Patent Publication Number: US-9885217-B2

Title: Non-marring shifting tool collet

Description:
FIELD OF THE INVENTION 
     The field of the invention is collets used in shifting tool applications and more particularly design features on such collets that allow them to be advanced through seal bores without marring the seal bores. 
     BACKGROUND OF THE INVENTION 
     A common method of moving downhole sleeves from an opened to closed position, or vice versa, is to use a shifting tool that is attached to the bottom of a work string. The more complicated shifting tools are hydraulically actuated. In those type tools, the latching mechanism is kept in a retracted position until shifting tool has reached the sleeve. The latching mechanism is then expanded, typically by fluid flow down the work string. Other shifting tools consist of a pair of spring-loaded opposing keys. The keys have a profile designed to seek out a mating internal profile on the sleeve. These tools are capable of passing other internal profiles in the tubing, but may be prone to fouling should debris work its way beneath the keys to obstruct their inward movement. A simpler shifting tool, that may be less likely to foul in debris-laden fluids, consists of a collet (similar shape as a bow-spring centralizer) with a profile also designed to engage a mating profile in the sleeve. For all of these shifting tool designs, translation of the work string while the shifting tool is engaged with the sleeve provides the opening or closing stroke for the sleeve. The present invention is intended for use on collet-style shifting tools. A collet is well-suited for snapping into the sleeve prior to actuation and snapping out of the sleeve after actuation due to its ability to deflect in a radial direction. In fact, the collet can be designed to successfully pass through other downhole devices with smaller inside diameters than the sleeve profile. However, a problem can occur when the shifting tool collet is asked to pass through a downhole device where the smaller bore is a sealing bore. The deflected collet fingers ride along the inside diameter of the sealing bore from end to end as the shifting tool passes through. Depending on the geometry of the collet fingers, the material types and hardnesses of the collet and seal bore, and the radial force required to deflect the fingers, the fingers can scratch or gall the seal bore impairing its ability to seal. Since the collet fingers&#39; outside diameter is larger than the seal bore through which it is passing, each deflected finger will “ride” on its two outermost edges. Previous efforts to reduce the likelihood of damage included hand-grinding or machining a large radius on those outer edges. Those efforts have met with mixed success. Hand-ground edge breaks are inconsistent and can still leave points or ridges. Collets are typically made of heat-treated alloy to withstand the repetitive bending stresses they encounter, and even well rounded edges on a hardened steel collet finger could initiate galling when passing through seal bores of lower hardness material (e.g., 13 chrome 80K MYS). Another approach for reducing damage has been to coat the collet finger surfaces. However, since the shifting tool is a rental tool that is reused from well to well, the coating on the collet would have to be reapplied on a frequent basis as it wears during service. A third approach is to add a replacement insert of a softer material that would provide temporary protection and could be easily replaced such as a brass insert held in place by an angled groove shoulder and set screw. The downside of this particular application of that concept is that it requires wider slots between collet fingers in order to install the inserts. Consequently, contact between the collet finger and sleeve profile as well as collet finger tensile area are significantly reduced. 
     U.S. Pat. No. 8,678,096 shows a bow spring centralizer with particulate material on the outer surface of the bow springs to resist erosion. U.S. Pat. No. 5,678,633 shows a hydraulic shifting tool; U.S. Pat. No. 3,051,243 shows a key type shifting tool; U.S. Pat. No. 7,993,085 shows a fastener used to push out a collet for fixation purposes. 
     What is needed and provided by the present invention in one of its forms is a way to protect the seal bores through which the collets have to pass in a compressed state before reaching the tool that they ultimately engage for operation thereof. A sacrificial softer material is disposed to contact the seal bore wall so that if there is to be any wear, the sacrificial material wears down. The material can be removably mounted to the collet so that it can be easily replaced when the tool is removed from the borehole. Various attachment methods are contemplated as well as devices to adjust the degree of protrusion of the sacrificial material. 
     The sacrificial material needs to be inserted in a way that it is retained for functionality without limiting the number of fingers just to accommodate the insertion or fixation technique. For example,  FIG. 19  displays a laterally inserted sacrificial member  100  into an end of a dovetailed groove  102 . The issue with this design is that it limits the device to having four fingers so that the members  100  can be inserted and retained with a set screw  104 . Fewer fingers means higher stresses on each finger as dimensional transitions have to be negotiated and a more limited grip on the subterranean tool such as a sliding sleeve that ultimately has to be operated. 
     Those skilled in the art will better understand the variations of the present invention from a review of the detailed description with the associated drawings while recognizing that the full scope of the invention is to be found in the appended claims. 
     SUMMARY OF THE INVENTION 
     A flexible collet on a subterranean tool has sacrificial soft components to protect seal bores through which the collets have to compress to get through. The sacrificial components can be replaced when the tool is removed to the surface. In one embodiment, threaded fasteners are used alone or with washers for height adjustment such that the heads of the fasteners which are softer than the seal bore material ride on the seal bore and take the wear. The tool can ultimately be used to latch into shifting sleeves to move such sleeves to open or close wall ports. Alternatively, axial ridges with beveled profile ends or rolling members such as wheels or balls can be used to keep sharp edges off the seal bore. EDM methods can be used to create multiple fingers with an axial ridge profile and rounded end transitions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a prior art section view of a collet sleeve showing the profile on the collet that can engage a mating profile on a tool at a subterranean location; 
         FIG. 2  is a section view showing the collet profile in the engaged position to a subterranean tool and graphically illustrating the amount of deflection for the collet to pass through a seal bore; 
         FIG. 3  is a section view of the collet when passing a seal bore showing edge contact locations where seal bore scratching is likely to occur; 
         FIG. 4  is a perspective view of one embodiment showing holes to accept sacrificial screws; 
         FIG. 5  is the view of  FIG. 4  showing the screws in position; 
         FIG. 6  shows the screw heads extending radially beyond the outer face of the humps to protect the seal bore as the collet fingers flex inwardly to pass through; 
         FIG. 7  is an isometric view of an alternative embodiment, shown at an intermediate stage of manufacturing, featuring leading and trailing end bevels on the humps and an axial ridge running on top of the outer surface of the humps; 
         FIG. 8  is a section view through one of the humps showing the ridge and end bevels; 
         FIG. 9  is an exterior view of an embodiment showing rollers or balls; 
         FIG. 10  is a section view through  FIG. 9 ; 
         FIG. 11  shows opposed rollers connected by a shaft and disposed in non-parallel planes; 
         FIG. 12  is an alternative to  FIG. 11  showing the use of a shaft bearing and groove to retain lubricant; 
         FIG. 13  is another embodiment that is produced with wire EDM cutting techniques shown in section; 
         FIG. 14  is an enlarged view of the peripheral plunge profile made with plunge EDM (also known as ram EDM or die sinker EDM) before through cuts are made to create the fingers; 
         FIG. 15  is the view of  FIG. 14  after through cuts are made with wire EDM showing three collet fingers; 
         FIG. 16  shows that rounded end profiles can be created when the shapes of  FIG. 14  are created; 
         FIG. 17  is a section view of EDM cut fingers in an enlarged configuration for engagement to a subterranean tool; 
         FIG. 18  is the view of  FIG. 17  showing the fingers coming together such as in a seal bore before reaching the subterranean tool to be operated; 
         FIG. 19  is a 4 finger prior design that allows lateral insertion of sacrificial members into a dovetailed groove. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  illustrates a flexible collet  10  of a known design. It has ring ends  12  and  14  that are supported by a tool mandrel that is not shown. Between the ring ends  14  and  12  are a plurality of finger structures  16  that are circumferentially spaced. Each of the fingers  16  has a centrally located profile shape that generally comprises opposed humps  18  and  20  that define a recess  22  in between. A subterranean tool that is not shown will have a mating profile to that shown in  FIG. 1  that is formed by the humps  18  and  20  that define recess  22  in between. As shown in  FIG. 2 , the finger structures  16  are designed to flex to get through seal bores such as  24  and then later spring out into the mating profile of a subterranean tool that is not shown. Dimension lines  26  define the amount of radial flexing from the innermost position of the collet  10  when going through a seal bore  24  to the extended position at a later time where there is registry with a downhole tool such as a sliding sleeve for example and not by way of limitation.  FIG. 2  shows the outer surface  28  of the humps  18  and  20  at its full extension when the recess  22  engages a similarly shaped projection on the subterranean tool that is not shown.  FIG. 3  shows that sharp edges  30  and  32  can score the seal bore surface  24  as the collet  10  passes through it with collet  10  radially and inwardly deflected. 
       FIGS. 4-5  illustrate the machining of opposed bevels  34  and  36  on one or both of the opposed humps  18  or  20 . Bores or through holes  38  and  40  are drilled or formed in beveled surfaces  34  and  36  and then tapped for a thread into which fasteners  42  and  44  can be inserted. Alternatively the fasteners  42  and  44  can be put through the outermost surface(s)  28  on either or both sides of recess  22 . Depicted in  FIGS. 5 and 6  are soft material cap screws with rounded heads preferably made of soft metals such as brass, bronze or copper. The heads can have a pattern to facilitate screwing them in. Alternatively, adhesives can be used instead of threads. Another alternative is an interference fit of a rod of soft material. A washer  46  can be used to adjust the height of the top of the cap screw or other shape that is used so that the radial extension of the screws  42  and  44  is beyond the outer surface  28  of the humps  18  and  20  as shown in  FIG. 6 . In that way the seal bore wall  24  engages the screws  42  and  44  rather than the outer surface  28  of the humps  18  and  20 . The screws  42  or  44  or equivalent structures can be made of plastics, composites or other materials that are softer than the seal bore wall  24 . 
       FIGS. 7 and 8  are an alternative embodiment involving machining leading and trailing bevels of about 15 degrees on humps  18  and  20  in preferably four corner locations such as  50 ,  52 ,  54  and  56  as illustrated for hump  20 . While all four corners are shown to be beveled for hump  20  less than the four corners can be beveled. Hump  18  preferably has the same bevel pattern as hump  20  but they can also differ. The idea is that as the collet finger  16  flexes to get into the seal bore  24  the edge corners will be held away from the seal bore  24  and avoid contact with it that could cause damage. Working in tandem with the corner bevels are a generally axial ridge  58  that can be preferably in the middle of the finger  16 . Although a single ridge is shown a plurality of ridges can also be employed. The ridge  58  can be integrated into the finger  16  structure and can have a curved outer face  60  that is contoured to the wall of the seal bore  24  or it can optionally have a sacrificial insert  62  that runs to all or part of the length of the hump  18  or  20  and can be readily removed when worn. Alternatively it can have drilled and threaded holes or grooves into which sacrificial shapes can be secured. The idea is that the ridge  58  spaces the rest of the outer surface  28  of either hump away from the seal bore wall  24 . The end bevels also work in tandem with ridge  58  to ensure the leading and trailing corners such as  50 - 56  also clear the seal bore wall  24  as the fingers  16  begin to flex as the humps enter or leave the seal bore wall  24 . 
       FIGS. 9-12  illustrate an alternative embodiment where the seal bore wall  24  is protected with rolling members such as wheels or balls. Specifically, rollers  74  are attached to the collet fingers  16  in strategic locations so that contact between deflected fingers  16  and restricted bores  24  occurs on the rollers. Rolling motion vs. sliding motion between the collet and the downhole tubular components will make the collet  10  less likely to scratch or gall sensitive seal bore surfaces  24 . Also, wear should be reduced, resulting in a longer life expectancy. Plates  70  are attached to create the humps  18  and  20  by using fasteners  72  to hold the rollers  74  in place as shown in  FIGS. 9 and 10 . The plates  70  are designed with shoulders  76  so that the main brunt of a shifting force or deflecting force is directed into the collet fingers  16  rather than the fasteners  72 . The fasteners  72  are attached in more than one angular orientation (“toe-nailed”) to make it more difficult for an outward radial force to loosen the plates  70 . The rollers  74 , fasteners  72 , and/or plates  70  can be replaced as needed between runs if worn or damaged during use. Collet fingers  16  may be designed to accommodate rollers  74  and plates  70  of other diameters; thus, allowing the shifting tool to be modified between runs to work on multiple sizes or inside diameters of sleeves. 
     Since the rollers  74  are replaceable, they can be made out of a softer metallic material (e.g., brass) than the tubular components they will pass through. Rollers  74  could be coated with a dry film lubricant or powder coating  78  to further reduce friction with downhole tubular components. The outer surfaces of the rollers could be covered with a more spongy material such as a PEEK coating or bonded rubber, all schematically illustrated by number  78 , to provide even more protection to surfaces of downhole tubular components. Rollers  74  could be made of composite materials or thermoplastics such as Nylon. As shown in  FIG. 12 , axles  82  and inside walls of the rollers  74 ; races and sidewalls of the plates  70 ; and races and sidewalls of the collet fingers  16  could be coated or hardened to reduce friction with one another. Replaceable split bearing sleeves  80 , made of metallic, composite, or thermoplastic materials could be located around the axles  82  of the rollers  74 . Bearing sleeves  82  could be designed to handle thrust loads in addition to radial loads. Bearing sleeves  80 , axles  82  of rollers  74 , or races of plates  70  and collet fingers  16  could be manufactured with grooves  84  to trap grease. Leaf springs (not shown) could be placed between the bearing sleeves  80  and collet fingers  16  to achieve a shock absorber effect when the rollers  74  first strike a surface. A split rubber sleeve  86  could be placed around a set of bearing sleeves  80  to achieve the same effect. The axle  82  of the roller  74  could be designed with a bulbous midsection and the bearing sleeves  80  could be designed with a mating inside surface. That would allow the roller or roller pairs  74  to rock slightly which could be of benefit if the shifting tool is forced off centerline while passing through a restricted inside diameter. Fastener  72  pattern could be varied (number of fasteners, size of fasteners—diameter or length, orientation of fasteners). Fasteners  72  could be made of any material compatible with the other shifting tool components provided they are of sufficient strength to hold the plates  70  in place. Structural adhesives could be added to the fasteners  72  to prevent loosening or to provide an additional holding force. Plates  70  could be riveted to the collet fingers  16  in lieu of using threaded fasteners. Roller  74  shape can be varied to optimize the contact area between the outer surface of the rollers  74  and the inner surface  24  of the downhole components that the shifting tool will pass. Plates  70  could be made of higher yield strength material than the collet  10  or the plates  70  could be surface-hardened to increase their wear resistance or lessen the damage sustained when shifting sleeves that are not shown. Plates  70  and collet fingers  16  could be designed to hold ball bearings in sockets instead of rollers  74  in races and the reference  74  is designed to schematically represent the use of rollers or spheres. 
     In  FIGS. 13-18  a shifting collet is designed for manufacture using plunge EDM. This allows each finger  16 , in its deflected position, to present a favorable profile for contact with the restricted bore through which the collet  10  is passing. Also, the axial slots  90  separating the fingers  16  are cut with wire EDM. This allows slot width between fingers  16  to be minimized so that the maximum number of fingers can be achieved. Maximizing the number of fingers  16  minimizes the contact load between each finger  16  and the restricted bore  24 . These two features (favorable contact profile and increased finger count) will lessen the tendency of deflected collet fingers  16  to damage the surface of restricted bores. A section view of a collet  10  is shown in  FIG. 13 . In this instance, the collet  10  is shown as fixed at one end  92  and guided at the other  94 ; although, the concept would work on a collet fixed at both ends as well. In  FIG. 14 , the profile shown is intended to represent the shape of a plunge EDM electrode. The profile consists of a small radius  96  (much smaller than the large outside diameter of the collet) flanked by two small flats  98  and  100 . Multiple plunges would be made around the circumference of the large outside diameter schematically represented by line  102  in  FIG. 15  so that the flats  98  and  100  contact adjacent flats  104  and  106 . Then, wire EDM is used to cut long slots along the axis of the collet  10  to form the fingers  16 . The wire EDM cuts would essentially remove the flat parts  98  and  100  and  104  and  106  of the plunge cuts, leaving the fingers  16  with small radii  96  on their outer surfaces. As shown in  FIG. 15 , the corners  108  and  110  of each finger  16  would be recessed from the largest outside diameter of the resulting collet  10 . The wire EDM cuts would extend through the entire part so that a pair of slots  90  (180 degrees apart) would be cut simultaneously. An end view of a collet  10  manufactured using such a method is shown in  FIGS. 17 and 18 . In the instance shown, there are a total of 30 fingers  16 . The EDM slot width and number of fingers are designed so that there remains sufficient room between the collet fingers  16  when they are in a deflected position (See  FIG. 18 .). Clearance preferably remains so that debris will not obstruct radial movement of the fingers  16 . Two advantages are apparent from this style of collet  16 : 1) the deflected collet fingers  16  will “ride” through a restricted bore on their crown  96 ; no sharp edges  108  and  110  will drag through the seal bore; and, 2) the force required to deflect each finger is significantly reduced since the load is shared by 2 to 3 times the “normal” number of collet fingers  16 ; less surface contact force results in less surface contact stress. The plunge EDM step makes it possible to create a part with a variety of radii and shapes of the collet finger  16  profile. A profile with a smaller radius that guarantees smooth contact at the crown  96  would be preferable. The wire EDM process is preferred for cutting the axial slots  90  because of the difficulty in machining closely-spaced slots  90  by conventional milling without damaging the fingers  16 . Also, the slot  90  width could be optimized since it would not have to conform to cutter width. In typical collet designs, the number of fingers is minimized to reduce manufacturing cost. The advantage of the multitude of EDM cut fingers  16  is that the contact stresses are spread over a significantly larger surface area of the Seal Bore inside diameter. 
     Axial cuts  90  could remove a portion of the radius of the plunge EDM profile or axial cuts  90  could leave a portion of the flat  98  and  100  of the plunge EDM profile without affecting the contact location of the fingers  16 . The plunge EDM profile could vary (e.g., each finger  16  could have multiple axial ridges, further reducing contact load). Axial cuts could be made by laser or high-pressure water jet (abrasive jet). End profile of the plunge EDM cuts could be optimized to round  112  the entry surface of each finger as shown in  FIG. 16 . 
     Those skilled in the art will appreciate that the design variations offer different ways to avoid marring a seal bore with passing collet fingers that must still spring out and engage a downhole tool and move it, such as a sliding sleeve for example.  FIGS. 1-6  illustrate the use of easily mounted sacrificial objects that hold sharp edges from the seal bore wall in a way that makes the sacrificial objects easy to insert and later remove for replacement without having to limit the number of fingers to accommodate the specific fixation technique. The height of the sacrificial members can also be adjusted. In an alternative technique of  FIGS. 7-8  an axial ridge can be provided with or without a sacrificial insert coupled with end bevels adjacent the outermost surface of the collet profile to again keep sharp edges from touching the seal bore.  FIGS. 9-12  illustrate using rolling resistance of a sacrificial component such as wheels or spheres to keep sharp edges from contacting the seal bore wall.  FIGS. 13-18  show a manufacturing technique that allows for a higher finger count for a given diameter as well as an axial hump to keep sharp edges off the seal bore wall with an option of rounding transitions to the finger profile on opposed ends of the profile to ease flexing while passing through seal bores and ultimately into the profile of the tool to be operated at the subterranean location. 
     While the above description was written in contemplation of the shifting tool passing through a seal bore, the concepts apply when passing through any restriction with an ID that needs to be protected—such as a subterranean tool with ID seals. 
     The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below: