Patent Publication Number: US-11047184-B2

Title: Downhole cutting tool and anchor arrangement

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This is related to and claims priority benefits from Great Britain Provisional Patent Application No. GB1813865.1, filed on Aug. 24, 2019, and titled “Downhole Cutting Tool and Anchor Arrangement,” which is hereby incorporated herein in its entirety by this reference. 
     TECHNICAL FIELD 
     The present disclosure relates to a downhole cutting tool, in particular a punching tool operable to create holes through a downhole tubular component, for example casing, tubing or drill pipe. In particular, the present disclosure relates to an improved anchoring arrangement associated with a punching tool 
     BACKGROUND 
     Tools for cutting downhole tubular component, for example casing, tubing or drill pipe are typically deployed on the end of wireline, drill pipe, coiled tubing or other tubular. 
     Typically, punching and cutting tools are located towards the end of a tool string, which is deployed within the casing, tubing or drill pipe to perform a cut from inside to outside. It will be appreciated that the components used to perform the cutting action are typically contained within a tubular casing/housing from within which the punch or cutter extend to perform the punching or cutting action. In addition to the punch or cutter being contained within the housing one or more anchor mechanisms are also contained within the housing until the tool reaches the depth at which the cutting or punching action is to be performed. 
     Typically, downhole mechanical cutting and punching tools utilise at least one anchor mechanism positioned as close to the punch or cutter as possible to reduce displacement of the tool head, which contains the cutter or punch, such that accuracy of the cut is maximised. 
     SUMMARY 
     Some examples of the present disclosure provides a downhole cutting tool operable, when deployed, to create a cut through a wall of a tubular member, the cutting tool comprises: a tool head assembly, comprising a tubular body providing a housing, which houses a cutting member, a first stabilizing anchor located downstream of the cutting member and a second stabilizing anchor upstream of the cutting member. 
     In conventional downhole cutting tools all anchoring members are located upstream of the cutting member and the cutting member is located downstream of the anchors and generally towards the end of the tool head. This arrangement means the cutting member, for example a punch tool, cutting disc, etc., is located on a free end of the tool head. As such when the cutter is advanced for cutting and makes contact with the tubular wall the end of the tool head is subject to bending forces, which may misalign the cutter, may add additional load to the tool and may cause unwanted vibration when performing the cutting action. It will be appreciated, by providing an anchor member downstream of the cutting member the bending forces, flexing of the cutting member and vibration of the cutting member is at least reduced. Additionally, in the example where a severing cutting member is used, for example a cutter that cuts through the entire circumference of the tubular, the downstream and upstream anchors maintain the position of the resulting two pieces of tubular until the cut is complete and the anchors are released. 
     The downhole cutting tool may further comprise an actuating mechanism operable to control simultaneous activation and deactivation of the first and second anchors. 
     The downhole cutting tool may further comprise a locating anchor and a second actuating mechanism, wherein the locating anchor is located upstream of the first stabilizing anchor, the second stabilizing anchor and the cutting member, wherein the second actuating mechanism is operable to actuate the locating anchor independently of the first stabilizing anchor and the second stabilizing anchor. 
     The downhole tool may comprise at least an upper section and a lower section, wherein the locating anchor is housed in the upper section and wherein the first stabilizing anchor, the second stabilizing anchor and the cutting member are housed in the lower section 
     The lower section may be rotationally connected to the upper section, wherein the lower section and the upper section include a common longitudinal axis and the lower section rotates relative to a stationary upper section about the common longitudinal axis. 
     Rotation of the lower section facilitates adjusting the angular position of the cutting member relative to the wall to be cut. 
     The cutting member may comprise a hole cutter. The hole cutter may comprise an annular cutter, which creates a circular cut through the wall and produces a cylinder of waste material when the cutter breaks through the wall. Alternatively, the cutting member may comprise a fluted drill bit. 
     In one example, a method includes: 
     deploying a cutting tool downhole in an inner area defined by a tubular member, the cutting tool comprising a tubular body providing a housing that houses a cutting member, a first stabilizing anchor downstream of the cutting member, a second stabilizing anchor upstream of the cutting member, and a locating anchor; 
     extending the locating anchor to maintain the cutting tool at a desired depth within the tubular member and to prevent vertical displacement of the cutting tool with respect to the tubular member; 
     extending the first stabilizing anchor and the second stabilizing anchor to maintain an angular position of the cutting member with respect to the tubular member; and 
     cutting the tubular member by extending the cutting member to the tubular member. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a downhole punch tool according to an embodiment of the present disclosure; and 
         FIG. 2  illustrates a cross-sectional view about the axial centreline of the downhole punch tool illustrated in  FIG. 1 . 
         FIG. 3  illustrates a cross-sectional view of the downhole punch tool of  FIG. 1  positioned within a tubular member. 
     
    
    
     DETAILED DESCRIPTION 
     An example of a downhole punch tool  10  is illustrated in  FIGS. 1 and 2 and 3 . The downhole punch tool  10  is suitable for producing one or more holes through a downhole casing, tubing (e.g. tubing member  5  as depicted in  FIG. 3 ), drill pipe etc. in which the punch tool  10  is deployed. 
     For ease of representation the tool  10  is illustrated as three portions in  FIG. 1  i.e. an upper portion  12 , a middle portion  14  and a lower portion  16 . In  FIG. 2 , the lower portion  16  is further divided in two, thereby providing a more detailed view of the internal components of the lower portion  16 . The dotted line  18  in  FIGS. 1 and 2  represents the assembled arrangement, where the adjoining sections of each portion  12 ,  14 ,  16  are connected by the dotted line. 
     It will be appreciated, with reference to  FIG. 2 , that each portion  12 ,  14 ,  16  includes an assembly of multiple tubular elements/sleeves to form the overall structure of the punch tool  10 . Functionally, the upper portion  12 , the middle portion  14  and the lower portion  16  each have a role to play during operation of the punch tool  10 ; these roles and the components facilitating the roles are described further below with reference to the internal and external elements of each portion  12 ,  14 ,  16 . 
     When assembled, the upper portion  12  connects the punch tool  10  to an electronic control section of a tool string (not illustrated), which facilitates deployment of the punch tool  10  into the casing, tubing, drill string etc. in a conventional manner. 
     Connection of the punch tool  10  to the tool string is via a mechanical and electronic connection  22  located at the top of the upper portion  12 ; connection of the upper portion  12  to the tool string (not illustrated) is in the direction indicated by arrow A. 
     The upper portion  12  houses a locating anchor  20 , which (as described further below) is extendable and retractable for deployment in, and recovery from, a casing, tubing, drill string etc. in which the punch tool  10  is deployed. 
     The locating anchor  20  facilitates fixing the punch tool  10  at a desired depth within the casing, tubing, drill pipe etc., whilst allowing subsequent adjustment of the angular position of the middle portion  14  and lower portion  16  relative to the casing, tubing, drill pipe etc. This means the hole cutter  30  (described further below) of the punch tool  10  can be located at the correct depth and in the correct angular position before a hole cutting action is performed. 
     The middle portion  14  is connected at one end to the upper portion  12  and at the opposite end to the lower portion  16 . The connection of the middle portion  14  to the upper portion  14  is such that the middle portion  14  can rotate relative to the fixed upper portion  12  i.e. when the locating anchor  20  is extended. 
     The lower portion  16  is rotationally fixed to the middle portion  14 , such that both the middle portion  14  and the lower portion  16  rotate as a unit relative to the upper portion  12  when the locating anchor  20  is extended and engaged with the inner surface of the casing, tubing or drill pipe etc. in which the punch tool  10  is deployed. 
     Rotation of the middle portion  14  and the lower portion  16  allow adjustment of the angular position of the punch tool  10  such that the middle portion  14  and the lower portion  16  can be correctly oriented at a fixed depth relative to the inner surface to be cut. 
     The lower portion  16  defines a tool head assembly  25 , which includes the tool head  24  of the punch tool  10  and a tubular body  27 , which houses two stabilising anchors  26 ,  28  and a hole cutter  30  (see  FIGS. 1 and 2 ). 
     Relative to the direction of deployment, the two stabilising anchors  26 ,  28  are arranged such that one anchor  26  is located below (upstream) the hole cutter  30  and the other anchor  28  is located above (downstream) the hole cutter  30 . 
     When deploying the punch tool  10  in a casing, tubing or drill pipe etc. the punch tool  10  is lowered into the casing, tubing, drill pipe etc. to a desired depth before deploying the locating anchor  20 , which fixes the punch tool  10  against further vertical displacement downhole. Once the depth is fixed, rotation of the middle portion  14  and lower portion  16  can be activated to adjust the position of the hole cutter  30  relative to the surface of the casing, tubing, drill pipe etc. in which the punch tool  10  is deployed. 
     When the hole cutter  30  is oriented at the desired angular position the stabilising anchors  26 ,  28  can be extended simultaneously to secure the anchors  26 ,  28  against the surface of the casing, tubing, drill pipe etc. in which the punch tool  10  is deployed. 
     After activating the anchors  26 ,  28  the hole cutter  30  can be actuated and extended relative to the lower portion  16  such that a hole can be cut through the wall of the casing, tubing, drill pipe etc. 
     When the cutting/punching operation is complete the hole cutter  30  can be retracted into the lower portion  16 . At this point the stabilising anchors  26 ,  28  can be released/retracted and the angular position of the hole cutter  30  can be adjusted if more than one hole is required at the same depth. Again, rotation of the middle portion  14  and lower portion  16  adjusts the angular position of the hole cutter  30  to the next desired angular position, at which point the stabilising anchors  26 ,  28  can be deployed to secure the hole cutter  30  in the desired angular position before the hole cutter  30  is activated. This process can be repeated at various angular positions by releasing the anchors  26 ,  28  before rotating the middle and lower portions  14 ,  16  to a desired angular position. 
     It will be appreciated that the vertical position of the hole cutter  30  can be adjusted between cuts, i.e. by releasing all three anchors  20 ,  26 ,  28  and raising or lowering the punch tool  10  to a different position. Again, when the hole cutter  30  is located at the desired vertical position the locating anchor  20  can be activated to fix the upper portion  12 , thereby allowing rotation of the middle and lower portions  14 ,  16  to the desired angular position of the hole cutter  30 . 
     Referring to  FIGS. 1 and 2 , the locating anchor  20  and the stabilising anchors  26 ,  28  each include three circumferentially spaced anchor elements  32 . Each anchor element  32  includes two link arms  34 , which are joined together at an elbow  36  and pivotally connected at the opposite ends to a sleeve within the portion  14 ,  16 , housing the anchors  20 ,  26 ,  28 . 
     The elbow  36  of each anchor element  32  is operable, when deployed to press against the internal surface of the casing, tubing, drill pipe etc. in which the punch tool  10  is deployed. In the illustrated example, three anchor elements  32  are used to ensure the punch tool  10  is centralised and stable. 
     In the illustrated example (see  FIG. 2 , upper portion  12 ), the elbow  36  of the locating anchor  20  is defined by a serrated disc such that, when deployed, there is a degree of ‘bite’ to avoid slippage during adjustment of the angular position of the hole cutter  30  as described above. 
     It will be appreciated that the force of the elbows  36  being pressed against the inside of the casing, tubing, drill pipe etc. provides an anchoring force. In the event there is corrosion or degradation within the casing, tubing, drill pipe etc. the serrations are expected to apply a deforming action i.e. bite into the surface. As such, a serrated element may enhance the function of the anchor  20 ,  26 ,  28  in the contact area. 
     Visible in  FIG. 2  are the internal components operable to control deployment of the anchors  20 ,  26 ,  28 , adjustment of the angular position of the hole cutter  30  and operation of the hole cutter  30 . 
     The upper portion  12  houses the locating anchor  20 , as described above, an electric motor  40  connected to a motor drive piston  42  via a gear system  44 , an anchor actuating piston  46  and an actuating sleeve  48 . At least one end of each link arm  34  of the locating anchor  20  is pivotally connected to the actuating sleeve  48  such that actuation of the motor  40  drives the motor piston  42  via the gear system  44 . 
     Driving the motor piston  24  displaces fluid from a fluid chamber  50  below the piston  42 , which displaces the anchor actuating piston  46 , which in turn displaces the actuating sleeve  48  downwards (to the right in  FIG. 2 ), which actuates/extends the locating anchor  20  to fix the punch tool  10  in the desired vertical location. 
     After extending the locating anchor  20 , if necessary, a primary function/role of the middle portion  14  can be actuated, where the middle portion  14  and lower portion  16  rotate as a unit to adjust the angular position of the hole cutter  30 . The middle portion  14  houses a gear system  52  towards the top of the middle portion (to the left of  FIG. 2 ). When actuated, the gear system  52  facilitates rotation of the middle and lower portions  14 ,  16 . Rotation of the middle and lower portions is facilitated by a motor  35 , which is situated proximate the locating anchor  20 . In the illustrated example the motor  35  is located just above (to the left in  FIG. 2 ) of the locating anchor  20 . 
     The lower section (to the right of  FIG. 2 ) of the middle portion  14  houses components operable to actuate the stabilising anchors  26 ,  28 . In addition, the lower section (to the left of  FIG. 2 ) of the tool head  24  includes a sleeve  60 , which moves to actuate the lower stabilising anchor  28  (leftmost anchor in  FIG. 2 ). 
     The stabilising anchors  26 ,  28  are deployed in a similar manner to the locating anchor  20 , as described above. However, both stabilising anchors  26 ,  28  are deployed/actuated simultaneously. Therefore, a single motor  62  (housed in the middle portion  14 ) actuates a drive piston  64  via a gear system  66  to displace fluid  68 , which moves an actuating piston  70  and a sleeve  72  connected thereto. The sleeve  72  is connected to the upper stabilising anchor  26  and to a further sleeve  74 , which is connected to the lower stabilising anchor  28 , such that displacement of the upper sleeve  72  causes simultaneous displacement of the lower sleeve  74  such that both stabilising anchors  26 ,  28  are actuated simultaneously. A flow path (not visible) associated with deploying the stabilising anchors  26 ,  28  is provided from the motor  62 , down via the piston  64 , through the tool body to a piston  65  located in the tool head  24 . When activated, the fluid flow drives the piston  65  downwards (to the left in  FIG. 2 ), which facilitates movement of sleeve  74 , which simultaneously activate the stabilising anchors  26 ,  28 . A spring  75 , located around the piston  65 , is provided for return/retraction of the stabilising anchors  26 ,  28 , when fluid pressure is removed. 
     The lower portion  16  houses the drive system for the hole cutter  30  i.e. the drive system operable to rotate the hole cutter  30  and the independent drive system operable to radially extend and retract the hole cutter  30  during and after the cutting operation is complete. 
     In the illustrated example the hole cutter  30  is provided by an annular cutter, which creates a circular cut and produces a cylinder (a core) of waste material as the cutter  30  rotates and advances through the wall of the casing, tubing or drill pipe in which the punch tool  10  is deployed. When the hole cutter  30  breaks through, a circular hole remains in the wall. 
     The hole cutter  30  is mounted in a carriage  80 , which is located towards the tool head  24  in the lower portion  16  of the punch tool  10  and between the two stabilising anchors  26 ,  28 . By providing a stabilising anchor  26 ,  28  above and below the hole cutter  30  the effect of bending forces and vibration on the hole cutter  30  is improved compared with conventional tools, where anchors are only located above the cutter. 
     In the illustrated example, two electric motors  82 ,  84  are provided in the lower portion  16  to drive the hole cutter  30 . The first motor  82  is used to control rotation of the hole cutter  30  and the second motor  84  is used to control radial advancement and retraction of the hole cutter  30 . The first motor  82  is coupled to a universal joint  86  via a drive shaft  88  and twin bevel gears  90 ,  92 , which engage to rotate the hole cutter  30 . 
     The second motor  84  is located below (upstream of) the hole cutter  30  and is connected with a feed drive gear system  94 , which is connected to the carriage  80 , in which the hole cutter  30  is mounted. 
     The carriage  80  slides to advance and retract the hole cutter  30 . A dovetail connection (not visible) ensures control of the linear displacement of the carriage  80  and therefore the hole cutter  30 . 
     Whilst specific embodiments of the present disclosure have been described above, it will be appreciated that departures from the described examples may still fall within the scope of the present disclosure.