Abstract:
A downhole tool for incorporation in a drill pipe for selective operation of the tool from surface level when the tool is in a wellbore. The tool comprises a controller electrically powered by a power source separate from surface level, a first sensor of the controller to detect a dynamic variable of the tool in the wellbore and produce an output signal dependent thereon; a second sensor of the controller to detect a mechanical signal transmitted from an operator at surface level; a motor driven by the power source under the control of the controller when said mechanical signal is received; and an actuator driven by the motor to actuate the tool; wherein the controller switches between at least two states in response to changes in said dynamic variable, only in said second state the controller being receptive to said mechanical signal from the operator to drive the motor. The tool may be a disconnect device and/or a circ sub. A disconnect device has axially displaceable die retention sleeve preventing radial movement of dies that lock between the dies and a mandrel. When the retention sleeve is moved so that the dies can move, the disconnect is actuated. A circsub has a body having a throughbore receiving a piston movable between open and closed positions to control ports in the body selectively connecting the throughbore with the wellbore, said motor driving said actuator to enable or disable movement of the piston to said open position.

Description:
[0001]    This invention relates to disconnect and other devices for a downhole assembly or tool, and more specifically to a disconnect device that allows a controlled disconnect from a drilling bottom hole assembly. It also relates to such tools as circulating subs and other devices requiring a controlled movement to actuate them. 
       BACKGROUND 
       [0002]    In the oil and gas industries, disconnect devices are typically used to separate a bottom hole assembly (BHA) from a drill string if, for example, the BHA becomes stuck. Once the drill string has been disconnected from the BHA, the operators can then attempt to recover the stuck BHA with a “fishing” tool. However, in situations where recovery of the BHA is impractical or impossible, the stuck BHA will be abandoned and drilling will recommence along a different route with a new BHA attached to the drill string. 
         [0003]    Typical methods for disconnecting a drill string from a stuck BHA involve dropping a dart, ball or mud slug of high density fluid from the surface to interact with a shear pin or other locking device and actuate the separation. For example, WO-A-03/029605 (Weatherford/Lamb, Inc.) describes a disconnect device having two portions connected by a lock nut. The two portions separate when a predetermined fluid force is applied to a piston in the disconnect device causing a tensile sleeve to fail. In one particular embodiment, the tensile sleeve&#39;s failure permits an annular piston to dislodge a wedge sleeve from the lock nut, thereby permitting separation. Such arrangements require the circulation of drilling mud to transport the interacting article (dart, ball or mud slug). However, this is often impossible when the BHA becomes stuck. Another disconnect device that relies on the circulation of fluid is described in GB-B-2351101. The GB-B-2351101 device comprises a radially expandable locking ring that is configured to expand and thereby disconnect the device. 
         [0004]    Alternatively, drill strings can be separated without using specialist tools by performing a precise series of “back off” movements and rotations such as turning the drill string leftward and overpulling to affect a release. This technique is often complicated and difficult and is consequently unreliable. 
         [0005]    A third option is to separate the drill string above the point at which it is stuck by explosive means. US-A-2004/0200343 (Titan Specialties, Ltd.) describes a pipe severing tool that is positioned into a well bore before exploding to actuate separation. The tool comprises explosive pellets and electrically initiated exploding wire detonators (EBVV) that are positioned at opposite ends of a tubular housing for simultaneous detonation by a capacitive firing device. 
         [0006]    This technique is often used as a last resort and usually requires the skills of a specialist team which may take several days to arrive at the rig and sever the drill string. Due to the high operating costs of drill rigs, this significant time period of non-operation can lead to substantial financial losses which are highly undesirable. Additionally, the damaged end of the drill string must be replaced before a new BHA can be connected and drilling can recommence. Furthermore, most explosive disconnection techniques are dependent upon gravity for locating the explosives close to the point at which the tool is stuck. It follows that explosive disconnection is generally not an option for the disconnection of a BHA in a horizontal section of the well bore. 
         [0007]    There is therefore a need to provide a disconnect device that allows for a controlled disconnect from the BHA with no physical input from the surface other than mechanical signals. The present invention satisfies this need and allows for the drill string to be retracted undamaged so that drilling can recommence as quickly and as easy as possible following the disconnection. It is a further object of the present invention to provide a secure disconnect device that will only actuate when the tool is stuck and the operator wishes to do so. 
         [0008]    It is a further object to provide a tool that is actuated by controlled movements of the tool without other signalling from the surface so that tools such as circulating subs can be reliably activated when required. 
         [0009]    WO-A-2010/061231 discloses a selectively operable downhole tool for incorporation in a drill pipe for selective operation of the downhole tool from surface level when the tool is in a wellbore, said selectively operable tool comprising: 
         [0010]    a controller electrically powered by a power source separate from surface level; 
         [0011]    a first sensor of the controller to detect a dynamic variable of the tool in the wellbore and produce an output signal dependent thereon; 
         [0012]    a second sensor of the controller to detect a mechanical signal transmitted from an operator at surface level; 
         [0013]    a first motor driven by the power source under the control of the controller when said mechanical signal is received; and 
         [0014]    a first actuator driven by the first motor to actuate the tool; wherein 
         [0015]    the controller switches between at least two states in response to changes in said dynamic variable, only in said second state the controller being receptive to said mechanical signal from the operator to drive the first motor. 
         [0016]    Of course, the dynamic variable is frequently controlled to a greater or lesser extent by the operator. Variables such as vibration, temperature, hydrostatic pressure, are consequences of the situation but are not specifically determined by the operator and thus are essentially independent. However, other variables are more clearly under the control of the operator such as rotational accelerations or compressive forces or pump pressures, for instance. Mechanical signals transmitted by the operator from the surface typically take the form of changes in pump pressure, rotation of the drill string or load imposed on the drill string. Therefore, said first and second sensors may conceivably be detecting the same variable, except that, in the case of the first sensor, the detection is in response to some operational condition that serves to switch the controller between said states and in the case of the second sensor, the detection is in response to a specific operator signal that serves to cause the controller to actuate the tool. Even then, in some instances, the operational condition that causes switching between states of the controller might be deliberately induced to cause the controller to switch states. 
         [0017]    WO-A-2010/061231 also discloses a disconnect tool for incorporation in a drill string between a downhole assembly and a drill pipe to selectively disconnect the downhole assembly from the drilling pipe when the downhole assembly is stuck in a wellbore, said disconnect tool comprises: 
         [0018]    first and second parts that are releasably connected to one another by a disengagement apparatus, one of said first and second parts being adapted for connection to said drilling pipe and the other of said first and second parts being adapted for connection to said downhole tool, wherein 
         [0019]    said disengagement apparatus comprises an actuator and first and second coupling elements, 
         [0020]    the first coupling element comprising:
       a die retention sleeve, axially movable in the first part from an operational position towards a disconnect position of the disengagement apparatus;   a clutch housing, disposed within said die retention sleeve, said clutch housing being axially and rotationally fixed in the first part;   windows in said clutch housing circumferentially spaced around the clutch housing; and   radially displaceable capture dies housed in said windows, and the second coupling element comprising:   an interface of said second part adapted to be engaged by said capture dies, wherein,       
 
         [0026]    the actuator moves the retention sleeve between its operational and disconnect positions, so that 
         [0027]    when the first and second parts are engaged with one another and the retention sleeve is in its operational position, the capture dies bear against both the die retention sleeve and said interface of the second part to lock said first and second coupling elements and parts together, and 
         [0028]    when the retention sleeve is moved to its disconnect position, the capture dies can move radially to disengage from said interface so that said coupling is unlocked and said parts can separate. 
       BRIEF SUMMARY OF THE DISCLOSURE 
       [0029]    In accordance with a first aspect of the present invention there is provided downhole tool for incorporation in a drill pipe for selective operation of the tool from surface level when the tool is in a wellbore, said selectively operable tool comprising: 
         [0030]    a controller electrically powered by a power source separate from surface level; 
         [0031]    a first sensor of the controller to detect a dynamic variable of the tool in the wellbore and produce an output signal dependent thereon; 
         [0032]    a second sensor of the controller to detect a mechanical signal transmitted from an operator at surface level; 
         [0033]    a first motor driven by the power source under the control of the controller when said mechanical signal is received; and 
         [0034]    a first actuator driven by the first motor to actuate the tool; wherein the controller switches between at least two states in response to changes in said dynamic variable, only in said second state the controller being receptive to said mechanical signal from the operator to drive the first motor, characterised in that the downhole tool further comprises a second motor and a second actuator driven by the second motor, said second actuator comprising a mechanical brake having an engaged position and a disengaged position, said mechanical brake being configured to prevent actuation of the tool when in said engaged position, wherein, once the controller receives the mechanical signal from the operator to drive the first motor the controller is configured to sequentially: 
         [0035]    drive the second motor to move said mechanical brake from the engaged position to the disengaged position; and 
         [0036]    drive the first motor to actuate the tool. 
         [0037]    In one embodiment of the present invention, the downhole tool is a disconnect device. The dynamic variable may be rotational acceleration which, when it ceases because the bottom hole assembly (BHA) becomes stuck, serves to switch the tool between an active mode and a listening mode, in the latter of which it awaits signals from the surface that instruct it to disconnect. The surface signals may conveniently be compressive forces on the drill string detected as compressions by proximity sensors or strain gauges. 
         [0038]    In a quite different embodiment, the downhole tool is a circulating subassembly (circsub) disposed above a BHA, or forming part of it. A circulating subassembly is generally employed in two situations. A first is when increased debris clearance is desired. For example, the drill may be progressing very rapidly and be generating more debris than usual that needs to be recovered. Alternatively, it may be desired to clean the hole when drilling has finished. A second application is when drilling mud is being lost and it is necessary to circulate lost circulation material (LCM) to block cracks and crevices in the well bore and through which the mud is leaking into the formation. To ensure that the LCM does not simply block the drill equipment, a large exit from the drill conduit is desirable. In this case, the dynamic variable that switches the tool from normal, active mode to a listening mode may be fluid pressure. However, it may also comprise something as straightforward as some specific combination of rotational acceleration and pressure for a set period of time that is then terminated and, within another period of time, a new or further combination of the same parameters causes the circsub to activate. 
         [0039]    A mechanical brake may prevent damage to the first motor that may otherwise be caused by vibrations being transmitted from the tool to the first motor via the first actuator. Such vibrations could cause the first motor to be driven via the first actuator. 
         [0040]    Both a disconnect and circsub according to the invention may be employed in the same drill string. 
         [0041]    In accordance with a second aspect of the present invention there is provided a disconnect tool as described above as disclosed in WO-A-2010/061231, characterised in that said pinion is fixed to an output shaft so that relative axial movement between the pinion and the output shaft is prevented, the disconnect tool further comprising a second motor and a second actuator controlled by said second motor, said second actuator comprising a mechanical brake having an engaged position and a disengaged position, said mechanical brake being configured to prevent screwing of the sleeve when said mechanical brake is in said engaged position. 
         [0042]    In one embodiment, said actuator is an axially fixed cam collar having a first cam surface and the sleeve having a second cam surface, a spring axially biasing the sleeve into mutual engagement of the cam surfaces, one of said cam collar and sleeve being rotatable by a motor between release and lock positions of the collar, which respectively permit or block the sleeve from moving to its disconnect position. Preferably, the sleeve is rotationally fixed in the first part. In a preferable embodiment, the spring urges the die retention sleeve to move to its disconnect position when the collar is rotated to its release position. 
         [0043]    Alternatively, said actuator comprises the sleeve being screw threaded on said first part and having a circumferential rack driven by a pinion of a motor, whereby screwing of the sleeve on the first part moves it axially between said operational and disconnect positions. Said pinion may be threaded on a coarsely threaded output shaft of the motor and is translatable along said shaft between driving and secured positions, in the driving position it being engaged only with said rack whilst in the secured position it being engaged with a block of the sleeve preventing further rotation of the pinion whilst permitting axial movement thereof. 
         [0044]    In an alternative embodiment the pinion may be fixed to an output shaft so that relative axial movement between the pinion and the output shaft is prevented, the disconnect tool further comprising a second motor and a second actuator controlled by said second motor, said second actuator comprising a mechanical brake having an engaged position and a disengaged position, said mechanical brake being configured to prevent screwing of the sleeve when in said engaged position. 
         [0045]    Said mechanical brake may preferably comprise a plurality of teeth configured to engage said circumferential rack, said second motor being configured to move said plurality of teeth axially between said engaged position in which said teeth engage said circumferential rack and said disengaged position in which said teeth do not engage said circumferential rack. The axial movement of the teeth between said engaged and disengaged positions may be effected by a lead screw controlled by said second motor. 
         [0046]    In a further embodiment said sleeve may comprise a first, retaining sleeve and a second, intermediate sleeve, said first sleeve being screw threaded on said first part and said second sleeve having said circumferential rack, wherein said first sleeve is provided with internal or external splines configured to engage corresponding external or internal splines on said second sleeve, whereby rotation of one of said first and second sleeves is transmitted to the other sleeve, and some relative axial motion between said first and second sleeves is permitted. In this embodiment the disconnect device may advantageously further comprise a motion sensor, preferably a hall effect magnetic sensor, configured to detect relative axial motion between said first and second sleeves. Such a motion sensor may conveniently receive signals from the operator, for example the signal to move the retention sleeve to the disconnect position. 
         [0047]    The above described embodiment of the invention provides reliable means for retaining the first and second parts of the disconnect tool together under normal operating conditions and allows for a mechanical separation upon actuation of the actuator. The above arrangement provides disconnect means that does not explosively sever components and therefore does not damage the drill string. Drilling can recommence quickly, therefore, as soon as a new BHA is attached. 
         [0048]    Preferably, the capture dies comprise a series of grooves and ridges and said interface and said die retention sleeve have surfaces that are each complimentary to said series of grooves and ridges. The complimentary ridges of the capture dies and die retention sleeve are preferably part-cylindrical lands adapted to seat on each other in said operational position of the disengagement apparatus. Preferably, the complimentary grooves and ridges of the capture dies and die retention sleeve have part-conical side surfaces whereby the ridges on one can inter-digitate with the grooves on the other when the disengagement apparatus is in said disconnect position. The complimentary grooves and ridges of the capture dies and interface are preferably smoothly-curved in axial section whereby, in said disconnect position of the disengagement apparatus, relative axial movement of said first and second parts in a tool separation direction displaces the capture dies radially outwardly, inter-digitating said complimentary grooves and ridges of the capture dies and die retention sleeve. 
         [0049]    In a further preferable embodiment, the windows comprise abutment elements that abut ledges on said capture dies to restrict inward radial movement thereof. These prevent the dies falling into the internal bore of the tool after disconnection. 
         [0050]    Compressive forces are preferably transferred between said first part to said second part through shoulder elements on said first and second parts, and tensile forces are preferably transferred between said first part to said second part through said disengagement apparatus. Torque forces are preferably transferred between said first part to said second part through a splined connection between said first and second parts. 
         [0051]    In another preferable embodiment, the interface extends through and above said disengagement apparatus and is sealed to said first part above and below said disengagement apparatus to define a chamber enclosing said disengagement apparatus between said first and second parts, said chamber being filled with oil to lubricate said disengagement apparatus. Preferably, pressure equalisation bellows or a pressure equalisation piston in said chamber cause a pressure change in said oil in response to a pressure change in drilling mud external said tool and in communication with said bellows or piston. 
         [0052]    In a further preferable embodiment, the disconnect tool also comprises a controller to control actuation of said disengagement apparatus, the controller comprises: 
         [0053]    at least one first sensor that detects at least one dynamic variable and produces at least one output signal based thereon; 
         [0054]    at least one second sensor that is adapted to receive signals from an operator at the surface; wherein said controller is adapted to actuate said disengagement apparatus to disconnect the tool when a predetermined series of output signals are produced and a predetermined series of signals are received from the operator at the surface. 
         [0055]    Indeed, a disconnect tool in accordance with the second aspect of the invention may also be a selectively operable downhole tool in accordance with the first aspect of the present invention. 
         [0056]    In the embodiments in which the sleeve comprises a first and second and a motion sensor is provided to sense relative axial motion of the first and second sleeves the second sensor may comprise said motion sensor and said predetermined series of signals comprises a predetermined series of movements of the drill string that cause a predetermined series of relative movements between said first and second sleeves. 
         [0057]    Preferably, the controller forms part of a sensor module, wherein said sensor module further comprises power units and is a self contained electronic control unit and the sensor module preferably includes said motor. The sensor module is preferably a sleeve member within said chamber, wherein said controller and power units are isolated from said oil by seals between said sleeve member and said first part. Preferably, the motor is disposed in a bore of said sleeve member opening into said chamber, the motor being isolated from said oil by seals around an output shaft of the motor. However, said motor can be arranged to function within an oil-filled environment, and this may be preferable to avoid friction between the output shaft and seals thereon. In this event, a high temperature, high pressure cable is required that can itself seal between the oil chamber and the sensor module. 
         [0058]    Of course, it is highly undesirable for the tool to disconnect when the operator does not wish the disconnection to take place and/or the tool is not stuck in the well bore. An unintentional disconnection such as this would incur significant financial losses and would disrupt drilling considerably. The controller, power unit and motor are preferably isolated from oil to prevent damage, as these components are essential to the detection and subsequent disconnection of the disconnect tool. It is therefore critical that they remain active to ensure that disconnection only occurs when desired and a strict set of criteria is met. 
         [0059]    Preferably, the predetermined series of output signals produced by the sensor(s) are indicative of a stuck tool and the predetermined series of signals received from the operator are confirmatory signals that the operator wishes to commence with disconnection. Only under these conditions will the tool disconnect. 
         [0060]    The first sensor preferably comprises at least one accelerometer for measuring the acceleration of the device. In a preferable embodiment, the tool has three accelerometers for measuring axial, radial and rotational acceleration respectively. Each accelerometer is preferably a switch and is in logical state ‘1’ or ‘0’ depending on whether the measured acceleration exceeds, or is below, a predetermined threshold. Preferably, the controller produces a logical ‘1’ or ‘0’ depending on whether the measured acceleration exceeds, or is below, a predetermined threshold. 
         [0061]    By measuring acceleration along three axes, the behaviour of the BHA can be inferred. Therefore, the predetermined series of output signals from the sensors received by the controller to actuate disconnection can be set to be indicative of a stuck BHA and not represent the BHA in any other condition (e.g. lying dormant at the bottom of the well bore). By the careful choice of the predetermined series of output signals, the disconnect tool will be incapable of disconnecting when the BHA is not stuck in the well bore. 
         [0062]    Preferably, the tool has at least one compression sensor for measuring compression of the drill string. The compression sensor preferably measures compression by measuring the displacement between two internal components of said tool. Preferably, the compression sensor is a strain gauge. Preferably, the compression sensor is a switch and is in logical state ‘1’ or ‘0’ depending on whether the measured compression exceeds, or is below, a predetermined threshold. The controller preferably produces a logical ‘1’ or ‘0’ depending on whether the measured compression exceeds, or is below, a predetermined threshold. 
         [0063]    The compression sensors are preferably capable of receiving compression signals from the operator at the surface. The purpose of incorporating the compression signals in the disconnect process is to ensure, with confirmatory signals, that the operator wishes to commence with the disconnection. Again, this will ensure that the tool does not disconnect undesirably. 
         [0064]    Thus, the tool is preferably a disconnect tool for incorporation in a drill string between a downhole assembly and a drill pipe to selectively disconnect the downhole tool from the drilling pipe when the downhole assembly is stuck in a wellbore, said disconnect tool comprising: 
         [0065]    a first part for connection to said drilling pipe and a second part for connection to said downhole assembly; 
         [0066]    a disengagement apparatus to release connection between said first and second parts; wherein 
         [0067]    said controller is adapted to change the tool from an active state to a disconnect state when said at least one output signal has satisfied at least one criterion indicating that the tool is stuck, and 
         [0068]    said controller is adapted, when in said disconnect state, to actuate said disengagement apparatus to disconnect the tool when a disconnect operator signal is received by said second sensor. 
         [0069]    This logical process requires that a specific set of events must occur before the disconnect tool disconnects. In particular, a criterion must be met regarding the operational state of the tool and a criterion must be met with respect to the operator&#39;s intentions, with the tool preferably only disconnecting when the BHA is stuck and the operator wishes to commence with the disconnect sequence. 
         [0070]    It is preferable that prior to entering said disconnect state, the tool enters a listening state; 
         [0071]    said tool changing from said listening state to said disconnect state when the tool has been in said listening state after a first period of time and dependent upon receipt or non-receipt of a transfer operator signal by said second sensor in said first period of time. Said tool preferably returns to said active state unless said transfer operator signal is received by said tool in said first time period. 
         [0072]    Preferably, the controller actuates the disengagement apparatus to disconnect the tool when said disconnect operator signal is received by said second sensor during a period of time following the controller entering said disconnect state. Between said listening and disconnect states, the tool preferably enters a countdown state, said tool changing from said countdown state to said disconnect state upon receipt of a countdown operator signal received by said second sensor during a period of time in said countdown state. Preferably, the, or each operator signal is a compression of the drill string and said at least one second sensor is a compression sensor. 
         [0073]    The listening and countdown states allow for fail-safe periods where the disconnect sequence can be abandoned. Within each of these states, the operator must produce a compression signal (or not produce a compression, in alternative embodiments) to confirm that disconnection is still desired. Such a system prevents accidental or undesirable disconnection occurring at the expense of the drilling budget and schedule. 
         [0074]    The compression sensor preferably measures compression by measuring the displacement between said two parts or the compression sensor is preferably a strain gauge. Alternatively, the compression sensor is a switch and is in logical state ‘1’ or ‘0’ depending on whether the measured compression exceeds, or is below, a predetermined threshold. Preferably, the controller produces a logical ‘1’ or ‘0’ depending on whether the measured compression exceeds, or is below, a predetermined threshold. 
         [0075]    The transfer operator signal is preferably a continuous compression signal and the countdown operator signal is preferably a series of periodic compression signals. Preferably, the disconnect operator signal is equal to said transfer operator signal. 
         [0076]    Preferably, the at least one sensor is an accelerometer and preferably, the tool has three accelerometers for measuring axial, radial and rotational acceleration respectively. Preferably, the, or each accelerometer is a switch and is in logical state ‘1’ or ‘0’ depending on whether the measured acceleration exceeds, or is below, a predetermined threshold. The controller preferably produces a logical ‘1’ or ‘0’ depending on whether the measured acceleration exceeds, or is below, a predetermined threshold. 
         [0077]    Preferably, the criterion indicating a stuck tool is that the measured axial acceleration exceeds a predetermined threshold, the measured radial and rotational accelerations are below a predetermined threshold, and the measured compression periodically exceeds a predetermined threshold. 
         [0078]    Preferably, A disconnect tool as claimed in any of the second aspect of the present invention is also A disconnect tool as claimed in the first aspect of the present invention. 
         [0079]    A tool according to the first aspect of the present invention may comprise a circsub, said circsub tool comprising a body having a throughbore receiving a piston movable between open and closed positions to control ports in the body selectively connecting the throughbore with the wellbore, said motor driving said actuator to enable or disable movement of the piston to said open position. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0080]    Embodiments of the invention are further described hereinafter with reference to the accompanying drawings, in which: 
           [0081]      FIG. 1A  is a side view of a disconnect device according to the present invention, and  FIGS. 1B, 10 and 1D  are cross-sectional views taken along the lines A-A, O-O and C-C, respectively, of  FIG. 1   a;    
           [0082]      FIG. 2  is an exploded view of a disengagement apparatus according to the present invention; 
           [0083]      FIG. 3A  is a side view of a sensor module according to the present invention, 
           [0084]      FIG. 3B  is a cross-sectional view taken along line I-I of  FIG. 3A , and  FIG. 3C  is a bottom view of the sensor module of  FIG. 3A ; 
           [0085]      FIG. 4  is a perspective view of part of the disconnect device showing the interface between the sensor module and disengagement apparatus according to the present invention; 
           [0086]      FIG. 5A  is a side view of the disengagement apparatus when it is in an ‘engaged’ arrangement with the mandrel, and  FIG. 5B  is a corresponding partial cross-sectional view; 
           [0087]      FIG. 6A  is a side view of the disengagement apparatus immediately following the release of the mandrel, and  FIG. 6B  is a corresponding partial cross-sectional view; 
           [0088]      FIGS. 7A  and B are partial sections in two positions through an alternative embodiment of a disconnect tool in accordance with aspects of the present invention; 
           [0089]      FIG. 8  is a perspective transparent view of part of the tool of  FIG. 7 ; 
           [0090]      FIGS. 9A , B and C are a side view and two sectional views along the line A-A of  FIG. 9A ,  FIG. 9B  showing in an open position and  FIG. 9C  showing in a closed position, of a circulating sub in accordance with an aspect of the present invention; 
           [0091]      FIG. 10  shows an enlarged view of the circulating sub shown in  FIG. 9 ; 
           [0092]      FIG. 11  is an exploded view of a disengagement apparatus according to another aspect of the present invention; and 
           [0093]      FIG. 12  is a cross-sectional view of a brake according to an aspect of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0094]    A disconnect device  10  in accordance with the present invention is shown in  FIG. 1A .  FIG. 1B  shows a cross section of the device  10  of  FIG. 1A  along line A-A. With reference to  FIGS. 1A and 1B , the device  10  is generally cylindrical and has a mandrel  12  that is located within a bore  14   a  of a spline housing  14  and a bore  16   a  of a trigger housing  16 . The spline housing  14  surrounds a middle portion  12   b  of the mandrel  12  whilst the trigger housing  16  surrounds an upper portion  12   a  of the mandrel  12 . An upper portion  14   b  of the spline housing  14  has a smaller diameter than the trigger housing  16  and is connected in a lower portion  16   c  of the trigger housing  16 . The interface between the upper portion  14   a  of the spline housing  14  and the lower portion  16   c  of the trigger housing  16  forms a housing connection  22  that prevents axial movement therebetween. 
         [0095]    A lower portion  12   c  of the mandrel  12  extends below the spline housing  14  and is shown exposed. The device  10  has a top connector  18  on the upper portion  16   b  of the trigger housing  16  that connects the device  10  to an upper part of a drill string (not shown) and a bottom connector  20  on the lower portion  12   c  of the mandrel  12  that connects the device  10  to a lower part of the drill string (not shown). The lower drill string part will typically be connected to, or at least be closely connected to, a bottom hole assembly (BHA) during operation. As described below, the disconnect device  10  acts as a releasable member between the upper drill string part and the lower drill string part comprising the BHA. 
         [0096]    Intermediate the trigger housing  16  and the mandrel  12 , above the spline housing  14 , there is located a disengagement apparatus  28   FIG. 2  shows a detailed exploded view of the disengagement apparatus  28 . The disengagement apparatus comprises a die retention sleeve  30  within which is disposed a clutch housing  38 . When assembled, the clutch housing  38  is located between the mandrel  12  and the die retention sleeve  30 . The inner surface of the die retention sleeve  30  has a grooved or ribbed profile made up of several concentric grooves  31   a  and ridges  31   b . A plurality of capture dies  34 , having complimentary outer grooves  35   a  and ridges  35   b , are disposed within windows  37  around the circumference of the clutch housing  38 . The windows  37  comprise abutment elements  37   a  that prevent the capture dies  34  from passing entirely through the windows  37  radially inwards, but do not prevent or restrict movement radially outwards. The clutch housing  38  is prevented from rotating about its longitudinal axis with respect to the die retention sleeve  30  by location pin  40 . The location pin  40  passes through a longitudinal slot  30   b  in the surface of the die retention sleeve  30  and is fixed in sockets  38   a  in the clutch housing  38 . 
         [0097]    The portion of the mandrel  12  that is in radial alignment with the die retention sleeve  30  (when assembled) also has a grooved face made of grooves  12   a  and ridges  12   b  (see  FIG. 1D ). The inner surfaces of capture dies  34  have inner grooves  36   a  and ridges  36   b  that are complimentary to the grooves  12   a  and ridges  12   b  of the mandrel  12 . The inner grooves and ridges  36   a,b  of the capture dies  34  and the complimentary grooves and ridges  12   a,b  of the mandrel appear smoothly curved when viewed in an axial section. When assembled, the inner grooves  36   a  and ridges  36   b  of capture dies  34  can mate with the ridges  12   b  and grooves  12   a  respectively of the mandrel  12  such that axial movement is prevented therebetween by interference. Under normal drilling operation, the outer ridges  35   b  of the capture dies  34  are in abutment with the ridges  31   b  of the die retention sleeve  30  pressing the capture dies  34  into mutual engagement of the ridges and grooves  36   a,b / 12   a,b . The ridges  31   b  of the sleeve and the outer ridges  35   b  of the capture dies  34  have part conical side surfaces whereby the ridges on one surface ( 31   b  or  35   b ) can inter-digitate with the grooves ( 35   a  or  31   a ) of the other when the disengagement apparatus moves into a disconnect position. 
         [0098]    An upper portion of the die retention sleeve  30  has a cam feature  30   a  that is capable of abutting against a complimentary cam feature  32   a  on a cam collar  32  located above the die retention sleeve  30 . The cam collar  32  is retained axially between the upper portion of the die retention sleeve  30  and a flange  38   b  on an upper edge of the clutch housing  38 . The cam collar  32  is free to rotate with respect to the die retention sleeve  30  by the amount allowed by cam features  30   a  and  32   a.    
         [0099]    At a lower end of the die retention sleeve  30  a cap  46  axially retains a spring  44  between the die retention sleeve  30  and a flange  46   a  ( FIG. 1D ) of the cap  46 . When compressed, the spring  44  acts against the die retention sleeve  30  and the flange  46   a  of the cap  46 . A spigot  46   b  on the cap  46  retains and aligns the die retention sleeve  30  and its ridges  31   b  with respect to the outer ridges  35   b  of the capture dies  34 . 
         [0100]    Since the disconnect device  10  is installed intermediate the upper and lower parts of the drill string, the device  10  must be capable of transmitting torque, compression and tensile forces if the BHA is to operate as desired. In the device  10 , torque forces are transmitted through the top connector  18  to the spline housing  14  via the housing connection  22  intermediate the trigger housing  16  and the spline housing  14 . The torque is then transferred from the spline housing  14  to the mandrel  12  via a spline  24  (see  FIG. 10 ) disposed within spline housing  14 . 
         [0101]    Compressive forces are also transmitted through the top connector  18  to the trigger housing  16 . From the trigger housing  16 , they are transmitted to the spline housing  14  via housing connection  22 . From the spline housing  14 , however, compressive forces are transmitted to the mandrel  12  through a shoulder  26  of the mandrel  12 . The shoulder  26  is located intermediate a radially narrow upper portion of the mandrel  12  and a radially wide lower portion of the mandrel  12 . The compressive forces are then transmitted from the mandrel  12  to the lower drill string portion via the bottom connector  20 . 
         [0102]    Under tension, however, no load is taken by the shoulder  26 . Instead, the tension exerted by the mandrel  12  is transmitted to the clutch housing  38  through the mating of the grooves  36   a  and ridges  36   b  of the capture dies  34  with the ridges  12   b  and grooves  12   a  respectively of the mandrel  12 . Since the clutch housing  38  is retained within the die retention sleeve  30 , which is disposed above the spline housing  14 , the tension is transmitted from the clutch housing  38  to the trigger housing  16  via the spline housing and housing connection  22 . The tension is then transmitted to the upper drill string via top connector  18 . 
         [0103]    Located above the disengagement apparatus  28  within the trigger housing  16  is a sensor module  50 . The sensor module  50  contains the drive, control and actuation components that cause rotation of the cam collar  32 . The sensor module  50  is shown in  FIGS. 3A-30  and  FIG. 4  shows the interaction between the sensor module  50  and the cam collar  32 . The sensor module  50  contains an electric motor  52  that has a gearbox  54 . The gear box  54  is drivably connected to a drive axle  56  that protrudes from a bottom end  50   a  of the sensor module  50 . The drive axle  56  is drivably connected to a pinion  64  such that a relative axial movement can occur between the drive axle  56  and pinion  64  whilst maintaining the drivable connection. As shown in  FIG. 4 , the pinion  64  engages with a toothed inner surface  32   b  of cam collar  32 . Operation of the motor  52  therefore causes rotation of the cam collar  32  relative the die retention sleeve  30 . Further motors may be disposed around the circumference of the sensor module  50  (see second drive axle  562 , for example, in  FIG. 4 ). In alternative embodiments of the invention, any suitable actuator may be used in the place of the one or more motors. 
         [0104]    With reference to  FIGS. 5A, 5B, 6A and 6B , rotation of the cam collar  32  enables the die retention sleeve  30  to move upwards under the bias of spring  44 . This is because the uppermost position of the die retention sleeve  30  is limited by abutment between the cam features  32   a  and  30   a . As the cam collar  32  rotates, the profile of cam feature  32   a  changes relative the cam feature  30   a  for any given point on the circumference. Since the spring  44  biases the die retention sleeve  30  to its uppermost position, the rotating cam collar  32  allows the die retention sleeve to move upwards to the position shown in  FIG. 6A . This movement allows the capture dies  34  to move radially outwards and release the mandrel  12 , as described below with reference to  FIGS. 5A and 5B . 
         [0105]      FIG. 5B  shows a cross-sectional view along the line D-D of  FIG. 5A .  FIG. 6A  shows a cross-sectional view along the line F-F of  FIG. 6A .  FIGS. 6A and 6B  show the disengagement apparatus  28  in a position that would disengage the mandrel  12  (if present). 
         [0106]    In  FIG. 5B , the outer ridges  35   b  of the capture dies  34  are in abutment with the ridges  31   b  of the die retention sleeve  30 . In this position, the capture dies  34  would be in a mating arrangement with the grooves  12   a  and ridges  12   b  of the mandrel  12  such that the mandrel  12  would not move relative the disengagement apparatus  28 . This ‘engaged’ arrangement is described above with reference to  FIG. 1D . 
         [0107]    In  FIG. 6B , the die retention sleeve  30  has moved upwards relative the cam collar  32  and the clutch housing  38 . Consequently, the ridges  31   b  of the die retention sleeve  30  are no longer in abutment with the outer ridges  35   b  of the capture dies  34 . Instead, the outer ridges  35   b  of the capture dies  34  are in radial alignment with the grooves  31   a  of the die retention sleeve  30 . The capture dies  34  are then able to move radially outwards and do so when a tension is applied to the housing  16  when it is desired to separate the coupling between the two parts of the disconnected device  10 . The smoothly curved surfaces of the inner grooves and ridges of the capture dies  36   a,b  and the complimentary smoothed surface of the grooves and ridges of the mandrel  12 , b  facilitate the radially outward movement of the capture dies when tension is applied. The wave-like structure of the outer grooves and ridges  35   a,b  of the capture dies  34  and the grooves and ridges  31   a,b  of the die retention sleeve  30  allow the mating arrangement shown in  FIG. 6B . With the capture dies  34  in the position shown in  FIG. 6B , the axial path of the mandrel  12  (including the axial path of the grooves  12   a  and ridges  12   b ) is clear and the mandrel  12  is no longer coupled to the rest of the device  10 . At this point, the mandrel  12  is disconnected from the remainder of the device  10  and will either move downwards under the influence of gravity, or, in the case of a stuck tool, remain in place whilst the remainder of the device  10  is withdrawn upwards and recovered. 
         [0108]    The above describes the mechanical process by which an upper portion of a drill string is disconnected from a lower portion. A further aspect of the present invention is directed towards a system that will only allow the disconnection to proceed when specific predetermined criteria are met. The following describes this system with reference to the above described disconnect device, however the skilled person will appreciate that other disconnect devices may be used without deviating from the scope of the invention. 
         [0109]    With reference to  FIGS. 3B and 3C , it can be seen that the sensor module  50  comprises a plurality of sensors  60 . The sensors may include proximity sensors, pressure sensors, accelerometers and temperature sensors. Although  FIG. 3C  shows four such sensors  60 , the skilled person will realise that this is in no way limiting to the actual number of sensors  60  that might be employed. The sensors  60  may be capable of measuring a dynamic variable across a continuous spectrum or alternatively they may be capable of detecting whether the dynamic variable is above or below a predetermined threshold. The sensors  60  are connected to one or more microprocessors in one or more pods  61  that are capable of evaluating the output signals from the sensors  60  and carrying out logic functions to permit and control disconnection. The one or more microprocessors therefore act as a controller for controlling disconnection. Alternatively, the sensors may also be mounted directly on circuit boards or other arrangements in pods  61  disposed around the sensor module  61 . One or more battery packs (not shown) embedded within the sensor module  50  provide power to the sensors  60  and microprocessors, as well as to the motor(s)  52  and may be embedded within one of the pods  61 . The sensor module  50  is sealed by seals  62  from high hydrostatic pressures. Thus, the sensor module  50  is a self contained electronic control unit that is capable of determining certain physical conditions and actuating disconnection based thereon. 
         [0110]    It is to be mentioned that in a downhole environment, a degree of redundancy and/or voting may be desirable to mitigate individual component failure. For example, in the case where three accelerometers are used, and the outputs from two accelerometers are in agreement with one another, but are in disagreement with the third, it might be desirable for the microprocessors to disregard the output from the third accelerometer as it represents a minority proportion of the entire data set. 
         [0111]    The internal components of the device  10  are generally lubricated by oil, however the sensor module  50  is sealed by seals  62  to protect its delicate components. Oil can be introduced into the device  10  through a port  70  to lubricate the internal components between seals  66 . Mandrel seals  12   d  prevent the oil entering the bore  12   e  of the mandrel  12 . Bellows  64  allow the variable pressure of the drilling mud outside of the device  10  to cause a proportional pressure change in the oil. The bellows  64  also act such that when the device  10  is under compression, they receive a small amount of oil. During disconnection, oil is initially drawn from the bellows  64  to allow the mandrel  12  to separate easily from the remainder of the device. In alternative embodiments of the invention, a pressure equalisation piston may be used in place of the bellows to equalise the drilling mud pressure and the oil pressure. 
         [0112]    To protect the clutch housing  38  and capture dies  34  from the high compressive loads encountered whilst drilling, the device  10  is made telescopic to a small degree. A spring  72  separates the clutch housing  38  from the sensor module  50  and holds the two components apart in the absence of a substantial force. If a substantial weight is applied to the device  10 , then the spring  72  will compress and the clutch housing  38  and sensor module  50  will move closer to one another. In this state, the device  10  is said to be under compression. 
         [0113]    Proximity sensors  60  can be a simple switch, and the small relative movement between the components can actuate such a switch. If preferred, however, the movement can be eliminated altogether and the proximity switch changed to a strain sensor that detects compression of the disconnect device  10 . 
         [0114]    Proximity sensors  60  can detect this relative movement and can produce an output signal either indicating the degree of compression (i.e. the magnitude of the relative displacement between the clutch housing  38  and the sensor module  50 ), or that the degree of compression has exceeded a predetermined threshold and that the tool is under ‘compression’. In the case where a predetermined threshold is used, any compression that does not exceed the predetermined threshold will be measured as ‘no compression’. 
         [0115]    Pressure sensors  60  in the sensor module  50  might measure oil pressure which is proportional to the hydrostatic pressure by virtue of bellows  64 . Again, the sensors  60  might measure oil pressure across a continuous spectrum or simply measure if it is below or exceeds a predetermined threshold. Alternatively, instead of absolute pressure, the sensors  60  may detect differential pressure between the through bore of the drill string and external pressure of the well bore. 
         [0116]    Temperature sensors  60  may be used to determine whether the temperature is within the range that it is safe to operate the device  10  and may be used to shut down the microprocessors if temperatures exceed a predetermined threshold. Additionally, the microprocessors could be used to control certain temperature dependent characteristics of internal electronic devices based on the measured temperature. 
         [0117]    Accelerometers  60  may also be used to monitor vibrations within the device  10  along any given axis. For example, the accelerometers  60  can provide an indication as to whether the tool is drilling, when there is no movement, when there are jarring operations, or when it is rotating. Although all the sensors employed are illustrated as sensors  60 , sensors that do not require access to the external environment, such as accelerometers, may be disposed within the sensor module itself, rather than at the locations  60  illustrated. 
         [0118]    The microprocessors collate the output data from the various sensors  60  and put the device into a particular ‘mode’ depending on the specific combination of data. The device&#39;s ‘modes’ are described below, assuming that the sensors  60  are operating on a threshold criterion. In particular, each sensor  60  will output a ‘1’ if its measured variable exceeds a predetermined threshold, and output a ‘0’ if its measured variable is below the predetermined threshold. Alternatively the microprocessors can convert an analogue signal from the sensors  60  to a logical ‘1’ or ‘0’ as desired. The microprocessors can also be selective in which sensor outputs are considered depending on which mode it is in. 
         [0119]    A visual display at the surface can be optionally used to indicate what mode of operation the device  10  is in and may also provide instructions to guide the operator. However, it is an aspect of the present invention that the disconnect device  10  can work isolated from the surface other than for final disconnect instruction signals. 
         [0120]    The device  10  is in ‘Active Mode’ when the tool goes below the rotary table of a drilling rig or platform. The microprocessors switch the device  10  into Active Mode when the output signals from the pressure sensors  60  indicate that the device is below the rotary table. This will be determined by the selection of the predetermined pressure threshold, the level of which can be adjusted by the operator. The predetermined thresholds of all the sensors  60  can be set such that when the device  10  is being stored at the surface, the microprocessors act to switch the unit off, based upon the sensor outputs. The device  10  should remain in Active Mode under all normal operation. ‘Normal operation’ may include the BHA running in the hole, the BHA static at the casing shoe, the BHA pulling out of the hole and other common operations such as reaming, drilling, circulating and wiping. 
         [0121]    If the BHA becomes stuck, the accelerometers  60  will not read any rotational or radial acceleration, but may still read axial acceleration caused by jarring. The output signals from the accelerometers  60  will be distinctly different when the BHA is stuck compared to the output signals produced during normal drilling operations. More specifically a stuck BHA will mean that accelerations measured within the sensor module  50  are, at most, vibration-like. During normal drilling, accelerations measured within the sensor module  50  will be representative of large axial and radial movements with 360° rotations. When vibration-like accelerations are measured, however, the microprocessors will consider data from the compression sensor to confirm that the BHA is stuck. If the BHA is stuck, and the operators are attempting to free it by jarring, the compression sensor  60  will measure the periodic ‘jar spikes’. In combination with the accelerometer outputs, the microprocessors will interpret this data to mean that the BHA is stuck, provided that the device is in Active Mode. The microprocessors will then put the device  10  into ‘Listening Mode’. 
         [0122]    When the device is in Listening Mode, the operator may have given up trying to free BHA and made the decision to disconnect. To commence disconnection, a signal must be sent to the device  10  whilst it is in Listening Mode. In one embodiment of the invention, the signal involves the operator slacking off the upper drill string to put the device under a continuous steady compression. With no more jarring, all the accelerometers  60  should read ‘0’ and the steady compression caused by the slack drill string will be measured by the compression sensor  60 . If these conditions are constant for a predetermined time period (e.g. 15 minutes) whilst the device  10  is in Listening Mode, the microprocessors will change the device mode to ‘Countdown Mode’. 
         [0123]    During Countdown Mode, a timer will begin a countdown of a predetermined time period. Within that time period, the operator can send a signal to the device to abort the countdown and reset the device  10 . This may be done, for example, by the operator lifting and tensioning the drill string once again. Alternatively, if the operator does not take any further action, and leaves the device  10  under compression for the entire predetermined time period, the microprocessors will move the device into ‘Disconnect Mode’. 
         [0124]    The Disconnect Mode allows for one final confirmation signal from the operator that they wish the disconnect sequence to begin. At this time, the operator has one final chance to abort the process and reset the device  10 . In one embodiment, for example, the confirmation signal might involve the operator producing a series of compression signals (e.g.  3 ) within a predetermined time period (e.g. 10 minutes) by sequentially tensioning and slackening the drill string. Of course, other embodiments are possible where other mechanical signals can be used to confirm the operator&#39;s intentions during Disconnect Mode. If the microprocessor receives data from the various sensors  60  that corresponds to the predetermined conditions produced by the confirmation signal, the microprocessors operate the motor  52  and begins the disconnect sequence described above. 
         [0125]    Turning to  FIGS. 7A  and B, an alternative arrangement of the disconnect device of  FIGS. 1 to 6  is shown in which the device  10 ′ does not employ the cam collar of the previous embodiment. The same reference numerals are employed below, except with a prime′ when the component is modified. Here, the retention sleeve  30 ′ has a flange  30 ′ c  having threads  30 ′ a  that are threaded on complementary threads  46 ′ c  of cap  46 ′ (forming a part of the clutch housing  38 ′). The other end  30 ′ d  of the retention sleeve  30 ′ has internal straight splines  30 ′ f  against which bears splines  56 ′ d  on a pinion gear  56 ′ a  on shaft  56 ′ of motor  52  and gearbox  54 . Pinion gear  56 ′ a  has a coarse internal thread  56 ′ b  engaged with a corresponding thread of the shaft  56 ′. 
         [0126]      FIG. 7A  shows the tool in normal use. The pinion is received in a cylindrical pocket  38 ′ b  of the clutch housing  38 ′ which pocket, at one end, is splined in correspondence with the splines of pinion  56 ′ a . Thus, in the position shown in  FIG. 7A , the pinion is unable to rotate about its axis, being fixed by the splines  38 ′ c . Consequently, since it is also in engagement with the splines  30 ′ f  of the retention sleeve  30 ′, it too is unable to rotate and the sleeve is held in position with its ridges  31   b  in conjunction against outer ridges  35   b  of the capture dies  34 . This in turn holds the inner ridges  36   b  of the capture dies in engagement with the grooves  12   a  of the mandrel  12 , preventing the mandrel  12  from being withdrawn (leftwardly in  FIG. 7A ) from the device  10 ′. 
         [0127]    In the position shown in  FIG. 7A , the device is shown under tension, the weight of the mandrel being supported through the disengagement apparatus  28 ′ by cap  46 ′ seated on nose  14   a  of the spline housing  14 . In this event, there is also a radially outwardly directed force on the capture dies  34 , themselves pressing radially outwardly on the die retention sleeve  30 ′. This would prevent the sleeve from rotating. Consequently, when it is desired to effect a disconnection, the device is placed in compression, so that the weight of the mandrel and the components beyond it is taken on the shoulders  26  (not visible in  FIGS. 7 and 8 ). A small gap  14   c  then appears (see  FIG. 7B ) between cap  46 ′ and nose  14   a  and the strain on the disengagement apparatus is relieved. When the motor  52  rotates in one direction, the pinion  56 ′ a  is unable to rotate so it is instead driven axially to the position shown in  FIG. 7B  by the thread on the shaft  56 ′ engaging its thread  56 ′ b . This proceeds until the pinion gear clears the splined part  38 ′ c  of the pocket  38 ′ b  and enters clear part  38 ′ d  in which it can rotate about its axis. The pinion gear no longer progresses along the shaft, instead preferring to rotate with the shaft  56 ′. In any event, it cannot progress further without contacting the base of the pocket  38 ′ b.    
         [0128]    Thus in the position shown in  FIG. 7B , the pinion gear can rotate and, in doing so, it starts to spin the retention sleeve about its own axis being the longitudinal axis of the tool  10 ′. This rotation progressively unscrews the retention sleeve  30 ′ from the cap  46 ′ until such time as the outer ridges  35   b  of the capture dies coincide with and fall into the grooves  35   a  of the retention sleeve  30 ′. At this point, as above, the capture dies release the mandrel  12  so that the device  10  can be separated as described above. 
         [0129]      FIG. 11  shows another alternative embodiment of the disconnection apparatus  10 ″ of the present invention. In the embodiment shown in  FIG. 11  retention sleeve  30 ″ is provided with an internal thread  30 ″ a , which internal thread is configured to engage a corresponding external thread  178  on clutch housing  38 ″. Similar to the embodiments shown in  FIGS. 1-10 , device  10 ″ includes capture dies  34  having outer ridges and grooves  35   a ,  35   b . The capture dies are disposed in windows  37  when device  10 ″ is assembled. The movement of capture dies  34  within windows  37  is limited by abutment elements  37   a , which prevent capture dies  34  from moving radially inwardly within clutch housing  38 ″. Clutch housing  38 ″ does not limit radially outward movement of the capture dies, however. When device  10 ″ is assembled retention sleeve  30 ″ is screwed onto clutch housing  38 ″, so that ridges and grooves on the internal surface of retention sleeve  30 ″ (not shown) align with, respectively, ridges  35   a  and grooves  35   b  on capture dies  34 . Similar to the embodiment shown in  FIGS. 7-9 , the disconnection is actuated by rotating retention sleeve  30 ″ with respect to clutch housing  38 ″, so that they move axially with respect to one another by virtue of engaging screw threads  30 ″ a , 178 . This axial movement causes ridges  35   a  to align with the grooves on the inner surface of retention sleeve  30 ″, so that capture dies  34  are allowed to move radially outwardly in windows  37 , thus allowing device  10 ″ to be disconnected from mandrel  12  (not shown). 
         [0130]    When device  10 ″ is assembled external splines  176  on retention sleeve  30 ″ engage internal splines  174  on the internal surface of intermediate sleeve  170 . In this way intermediate sleeve  170  and retention sleeve  30 ″ can move axially with respect to one another, but rotation of intermediate sleeve  170  about the longitudinal axis of the device  10 ″ is transmitted to retention sleeve  30 ″, and vice versa. Intermediate sleeve  170  is also provided with circumferential rack  172 , which rack is configured to engage spindle  178  and brake  180  (see  FIG. 12 ) which are respectively disposed on first and second motor assemblies  182   a,b . First and second motor assemblies  182   a,b  are disposed within recesses  190   a  (on motor housing  190 ),  192   a  (on motor housing extension  192 ) and  194   a  (on processor module retainer  194 ). They are secured to motor housing  190  with bolts  177   a , which engage threaded bores  190   b . Motor housing extension  192  and processor module retainer  194  are secured to motor housing  190  with bolts  177   b , which engage threaded bores  190   c . Bolts  177   a ,  177   b  may be provided with washers  179  to improve the load distribution between the head of the bolt and the surface it engages. The washers  179  may advantageously be locking washers to prevent loosening of the bolt due to vibrations. 
         [0131]    Each of first and second motor assemblies  182   a ,  182   b  are provided with a flange  184 . When device  10 ″ is assembled flanges  184  are disposed within groove  173  so that motor assemblies  182   a,b  are axially fixed relative to intermediate sleeve  170 . This ensures that spindle  178  and brake  180  are accurately positioned relative to rack  172  so that the teeth on spindle  178  and brake  180  mesh with the teeth on rack  172 . It should be noted that during assembly of device  10 ″ motor assemblies  182   a,b  must be inserted into intermediate sleeve  170  so that flanges  184  are disposed in groove  173  before the motor assemblies are attached to motor housing  190 . 
         [0132]    As described above, clutch housing  38 ″ and retention sleeve  30 ″ may move axially relative to each other by virtue of engaging screw threads  30 ″ a , 178 . When clutch housing  38 ″ and retention sleeve  30 ″ are fully screwed together, so that end  168  engages flange  169 , extension  199  protrudes out of retention sleeve  30 ″. To prevent retention sleeve  30 ″ from being fully unscrewed from clutch housing  38 ″ locking ring  175  is disposed within groove  196  after the clutch housing  38 ″ and retention sleeve  30 ″ are fully screwed together. Locking ring  175  then engages flat portion  198  at an end of retention sleeve  30 ″ if excessive unscrewing between clutch housing  38 ″ and retention sleeve  30 ″ occurs. The possible axial movement between clutch housing  38 ″ and retention sleeve  30 ″ is therefore limited in a first direction by the engagement between locking ring  175  and flat portion  198  and in a second direction by the engagement between end  168  and flange  169 . 
         [0133]    Locking ring  175  may be radially elastically expanded or compressed during assembly by virtue of split  175   a , which allows the circumference (and therefore radius) of ring  175  to increase or reduce slightly when it is radially expanded or compressed. Ring  175  then snaps back into its unloaded state when the radial expansion or compression is removed, for example when ring  175  is located in groove  197 . 
         [0134]    In normal use device  10 ″ transmits tensile loads between a BHA attached to mandrel  12  (not shown in  FIG. 11 ) and an upper drill string attached to connector  18  via trigger housing  16  (not shown in  FIG. 11 ). If the BHA becomes stuck disconnection may be effected by first withdrawing brake  180  so that it no longer engages rack  172  and then turning spindle  178  to cause intermediate sleeve  170  and retention sleeve  30 ″ to rotate relative to clutch housing  38 ″. 
         [0135]    Second motor assembly  182   b , which includes brake  180 , is shown in more detail in  FIG. 12 . Brake  180  is disposed on internally threaded member  202 , which is free to move axially, but cannot rotate, within slot  206  in motor housing  182   b . Internally threaded member  202  is controlled by motor  52   b  via lead screw  204 . To withdraw brake  180  motor  52   b  rotates lead screw  204  by a predetermined amount so that brake  180  moves axially within slot  206  so that flat portion  202   a  and not brake  180  aligns with rack  172  on intermediate sleeve  170 . Rotation of intermediate sleeve  170  (and therefore retention sleeve  30 ″) can then by performed by activating the motor in first motor assembly  182   a , which controls spindle  178  that engages circumferential rack  172 . 
         [0136]    The motors  52   a,b  in first and second motor assemblies  182   a,b  are each provided with integral high ratio gearboxes, for example planetary gearboxes, so that sufficient torque can be provided to actuate the removal of brake  180  and the disconnection of device  10 ″. In the embodiment illustrated in Figure lithe first motor assembly  182   a  comprises two motor assemblies. This may provide a degree of redundancy, as if one of the two first motor assemblies fails then the other may still be able to actuate the disconnection. It may also be necessary to provide sufficient torque, depending upon the torque required to actuate the disconnection and the torque provided by the motors. However, the skilled person will understand that the first motor assembly may comprise more or fewer motor assemblies, depending upon the construction of the device  10 ″, and in some embodiments the first motor assembly comprises a single motor assembly. 
         [0137]    Brake  180  prevents vibrations that occur during normal drilling from causing intermediate sleeve  170  to rotate relative to motor housing  190 . Because spindle  178  constantly meshes with circumferential rack  172  such rotations would cause motor  52   a  to be driven via its integral high ratio gearbox. This may damage the motor or the gearbox. Inclusion of the brake therefore obviates the need to disengage spindle  178  from rack  172  under normal drilling conditions. 
         [0138]    In the embodiment shown in  FIGS. 11-12  the operator may provide the signal to activate the disconnection sequence as described above, and the operation of the disconnection sequence may be controlled by the same sensor module  50  described above. Sensors or processors may be disposed within processor module housing  194 . Briefly, the device  10 ″ may enter a listening mode if acceleration sensors no longer detect the constant acceleration and vibration associated with normal drilling. To commence disconnection, a signal must be sent to the device  10  whilst it is in Listening Mode. In one embodiment of the invention, the signal involves the operator slacking off the upper drill string to put the device under a continuous steady compression. If these conditions are constant for a predetermined time period (e.g. 15 minutes) whilst the device  10  is in Listening Mode, the microprocessors will change the device mode to ‘Countdown Mode’. During Countdown mode the operator may send a signal to abort the countdown and reset the device. After a predetermined time period in Countdown Mode the device enters “Disconnect Mode”, in which the operator may send the final signal to disconnect the apparatus. Such a final signal may comprise a specified number (eg  3 ) of consecutive movements, for example tensioning and then slackening of the drill string. Such movements cause a small relative axial movement between clutch housing  38 ″ (which is axially fixed relative to retention sleeve  30 ″) and intermediate sleeve  170 . The relative movement between clutch housing  38 ″ and intermediate sleeve  170  may be detected by a motion sensor such as Hall effect magnet assembly  195 . Hall effect magnet assembly  195  may be disposed within notch  198  on clutch housing  198 , which notch is located within intermediate sleeve  170  when the device  10 ″ is assembled. 
         [0139]    Once the final signal is received the processor is configured to effect disconnection of the device  10 ″ from mandrel  12  (not shown) by first withdrawing brake  180  and then turning spindle  178  to cause relative axial movement between retaining sleeve  30 ″ and clutch housing  38 ″. 
         [0140]    Turning to  FIGS. 9A  to C and  10 , a further embodiment of an aspect of the present invention is a circulating subassembly (circsub)  100 . While circsubs are used in many applications independently of a disconnect device, they are also frequently used together, with either being above the other in a drill string. Preferably, the circsub  100  is used with a disconnect device according to the present invention with the same control module controlling both the disconnect device and the circsub. However, this is not essential. 
         [0141]    Circsub  100  comprises a body  102  with connectors  104 , 106  at each end. Within the body is a control sleeve  108  having an extension  110 . Within the bores  112 ,  114  and  116  of the extension, control sleeve and body respectively is axially slidably disposed a control piston  118 . The extension  110  and control sleeve  108  are fixed and have narrower bores than the body  112  so that, when mud pressure builds in the bores, there is a net force on the piston towards an open position as shown in  FIG. 9B . However, in the absence of mud pressure, a return spring  120 , acting between the control piston and control sleeve, can press the piston towards a closed position shown in  FIG. 90 . In the former position, ports  122  are exposed to the bore  116  and mud therein can bypass further travel done the bore to a BHA and instead escape back up the annulus surrounding the drill string in the well bore. The benefits of a circsub are well known and need no further explanation here. 
         [0142]    A motor  126  is disposed in the control sleeve and has a pinion  128  that drives a sleeve  130  around an axis centred on the longitudinal axis of the tool  100 . The sleeve has a circumferential rack (not visible in the drawings) with which the pinion meshes. The sleeve has castellations  132  (not easily visible in the drawings), at least on one side. The piston  118  likewise has castellations  134  (also not easily visible in the drawings), at least on another side. The respective castellations  132 , 134  are adapted to adopt one of two (or more) different axial orientations with respect to one another depending on the rotary position of one with respect to the other. 
         [0143]    In the open position, ridges of the castellations  132  coincide with grooves of the castellations  134  on the other, and vice versa. Therefore the two sets can interdigitate, and, between them, occupy a shorter axial length than when the ridges on one coincide (angularly) with the ridges on the other. When the castellations interdigitate (and when the mud pressure is elevated), the piston  118  occupies the position shown in  FIG. 9B . However, when the ridges oppose one another, as they do in  FIG. 90 , then regardless of the elevated mud pressure, the piston is prevented from moving to open the ports  122 . 
         [0144]    Movement of the sleeve  130  by the motor  126  is also under to control of a separately powered control unit (not shown) which conveniently is the same sensor module  50  described above, indeed, employing the same sensor package. However, by employing a different control algorithm, the module  50  can determine which motor  52 , 126  to operate, depending on whether the drill string is stuck, needing disconnecting, or merely blocked (or opened, requiring injection of LOM). 
         [0145]    For example, in one routine, a specific combination of rotation speed of the drill string and pump pressure is maintained for specified periods of time to signal the control module to open the circsub. That is, a first combination of events is detected by the sensors that has the effect of readying the control module to receive a second combination of events that effects a command to open. The first combination may comprise a specified rotation speed detected by the accelerometers while the pumps are operational, such condition being maintained for a period of time followed by a pause in both. 
         [0146]    Under normal drilling conditions circumferential rack on sleeve  130  may be engaged by a brake (not shown) controlled by a motor assembly similar to motor assembly  182   b , shown in  FIG. 12 . Such a brake may disengage the rack before sleeve  130  is driven by pinion  128 . The brake advantageously prevents rotation of sleeve  130  relative to the rest of the circsub assembly under normal drilling conditions. This prevents pinion  128  from being rotated by vibrations in the drill string. Such rotation of pinion  128  could otherwise damage motor  126 . 
         [0147]    While the circsub described above is either on or off (open or closed) circ subs are also conceivable that have intermediate positions where the ports are open to differing degrees. This is achieved by having intermediate positions of the interdigitating castellations  132 , 134  where the degree of axial movement permitted to the piston is variable. In that event further sequences of events can instruct the control module to open the circsub to whichever degree is desired. Finally, although rotation is preferably employed for controlling the circsub during normal operation, a further command sequence should be capable of being invoked in the event that the drill string gets stuck and/or the pumps cannot be operated or fail to generate the required pressure differences. Thus a sequence of compressions can also be employed. Being able to fully open the circsub in the event of the drill string sticking may be useful either to help free the drill string or assist its withdrawal if a disconnect is the only remaining option. 
         [0148]    Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of the words, for example “comprising” and “comprises”, means “including but not limited to”, and is not intended to (and does not) exclude other components, integers or steps. 
         [0149]    Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise. 
         [0150]    Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. 
         [0151]    The reader&#39;s attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference. 
         [0152]    All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. 
         [0153]    Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features. 
         [0154]    The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.