squared). The differing thicknesses will produce a similar effect to the differing circulation port diameters D2-D4 of the guide shoe 140.

In alternate embodiments, features of any of the retractable joints 160, 660a-d may be combined to construct the retractable joint. Similarly, any features of the guide shoes 140,740 may be combined to construct the guide shoe.

In alternate embodiments, a second (or more) 160,660a-d retractable joint may be disposed in the casing assembly 170 to increase the retraction length of the casing assembly 170.

The retractable joints 160,660a-d are advantageous over previous system(s) in that pressure and/or circulation is not required to activate them. Further, landing the guide shoe 140 at the bottom of the wellbore prevents pressure surge and damage to the formation and ensures that the washed out section of hole is cemented.

Individual components of the retractable joints 160,660a-d may be manufactured at a remote location and shipped to a well-site, such as the floating platform 105 for assembly or the retractable joints 160,660a-d may be assembled (with the temporary retaining members instead of the shear members) prior to shipment in a retracted position and shipped to the floating platform 105. The retractable joint 160 may be assembled using the same machinery used to make up the existing tubulars prior to running into the wellbore 100 as well as ordinary hand tools used in maintaining and assembling oilfield service tools. The retractable joints 160,660a-d may also be shipped as a unit ready to be run into the wellbore 100 once bucked onto the existing tubular. Shipping the retractable joints 160,660a-d to the floating platform 105 in pieces or partially assembled may alleviate shipping length restrictions.

In one embodiment, the manufacturing and assembly process may proceed at a manufacturing site as follows. The outer sleeve 245, the outer casing 230, the inner sleeve 225, and the crossover 222 are manufactured (some manufacturing steps may be performed at other manufacturing sites). The sealing member 235 is installed into the outer sleeve 245. The outer sleeve 245 is then slid over the inner sleeve. The slips 255 and springs 257 are inserted and the cap 247 is attached. The crossover 222 is attached to the inner sleeve 225. The outer casing 230 is attached to the outer sleeve 245. The crossover 222 is slid into the outer casing 230. The outer sleeve 245 is attached to the crossover 222 with the temporary retainers. Finally, the retractable joint 160 is delivered to the well-site. At the well-site, the crew may simply remove the temporary retainers, extend the retractable joint 160, insert the shear screws 240, and attach the guide shoe 140. The retractable joint 160 is then ready to be assembled with the casing 150 for insertion into the wellbore 100. Alternatively, the guide shoe 140 may be assembled and attached to the retractable joint 160 at the manufacturing site and delivered with the retractable joint 160 already attached. Alternatively, the retractable joint 160 may be assembled except for the crossover 222 and the outer casing 230 which may be attached at the well-site.

While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

Claims

1. A method of lining a pre-drilled wellbore, comprising: providing a casing assembly, the casing assembly comprising: a string of casing; and a retractable joint comprising an inner tubular and an outer tubular; running the casing assembly into the pre-drilled wellbore; and actuating the retractable joint, thereby reducing the length of the casing assembly through movement between the inner and outer tubulars.

2. The method of claim 1, wherein the retractable joint comprises a shearable member coupling the inner and outer tubulars.

3. The method of claim 2, wherein the act of actuating the retractable joint comprises setting at least some of the weight of the casing on the retractable joint, thereby breaking the shearable member.

4. The method of claim 1, wherein the casing assembly further comprises a hanger and the method further comprises landing the hanger into a casinghead.

5. The method of claim 1, further comprising injecting cement through the casing assembly and into an annulus between the casing assembly and the wellbore.

6. The method of claim 1, wherein the retractable joint is disposed at an end of the casing string distal from a surface of the wellbore.

7. The method of claim 1, wherein the casing assembly further comprises a second retractable joint.

8. The method of claim 1, wherein the retractable joint further comprises an anti-rotation member coupling the inner and outer tubulars.

9. The method of claim 8, wherein anti-rotation member comprises a slip.

10. The method of claim 8, wherein anti-rotation member comprises a ball.

11. The method of claim 8, wherein anti-rotation member comprises a shearable member.

12. The method of claim 8, wherein anti-rotation member comprises a spline.

13. The method of claim 1, wherein the outer tubular has a vane disposed on an outer surface thereof.

14. The method of claim 1, wherein the length of the casing assembly is greater than a depth of the wellbore.

15. The method of claim 1, wherein the casing assembly further comprises a guide shoe and the act of running comprises running the casing assembly into the pre-drilled wellbore until the guide shoe rests on the bottom of the wellbore.

16. The method of claim 1, wherein the casing assembly further comprises a guide shoe, the guide shoe comprising a body comprising an axial bore therethrough and at least one port through a wall thereof; a liner covering the port, the lining configured to rupture at a predetermined pressure; and a nose disposed on the body and made from a drillable material and having a bore therethrough.

17. The method of claim 16, wherein the nose has a blade disposed on an outer surface thereof.

18. The method of claim 16, wherein the body has a vane disposed on an outer surface thereof.

19. The method of claim 16, wherein the liner is made from a drillable material.

20. The method of claim 16, wherein the body further comprises a second port through the wall thereof, the second port is covered by the liner or a second liner having a thickness substantially equal to the thickness of the liner, the first port is axially disposed proximate to the nose and the second port is axially disposed distal from the nose, and the diameter of the second port is less than the diameter of the first port.

21. The method of claim 16, wherein the body further comprises a second port through the wall thereof, the second port is covered by a second liner having a thickness greater than the thickness of the liner, the first port is axially disposed proximate to the nose and the second port is axially disposed distal from the nose, and the diameter of the second port substantially equal to the diameter of the first port.

22. The method of claim 16, further comprising injecting wellbore fluid through the casing assembly, wherein the pressure will increase inside the guide shoe, thereby rupturing the liner.

23. The method of claim 22, further comprising drilling through the nose of the guide shoe.

24. The method of claim 1, wherein the retractable joint is configured so that the inner tubular will slide into the outer tubular when the retractable joint is actuated.

25. The method of claim 1, wherein the retractable joint is configured so that the outer tubular will slide over the inner tubular when the retractable joint is actuated and the inner tubular is made from a drillable material.

26. A guide shoe for use with a string of casing in a wellbore, comprising: a body comprising an axial bore therethrough and at least one port through a wall thereof; a liner covering the port, the liner configured to rupture at a predetermined pressure; and a nose disposed on the body, made from a drillable material, and having a bore therethrough.

27. The shoe of claim 26, wherein the nose has a blade disposed on an outer surface thereof.

28. The shoe of claim 26, wherein the body has a vane disposed on an outer surface thereof.

29. The shoe of claim 26, wherein the liner is made from a drillable material.

30. The shoe of claim 26, wherein the body further comprises a second port through the wall thereof, the second port is covered by the liner or a second liner having a thickness substantially equal to the thickness of the liner, the first port is axially disposed proximate to the nose and the second port is axially disposed distal from the nose, and the diameter of the second port is less than the diameter of the first port.

31. The shoe of claim 26, wherein the body further comprises a second port through the wall thereof, the second port is covered by a second liner having a thickness greater than the thickness of the liner, the first port is axially disposed proximate to the nose and the second port is axially disposed distal from the nose, and the diameter of the second port substantially equal to the diameter of the first port.

32. A method of using the shoe of claim 26, comprising: attaching the guide shoe of claim 21 to a string of casing; running the guide shoe into a wellbore; and injecting cement through the casing to the guide shoe, wherein the pressure will Increase inside the guide shoe, thereby rupturing the liner.

33. The method of claim 32, further comprising drilling through the nose of the guide shoe.

34. A retractable joint for use with a string of casing in a wellbore, comprising: an outer tubular having an inside diameter for a substantial portion thereof; an inner tubular having an outside diameter for a substantial portion thereof, wherein the outside diameter is less than the inside diameter; and an axial coupling axially coupling the inner tubular to the outer tubular.

35. The retractable joint of claim 34, wherein the axial coupling comprises a shearable member.

36. The retractable joint of claim 34, wherein the axial coupling comprises a slip.

37. The retractable joint of claim 34, further comprising a seal disposed between the inner and outer tubulars.

38. The retractable joint of claim 34, wherein an end of the inner tubular has a second outside diameter that is greater than the inside diameter.

39. The retractable joint of claim 34, further comprising an anti-rotation member coupling the inner and outer tubulars.

40. The retractable joint of claim 39, wherein the anti-rotation member comprises a slip.

41. The retractable joint of claim 39, wherein the anti-rotation member comprises a ball.

42. The retractable joint of claim 39, wherein anti-rotation member comprises a shearable member.

43. The retractable joint of claim 39, wherein anti-rotation member comprises a spline.

44. The retractable joint of claim 34, wherein the outer tubular has a vane disposed on an outer surface thereof.

45. A method for manufacturing a retractable joint for shipment to a well-site comprising: manufacturing an outer sleeve, an outer casing, an inner sleeve, and a crossover; sliding the outer sleeve over the inner sleeve; attaching the outer casing to the outer sleeve; attaching the crossover to the inner sleeve; sliding the crossover into the outer casing; attaching the outer sleeve to the crossover with temporary retainers; and sending the retractable joint to the well-site.

46. The method of claim 45, further comprising: receiving the retractable joint at the well-site; removing the temporary retainers; extending the retractable joint; inserting shear members; and attaching the retractable joint to a string of casing.