Patent Publication Number: US-9890611-B2

Title: Electromechanical device for engaging shiftable keys of downhole tool

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a national stage entry of PCT/US2015/036975 filed Jun. 22, 2015, said application is expressly incorporated herein in its entirety. 
     FIELD 
     The present disclosure relates generally to well bore completion operations. In particular, the subject matter herein generally relates to aperture control devices within a well bore. 
     BACKGROUND 
     During various phases of oil and gas operations it becomes necessary to control fluid communication between the inside of a well casing and the exterior of the well casing. A well casing and/or well liner will generally have one or more access points or holes positioned along its side. A movable door apparatus will have one or more complimentary openings. When an opening or “door” of such a movable door apparatus is moved into alignment with an access point of the well casing, inflow of materials, such as hydrocarbons exterior to the casing, into the interior or inside of the well casing is enabled. By moving the slidable doors out of alignment with openings in the well casing, inflow of materials is controlled. A shifting device, such as a well intervention tool, located within the well casing and acting under a force imposed by a tractor or under the force of an actuator, is used to shift the position of the slidable doors. The shifting device comprises shifter keys which are configured to engage the profile of the slidable doors. The keys may be independently movable. Once the profile of the slidable door is successfully engaged, the door can be moved uphole or downhole, as needed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Implementations of the present technology will now be described, by way of example only, with reference to the attached figures, wherein: 
         FIG. 1  is a schematic diagram of an embodiment of a wellbore operating environment in which a downhole tool, such as a well intervention tool as described herein, may be deployed; 
         FIG. 2  illustrates an example embodiment of a well intervention tool as described herein; 
         FIG. 3  illustrates a side view of a well intervention tool as described herein; 
         FIG. 4  illustrates an example of a well intervention tool having rotational functionality; 
         FIG. 5  illustrates a simplified version of component parts of an example of an actuable rotational motor; 
         FIG. 6  illustrates another example rotational motor; 
         FIG. 7  illustrates an example embodiment of a well intervention tool having vibrational functionality; 
         FIG. 8  illustrates a cut away view of the interior of an example embodiment of a well intervention tool; 
         FIG. 9A  illustrates an example vibration motor connected to an eccentric mass; 
         FIG. 9B  illustrates an exploded view of an example vibration motor; 
         FIG. 10A  illustrates an example of radial vibration being induced by a vibration motor; 
         FIG. 10B  illustrates an example of linear vibration being induced by a vibration motor; and 
         FIG. 11  illustrates and example profile of a shifting key. 
     
    
    
     DETAILED DESCRIPTION 
     It will be appreciated that for simplicity and clarity of illustration, where appropriate, reference numerals have been repeated among the different figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein can be practiced without these specific details. In other instances, methods, procedures and components have not been described in detail so as not to obscure the related relevant feature being described. Also, the description is not to be considered as limiting the scope of the embodiments described herein. The drawings are not necessarily to scale and the proportions of certain parts have been exaggerated to better illustrate details and features of the present disclosure. 
     In the following description, terms such as “upper,” “upward,” “lower,” “downward,” “above,” “below,” “downhole,” “uphole,” “longitudinal,” “lateral,” and the like, as used herein, shall mean in relation to the bottom or furthest extent of, the surrounding wellbore even though the wellbore or portions of it may be deviated or horizontal. Correspondingly, the transverse, axial, lateral, longitudinal, radial, etc., orientations shall mean orientations relative to the orientation of the wellbore or tool. Additionally, the illustrate embodiments are illustrated such that the orientation is such that the right-hand side or bottom of the page is downhole compared to the left-hand side, further the top of the page is toward the surface, and the lower side of the page is downhole. 
     Several definitions that apply throughout this disclosure will now be presented. The term “coupled” is defined as connected, whether directly or indirectly through intervening components, and is not necessarily limited to physical connections. The term “outside” refers to a region that is beyond the outermost confines of a physical object. The terms “comprising,” “including” and “having” are used interchangeably in this disclosure. The terms “comprising,” “including” and “having” mean to include, but not necessarily be limited to the things so described. 
     Disclosed herein is a well intervention tool which can be used to move or shift a slidable door apparatus within a casing interior to a well bore. The well intervention tool can have a longitudinal body, appropriately sized and configured to be moved along a length of the interior of the casing. The longitudinal body can have an inner cavity which houses various components such as those described herein. The longitudinal body can have one or more apertures or gaps running along its length. The aperture can be a slot sized to receive a key assembly which can be used to releasably couple the well intervention tool with a portion of the slidable door apparatus. The door apparatus can include one or more gaps or apertures, which when substantially aligned with a corresponding gap or aperture in a well casing, enable materials such as hydrocarbons to enter the well intervention tool from outside the casing for extraction. When the door apparatus is shifted out of alignment with such apertures, the flow of materials into the casing can be controlled or prevented, or both. 
     The well intervention tool as disclosed herein can help remove or prevent the collection of debris in the area of the door apparatus. Debris can interfere with coupling the keys to the door structure, either by preventing the well intervention tool from locating the door structure, or by preventing a good fit, or both. Various solutions to this problem involving the key assembly are disclosed herein. 
     The well intervention tool can also include a rotation assembly which is at least partially housed within the inner cavity. The rotation assembly can be actuated to cause the longitudinal body as well as the key assembly to rotate. Rotating the key assembly, and hence the key portion, can better seat the key portion within a receiving area of the slidable door apparatus because the rotation action thereof can have the effect of removing, shifting, or compensating for debris between the key portion and a key-receiving area of the slidable door apparatus within the casing. Thus engagement and interaction between the key assembly and the slidable door apparatus are encouraged. 
     The well intervention tool can also include a vibration assembly which is at least partially housed within the inner cavity. The vibration assembly can be actuated to cause the vibration assembly to vibrate the key portion. Vibrating the key assembly, and hence the key portion, can better seat the key portion within a receiving area of the slidable door apparatus because the vibrating action thereof can have the effect of removing, shifting, or compensating for debris between the key portion and a key-receiving area of the slidable door apparatus within the casing. Thus engagement and interaction between the key assembly and the slidable door apparatus are enhanced. 
     The keys of the well intervention tool can include various teeth or patterns which can improve displacement of the debris, thus improving engagement between the keys and the door structure. 
       FIG. 1  illustrates a schematic view of an embodiment of a wellbore operating environment in which a downhole tool, such as a packer, may be deployed. As depicted, an offshore oil or gas well  10  may include a semi-submersible platform  12  centered over a submerged oil and gas formation  14  located below the sea floor  16 . A subsea conduit  18  extends from the deck  20  of the platform  12  to a wellhead installation  22 , including blowout preventers  24 . The platform  12  has a hoisting apparatus  26  and a derrick  28  for raising and lowering pipe strings, such as substantially tubular, longitudinally extending inner work string  30 . The wellbore  32  extends through the various earth strata including formation  14 . An upper casing  34  is cemented within a vertical section of wellbore  32  by cement  36 . A liner  56  is secured to the lower end of the upper casing  34  by any means known in the art, such as expandable liner hangers, and the like. The liner  56  can be a casing, tubing or other tubular conveyance for fluids such as hydrocarbon or other fluidic materials. A further outer casing (not shown) may additionally be provided between the liner  56  and walls of the wellbore  32  and which may or may not be cemented. 
     The liner  56  may include one or more gaps or apertures  42 ,  44  through which materials such as hydrocarbons from within the formation  14  may pass into the liner  56  for extraction.  FIG. 1  also depicts a well intervention tool  100  which can be used to move a slidable door apparatus  50  with the liner  56  to control the inflow of the materials to be collected by the well  10 . 
     Although  FIG. 1  depicts a horizontal well, it should be understood by one skilled in the art that the present disclosure describing a well intervention tool can also be well-suited for use in vertical wells, slanted wells, multilateral wells, and the like. Also, although  FIG. 1  depicts an offshore operation, it should be understood by one skilled in the art that the present disclosure is equally well-suited for use in onshore operations. 
       FIG. 2  illustrates an example embodiment of the well intervention tool  100  described herein. During a search mode, the well intervention tool  100  will move uphole and downhole within the well casing or liner  56 , driven by a tractor or under gravity. The well intervention tool  100  can be provided via a conveyance  51  which can include wireline, slickline, e-line, tubing, coiled tubing or other conveyance or tubular conveyance. The tool  100  has one or more shifter keys (see  FIG. 3 ) which search for a slidable door structure  50  when in search mode. The door structure  50  contains at least one opening  52  which, when aligned with an opening  42  in the liner, will allow materials to enter the casing. The keys are shaped and configured such that they will engage the structure  50  once the sliding door profile is found. Once engaged by the keys, the door structure  50  can be shifted uphole or down hole. As discussed above, in horizontal completions the sliding door structure  50  can have debris inside it which can interfere or prevent a successful engagement by the keys. Vibrating the shifting keys, enables the shifting keys to be pushed into a greater depth with respect to an engagement region of the door structure  50 , thus increasing the likelihood of engagement, and hence the success of a shifting job. As discussed herein, the functionality of the shifting tool  100  can be enhanced when the shifting keys have a toothed profile because a toothed profile can be used to displace debris, allowing for deeper penetration by the keys. 
       FIG. 3  illustrates a side view of a well intervention tool  100 . As shown, the well intervention tool has a longitudinal body  102  which houses keys  110 . The keys  110  are urged outward, away from the interior of the longitudinal body  102 , by translating actuators  112 , which in this example are rods connected to a driving mechanism  87 , which can be a linear drive motor or any suitable driving mechanism known in the art. The keys can be connected to translatable sleeves  130 ,  132 . The translatable sleeves  130 ,  132  can be partially nested, one within the other. The translating actuators  112  are connected to an underside  135 ,  139  of the keys  110 . The keys  110  are urged by the translating mechanisms  112  from a first position  137 ,  141  in which they are substantially in alignment with longitudinal body  102  to an extended position away from the longitudinal body  102  as shown, when they are engaged with a slidable door structure. The keys  110  can also be connected by actuators  124  to a rotation device  114  or a vibration device  214 . In the case of a rotation device  114 , rotary motion is used to rotate the shifting keys  110  to a position to avoid the debris at the bottom of the casing/sleeve. This can be accomplished once the tool  100  has engaged into the sliding door or after some failed trials to engage the door. As discussed herein, the keys  110  will engage with a slidable door structure once the sliding door profile is found. If the search fails, the keys  110 ,  219  can be rotated by a preset angle, (for example, twenty degrees) and the tool movement can be repeated to search again. Searching and change of rotation can be done multiple times until the correct angle of rotation is found to engage the sliding door structure properly. In the case of a vibration device, a mechanical vibration can be introduced by a motor with an off-balanced wheel attached to a shaft. Once the keys  110  are in position the motor is actuated and a pulse is transmitted thru the linkages  124  into the keys  110 . The motor can be hydraulic or electromechanical in nature. The vibration can be introduced in a radial pattern or a linear depending on the application and position of the motor and unbalanced load. 
       FIG. 4  illustrates an example of a well intervention tool  100  having rotational functionality. The tool  100  has a longitudinal body  102  housing various components within an inner cavity  104 . The components include translatable keys  110  which are urged outwardly from within the longitudinal body  102 , through apertures  106  in the longitudinal body  102  by translating actuators  112  connected to an actuation mechanism  87 , such as a motor or engine or any suitable device known in the art. The actuation mechanism  87  pushes the actuators  112 , in this case pushrods, which in turn push the keys  110  away from the longitudinal body  102  in order to cause the keys  110  to engage with engagement portions  109  of a slidable door structure  50 . The pushrods  112  can be pivotably connected to the actuation mechanism  87  and the keys  110 , or pivotably connected to sleeves  130 ,  132  which are connected to the keys  110 . The slidable door structure  50  has an aperture or door  52  which when moved into alignment with an aperture  42  in the well casing  56  allows materials such as hydrocarbons to enter the casing  56  from within a formation  14 . The components also include a rotation assembly  114  which can be used to rotate the longitudinal body  102  and the keys  110  in order to improve the seating of the keys  110  to the door structure  50 . As indicated, rotating the keys  110  can dislodge debris from within the door structure  50 , leading to a better fit and thus improved shifting of the door structure  50  within the casing  56 . As illustrated, the rotation assembly can include a casing  116  containing an actuable motor  118  such as a linear drive motor. The motor  118  can rotate  117  the casing  116  (and hence the keys  110 ) about an axis  119  of a rod  120  connected to an interior portion  122  of the casing  116 . The rotation assembly  114  can be coupled to rotation actuators  124 , which are rods in this example. The actuators  124  can be coupled to an inner side of a key  110  or to a sleeve  130 ,  132  connected to a key  110 . Thus, by rotating the casing  116  about the rod  120 , the longitudinal body  102  and the key assembly  108  are also rotated within the casing  56 . As discussed, rotating the keys  110  can enable the outer portion  115  of the keys  110  to remove debris from the door structure  50 , thus leading to improved shifting of the door structure. The actuable motor  118  can be a stepper motor with a linear drive or a brushless DC motor or other suitable motor or device known in the art. 
       FIG. 5  illustrates a simplified version of component parts of an example of an actuable motor  118 , which may be an electronically commutated motor (ECM). Illustrated therein is a rotor  910  made up of a magnet and a stator  912  made up of a series of coiled stator pieces  914  surrounding the rotor  910 . The relative position of the rotor  910  is used by a motor controller (not shown) for electric commutation of the rotor  910  about rod  120 . A resolver  921  may be used to determine this rotor position, and in particular the degrees of rotation. Alternatively, or in addition to the resolver  921 , Hall effect sensors  922  can be employed to detect the position of the rotor  910 . In still other examples, sensors can be omitted altogether, for instance by employing sensorless commutation techniques used in ECM applications. 
       FIG. 6  illustrates an example brushless DC motor  950  as an electromechanical motor  118  having a housing  406  and a lead screw  402  connected to or comprising threaded rod  120 , (see  FIG. 4 ). The motor  950  can have a stator  408  and magnets  410 , for rotation of rotor  412  about the axis  119  formed by rod  120 . With rotation of the rotor  412 , the lead screw  402  extending from protective sleeve  414  can be rotated and transfer rotational motion to the actuators  124 , which in turn cause the keys  110  to rotate within the casing  56 . 
       FIG. 7  illustrates an example well intervention tool  100  having a vibration function. As can be seen in the figure, the well intervention tool  100  has a longitudinal body  102  which operates within a well casing  56 . The longitudinal body  102  has an inner cavity  104  containing various components. The longitudinal body  102  has apertures or slots  106  in its sides. A key assembly  108  is partially housed within the inner cavity  104 . The key assembly  108  has key portions  110  which protrude through the apertures  106  from inside the inner cavity  104 . As in the case of a well intervention tool having a rotational function (see  FIG. 4 ), the well intervention tool  100  shown in  FIG. 7  has translating actuators  112  coupled to an inner side  113  of the key portions  110 . The translating actuators  112  (pivotable rods in this example) resiliently urge the key portions  110  outward from within the inner cavity  104 , toward the wall of the lining or casing. The well intervention tool  100  illustrated also has a vibration assembly  214  housed within the inner cavity  104  which is used to cause the keys  110  vibrate, either linearly or rotationally, or both. As discussed above, vibrating the keys  110  can cause the outer portion  115  of the keys to shift or displace debris within the door structure  50 , thus leading to better engagement between the key assembly  108  and engagement portions  109  of the the door structure  50 . The vibration assembly  214  has a casing  216  which contains an actuable vibration motor  218 . The casing  216  of the vibration assembly  214  is coupled to one or more vibration actuators  224  (pivotable rods in this example). The vibration actuators are also coupled to the inner sides  113  of the keys  110 . Thus, when the  216  and vibration motor  218  vibrate, (linearly or radially), the vibration is transferred to the keys  110  by the vibration actuators  124 . As will be explained in greater detail below, the vibration motor  218  is connected to an eccentric mass  217 , which in this example is exterior to the motor  218 , although it will be understood that other configurations of the motor  218  and mass  217  are possible. 
       FIG. 8  illustrates a cut away view of the inner cavity of the longitudinal body (see  FIG. 7 ). As illustrated, translating actuators  112  connect a driving apparatus  87  to undersides  113  of the key portions  110 . As explained above, the translating actuators  112  push the outside of the keys  115  away from the inner cavity and toward the inside of a well casing  56 . The translating actuators  112  can be pivotably coupled to the vibration actuators  224 . The vibration actuators can be pivotably coupled to an actuator receiver such as disc  225 . Disc  225  can be connected to vibration assembly  214 . Alternatively, the vibration actuators  224  can be directly connected to the vibration assembly  214 . As illustrated, the vibration assembly includes an actuable vibration motor  218  connected to an eccentric weight  217 . 
       FIG. 9A  illustrates an example vibration motor  218  connected to an eccentric mass  217 .  FIG. 9B  illustrates an exploded view of an example vibration motor  218 . As illustrated, a motor case  301  surrounds coreless windings  303  which in turn surround magnet  305 . Magnet  305  abuts rear bearing  307  which abuts bearing washer inside the windings  303 . Case  301  and magnet  305  surround shaft  311  which passes through a front bearing  313  and washers  315  and. Shaft  311  is connected to eccentric mass  217  at one end and to a commutator  317  at the other end. Electric current passes through leads  219  via metal bushings  319  into the windings. The current induces the windings  303  and shaft  311  to rotate with respect to magnet  305 . Because the shaft is connected to an eccentric mass, the rotation causes the entire motor structure  218  to vibrate. As explained above, the vibration of the motor is ultimately transferred to the keys (see  FIGS. 7-8 ), which will shift or displace debris proximate to the outer portion of the keys  215 . 
       FIG. 10A  illustrates an example of radial vibration  1100  being induced by the vibration motor  218  connected to an eccentric mass or unbalanced load  217 . When the vibration has a radial pattern  1100 , the motion of the motor  218  has an x-component  1103  and a z-component  1101 , but not a y-component (parallel to shaft  311 ).  FIG. 10B  illustrates an example of linear vibration  1110  being induced by the vibration motor  218  connected to an eccentric mass or unbalanced load  217 . In the linear vibration pattern  1110 , vibration in the y-direction  1102  is induced, but not in the x-direction  1103  or the z-direction  1101 . 
       FIG. 11  illustrates and example profile of the outside of a key  110 . As shown, the exterior of the key  110  can have ridges  800  separated by substantially flat regions  802 . Each ridge  800  can be composed of a series of teeth  804 . Some of the teeth  804  can have rounded tips  805  to reduce damage to the well casing  56 . Some of the teeth  804  can have pointed tips  810  to better penetrate debris within the casing  56 . The teeth  804  can be separated by gaps  812  which allow debris to pass between the teeth  804 , thus enabling displacement of the debris by the keys  110 . 
     Statements of the Disclosure Include: 
     Statement 1: A well intervention tool having a rotation assembly, the rotation assembly including a casement containing at least one actuable motor configured to rotate the casement and a key assembly about an axis of a rod coupled to an interior portion of a longitudinal body housing the casement. 
     Statement 2: The well intervention tool of Statement 1, wherein the key assembly includes at least one key portion, the rotation assembly further including at least one rotation actuator coupled to the casement and to an inner side of key portion. 
     Statement 3: The well intervention tool of Statement 1 or Statement 2, wherein the actuable motor is a stepper motor with a linear drive. 
     Statement 4: The well intervention tool of Statement 1 or Statement 2, wherein the actuable motor is a brushless DC electrical motor 
     Statement 5: The well intervention tool of any of the preceding Statements, wherein the actuable motor is configured to cause the casement and the longitudinal body of the completion tool to rotate about a longitudinal axis of the well casing and the longitudinal axis of the longitudinal body. 
     Statement 6: The well intervention tool of any of the preceding Statements, further including a translating actuator, the translating actuator including a translating rod which is pivotably coupled to a translatable first sleeve located between the inner side of the key portion and the translating rod. 
     Statement 7: The well intervention tool of Statement 6, wherein a portion of the translating actuator is uphole of the key portion. 
     Statement 8: The well intervention tool of Statement 6 or Statement 7, wherein the translating rod urges the sleeve and the key portion towards the wall of the casing to cause the key portion to interact with the key-receiving region of the slidable door assembly, enabling the position of the door assembly to be shifted within the well casing by movement of the completion tool. 
     Statement 9: The well intervention tool of any of the preceding Statements, wherein the key assembly is partially housed within the inner cavity of the completion tool. 
     Statement 10: The well intervention tool of any one of Statements 2-9, wherein the key portion protrudes through an aperture from within the inner cavity towards an interior wall of a casing. 
     Statement 11: The well intervention tool of any one of Statements 2-10, wherein the rotation actuator includes a first rod connected to first sleeve, the first sleeve interposed between an inner side of a key portion and the rotation actuator. 
     Statement 12: The well intervention tool of any one of Statements 2-10, wherein the rotation actuator further includes a second rod connected to a translatable second sleeve interposed between the inner side of a key portion and the rotation actuator. 
     Statement 13: The well intervention tool of Statement 12, wherein the translatable first sleeve is at least partially nested within the translatable second sleeve. 
     Statement 14: The well intervention tool of Statement 12, wherein the second sleeve is at least partially nested within the first sleeve. 
     Statement 15: The well intervention tool of any one of the preceding Statements, wherein the at least one key portion of the key assembly has an outer side located opposite the inner side, which cooperates with a slidable door apparatus interior to a well bore. 
     Statement 16: A well intervention tool having a vibration assembly, the vibration assembly including a casement containing at least one actuable motor configured to vibrate the casement and a key assembly via a vibration actuator. 
     Statement 17: The well intervention tool of Statement 16, wherein the actuable motor is configured to impart a linear vibration to the vibration actuator. 
     Statement 18: The well intervention tool of Statement 16 or Statement 17, wherein the actuable motor is configured to impart a radial vibration to the vibration actuator. 
     Statement 19: The well intervention tool of any one of Statements 6-18, wherein the translating actuator includes a first translating rod pivotably coupled to a first translatable sleeve interposed between the inner side of the key portion and the translating rod. 
     Statement 20: The well intervention tool of Statement 19, wherein the translating actuator further includes a second translating rod pivotably coupled to a translatable second sleeve interposed between an inner side of a key portion and the second translating rod. 
     Statement 21: The well intervention tool of any one of Statements 2-20 wherein the at least one key portion of the key assembly has an outer side located opposite the inner side, the outer side configured to cooperate with a slidable door apparatus interior to a well bore. 
     Statement 22: The well intervention tool of Statement 21, wherein the outer side of the key portion comprises at least three ridges separated by substantially flat regions. 
     Statement 23: The well intervention tool of Statement 22, wherein at least one of the three ridges comprises a series of teeth. 
     Statement 24: The well intervention tool of Statement 23, wherein at least one tooth of the series of teeth has a rounded tip to prevent damage to a casing which interior to the well bore and the sliding door apparatus. 
     Statement 25: The well intervention tool of Statement 23 or Statement 24, wherein at least one tooth of the series of teeth has a pointed tip to penetrate debris interior to the well bore and the sliding door apparatus. 
     Statement 26: The well intervention tool of any one of Statements 23-25, wherein at least two teeth of the series of teeth are separated by gaps. 
     Statement 27: The well intervention tool of Statement 26, wherein the gaps are of sufficient dimensions to allow debris interior to the well bore to flow between the teeth. 
     Statement 28: A well intervention tool having a rotation-vibration assembly, the rotation-vibration assembly including a casement containing at least one actuable motor configured to: 
     rotate the casement and a key assembly about an axis of a rod coupled to an interior portion of a longitudinal body housing the casement; and 
     vibrate the casement and the key assembly via a vibration actuator. 
     The embodiments shown and described above are only examples. Even though numerous characteristics and advantages of the present technology have been set forth in the foregoing description, together with details of the structure and function of the present disclosure, the disclosure is illustrative only, and changes may be made in the detail, especially in matters of shape, size and arrangement of the parts within the principles of the present disclosure to the full extent indicated by the broad general meaning of the terms used in the attached claims. It will therefore be appreciated that the embodiments described above may be modified within the scope of the appended claims.