Method and apparatus for programmable robotic rotary mill cutting of multiple nested tubulars

Abstract

A methodology and apparatus for cutting shape(s) or profile(s) through well tubular(s), or for completely circumferentially severing through multiple tubulars, including all tubing, pipe, casing, liners, cement, other material encountered in tubular annuli. This rigless apparatus utilizes a computer controlled, downhole robotic three-axis rotary mill to effectively generate a shape(s) or profile(s) through, or to completely sever in a 360 degree horizontal plane wells with multiple, nested strings of tubulars whether the tubulars are concentrically aligned or eccentrically aligned. This is useful for well abandonment and decommissioning where complete severance is necessitated and explosives are prohibited, or in situations requiring a precise window or other shape to be cut through a single tubular or plurality of tubulars.

Claims

1. A cutting tool for cutting a tubular having a tubular bore, the tubular being capable of being disposed in a well bore, comprising: (a) a tool body configured to be lowered into the tubular bore, the tool body having a longitudinal Z-axis, a W-axis of rotation generally perpendicular to the Z-axis, and an anchoring system attached to the tool body, the anchoring system having engaged and non-engaged conditions, wherein during the engaged condition the tool body is anchored relative to the tubular, and during the non-engaged position the tool body is not anchored relative to the tubular; (b) the tool body including a cutting head movably connected to the tool body in both the Z and W axes, the tool body supporting a drive system that includes a first motor drive and a second motor drive; (c) the cutting head being coupled to the first motor drive, wherein the first motor drive causing the cutting head to be moved in the W-axis of rotation relative to the tool body; (d) the cutting head being coupled to the second motor drive, wherein the second motor drive causing the cutting head to be moved in the Z-axis relative to the tool body; (e) the cutting head including: a spindle housing pivotally connected to the cutting head at a pivot, the pivot being located at a first elevation, the spindle housing having: (i) an elongated cutting member with distal and proximal ends, and the elongated cutting member being rotationally connected to the spindle housing, the elongated cutting member having a longitudinal axis spanning between its first and second ends, (ii) the spindle housing having a first lower distal end portion and second upper proximal end portion, the upper proximal end portion being connected to the cutting head at the pivot, the spindle housing and elongated cutting member being able to travel through an arcuate path having first and second extreme arcuate positions, wherein the first extreme arcuate position is more closely aligned with the Z-axis compared to the second extreme arcuate position, and the second extreme arcuate position is more closely aligned with the W-axis compared to the first extreme arcuate position; (f) an arcuate actuator operatively connected to the spindle housing, the actuator having actuator first and second end portions, the first end portion being mounted to the cutting head at an elevational position which is below the first elevation, and at the other of its end portions being mounted to the spindle housing at a position also below the first elevation, the actuator moving the spindle housing and elongated cutting member between first and second extreme arcuate positions; and (g) a third motor drive operably connected to the elongated cutting member causing the elongated cutting member to rotate about the elongated cutting member's longitudinal axis and relative to the spindle housing.

2. The cutting tool of claim 1, wherein the spindle housing includes a support that extends along the length of the elongated cutting member and that supports the elongated cutting member, wherein the actuator attaches to the support.

3. The cutting tool of claim 1, wherein the elongated cutting member has an outer surface and a plurality of cutting blades on the outer surface, the plurality of cutting blades arranged in a plurality of helixes about the outer surface.

4. The cutting tool of claim 1, wherein pivoting the spindle housing moves the elongated cutting member into a cutting position that cuts the tubular initially with the distal end portion of the cutting member and then with the proximal end portion of the cutting member.

5. The cutting tool of claim 1, wherein the actuator is fluid driven.

6. The cutting tool of claim 5, wherein the actuator is a hydraulic cylinder.

7. The cutting tool of claim 1, wherein the elongated cutting member, actuator, and tool body form a triangle below the pivot bearing.

8. The cutting tool of claim 1, wherein the pivot bearing, the attachment of the actuator to the tool body and the attachment of the actuator to the spindle housing form the vertices of a triangle that extends below the pivot bearing.

9. The cutting tool of claim 1, wherein there are a plurality of nested tubulars including an innermost tubular and the tool body is configured to be lowered into the tubular bore of the innermost tubular.

10. The cutting tool of claim 9, wherein the elongated cutting member cuts into each of the nested tubulars when the spindle housing and elongated cutting member are rotated about the pivot, wherein the distal end of the elongated cutting member cuts the innermost tubular member at a first, higher elevation and the distal end of the cutting member cuts an outer tubular member at a second, lower elevation.

11. A cutting tool for severing a plurality of nested tubulars, each tubular having a tubular bore, the nested tubulars being disposed in a well bore and wherein there is an outer tubular and an inner tubular inside the bore of the outer tubular, comprising: (a) tool body configured to be lowered into the tubular bore, the tool body having a longitudinal Z-axis, a W-axis of rotation generally perpendicular to the Z-axis, and an anchoring system attached to the tool body, the anchoring system having engaged and non-engaged conditions, wherein during the engaged condition the tool body is anchored relative to the tubular, and during the non-engaged position the tool body is not anchored relative to the tubular; (b) the tool body including a cutting head movably connected to the tool body in both the Z and W axes, the tool body supporting a drive system that includes a first motor drive and a second motor drive; (c) the cutting head being coupled to the first motor drive, wherein the first motor drive causing the cutting head to be moved in the W-axis of rotation relative to the tool body; (d) the cutting head being coupled to the second motor drive, wherein the second motor drive causing the cutting head to be moved in the Z-axis relative to the tool body; (e) the cutting head coupled to the drive system at a pivot point, wherein the cutting head can travel through an arcuate path; (f) the cutting head including an elongated cutting member having a first lower distal end portion and a second upper proximal end portion; (g) an actuator mounted at one of its end portions to the second end of the cutting head and at the other of its end portions to the tool body at a position spaced below the pivot point, the actuator powering the cutting member to rotate about the pivot bearing through an arc a sufficient amount of rotation to cut both the inner and the outer tubular; and (h) a third motor drive that rotates the elongated cutting member.

12. The cutting tool of claim 11, wherein there are three or more nested tubulars and the cutting member is configured to simultaneously cut each of the nested tubulars as it is rotated about the pivot bearing.

13. The cutting tool of claim 11, wherein the cutting head includes a support that extends along the length of the cutting member and that supports the cutting member, wherein the actuator attaches to the support.

14. The cutting tool of claim 11, wherein the cutting member has an outer surface with a plurality of cutting blades on the outer surface.

15. The cutting tool of claim 11, wherein rotation of the cutting head about the pivot moves the cutting head into a cutting position that cuts the inner tubular initially with the distal end portion of the elongated cutting member and then with the proximal end portion of the elongated cutting member.

16. The cutting tool of claim 11, wherein first motor drive is positioned above the pivot.

17. The cutting tool of claim 11, wherein second motor drive is positioned above the pivot.

18. The cutting tool of claim 11, wherein the cutting member, actuator and tool body form a triangle below the pivot bearing.

19. The cutting tool of claim 11, wherein the pivot bearing, the attachment of the actuator to the tool body and the attachment of the actuator to the cutting head form the vertices of a triangle that extends below the pivot.

20. The cutting tool of claim 19, wherein the cutting member cuts into each of the nested tubulars when the cutting member is rotated about the pivot, wherein the distal end of the cutting member cuts the innermost tubular member at a first, higher elevation and the distal end of the cutting member cuts an outer tubular member at a second, lower elevation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The features, nature, and advantages of the disclosed subject matter will become more apparent from the detailed description set forth below when taken in conjunction with the accompanying drawings.

(2) FIG. 1 depicts the robotic rotary mill cutter of the preferred embodiment.

(3) FIGS. 2A and 2B, depict the upper and lower portions, respectively, of the robotic rotary mill cutter of the preferred embodiment.

(4) FIG. 3 depicts an expanded view of an inserted carbide mill of one embodiment.

(5) FIG. 4A depicts a top view of multiple casings (tubulars) that are non-concentric.

(6) FIG. 4B depicts an isometric view of non-concentric casings (tubulars).

(7) FIG. 5A depicts a portion of the robotic rotary mill cutter as it enters the tubulars.

(8) FIG. 5B depicts a portion of the robotic rotary mill cutter as it is severing multiple casings.

DETAILED DESCRIPTION OF THE INVENTION

(9) Although described with reference to specific embodiments, one skilled in the art could apply the principles discussed herein to other areas and/or embodiments.

(10) Throughout this disclosure casing(s) and tubular(s) are used interchangeably.

(11) This invention provides a method and apparatus for efficiently severing installed tubing, pipe, casing, and liners, as well as cement or other encountered material in the annuli between the tubulars, in one trip into a well bore.

(12) Reference will now be made in detail to the present embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts (elements).

(13) To help understand the advantages of this disclosure the accompanying drawings will be described with additional specificity and detail.

(14) The method generally is comprised of the steps of positioning a robotic rotary mill cutter inside the innermost tubular in a pre-selected tubular or plurality of multiple, nested tubulars to be cut, simultaneously moving the rotary mill cutter in a predetermined programmed vertical X-axis, and also 360 degree horizontal rotary W-axis, as well as the spindle swing arm in a pivotal Y-axis arc.

(15) In one embodiment of the present disclosure the vertical and horizontal movement pattern(s) and the spindle swing arm are capable of being performed independently of each other, or programmed and operated simultaneously in conjunction with each other. The robotic rotary mill cutter is directed and coordinated such that the predetermined pattern is cut through the innermost tubular beginning on the surface of said tubular with the cut proceeding through it to form a shape or window profile(s), or to cut through all installed multiple, nested tubulars into the formation beyond the outermost tubular.

(16) A profile generation system simultaneously moves the robotic rotary mill cutter in a vertical Z-axis, and a 360-degree horizontal rotary W-axis, and the milling spindle swing arm in a pivotal Y-axis arc to allow cutting the tubulars, cement, and formation rock in any programmed shape or window profile(s).

(17) The robotic rotary mill cutter apparatus is programmable to simultaneously or independently provide vertical X-axis movement, 360 degree horizontal rotary W-axis movement, and spindle swing arm pivotal Y-axis arc movement under computer control. A computer having a memory and operating pursuant to attendant software, stores shape or window profile(s) templates for cutting and is also capable of accepting inputs via a graphical user interface, thereby providing a system to program new shape or window profile(s) based on user criteria. The memory of the computer can be one or more of but not limited to RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, floppy disk, DVD-R, CD-R disk or any other form of storage medium known in the art. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC or microchip.

(18) The computer controls the profile generation servo drive systems as well as the milling cutter speed. The robotic rotary mill cutter requires load data to be able to adjust for conditions that cannot be seen by the operator. The computer receives information from torque sensors (see 52, and 53 of FIGS. 2A and 2B) attached to Z-axis, W-axis, Y-axis, and milling spindle drive motor, and makes immediate adaptive adjustments to the feed rate and speed of the vertical Z-axis, the 360 degree horizontal rotary W-axis, the spindle swing arm pivotal Y-axis and the RPM of the milling spindle motor.

(19) Software in communication with sub-programs gathering information from the torque devices, such as a GSE model Bi-Axial transducer Model 6015 or a PCB model 208-M133, directs the computer, which in turns communicates with and monitors the downhole robotic rotary mill cutter and its attendant components, and provides feeds and speeds simultaneously or independently along the vertical Z-axis, the 360 degree horizontal rotary W-axis, as well as the pivotal spindle swing arm Y-axis arc movement.

(20) The shape or window profile(s) are programmed by the operator on a program logic controller (PLC), personal computer (PC), or a computer system designed or adapted for this specific use. The integrated software via a graphical user interface (GUI) or touch screen, such as a Red Lion G3 Series (HM1s), accepts inputs from the operator and provides the working parameters and environment by which the computer directs and monitors the robotic rotary mill cutter.

(21) In the preferred embodiment, the vertical Z-axis longitudinal computer-controlled servo axis uses a hydraulic cylinder, such as the Parker Series 2HX hydraulic cylinder, housing the MTS model M-series absolute analog sensor for ease of vertical Z-axis longitudinal movements, although other methods may be employed to provide up and down vertical movement of the robotic rotary mill cutter.

(22) In a still further embodiment of the present disclosure the vertical Z-axis longitudinal computer-controlled servo axis may be moved with a ball screw and either a hydraulic or electric motor, such as a computer controlled electric servo axis motor, the Fanuc D21001150 servo, with encoder feedback to the computer system by an encoder (see 50 in FIG. 2A) such as the BE1 model H25D series incremental optical encoder. Servo motors and ball screws are known in the art and are widely available from many sources.

(23) In a still further embodiment of the present disclosure, the vertical Z-axis longitudinal computer-controlled servo axis may be moved with a rack and pinion, either electrically or hydraulically driven. Rack and pinion drives are known in the art and are widely available from many sources.

(24) In the preferred embodiment, the rotational computer controlled W-axis rotational movement is an electric servo motor, although other methods may be employed. The rotational computer-controlled W-axis servo motor, such as aFanuc model D21001150 servo, provides 360-degree horizontal rotational movement of the robotic rotary mill cutter through a specially manufactured slewing gear.

(25) Also in the preferred embodiment, the Y-axis pivotal milling spindle swing arm computer-controlled servo axis uses a hydraulic cylinder for ease of use, although other methods may be employed. The Y-axis pivotal milling spindle swing arm computer-controlled servo axis, may utilize the Parker Series 2HX hydraulic cylinder, housing the MTS model M-series absolute analog sensor (see 51 in FIG. 2B) inside the hydraulic cylinder to provide position feedback to the computer controller for pivotal spindle swing arm Y-axis arc movement.

(26) In a still further embodiment of the present disclosure an inertia reference system such as, Clymer Technologies model Terrella6 v2, can provide information that the robotic rotary mill cutter is actually performing the movements sent by the computer controller as a verification reference. If the reference shows a sudden stop, the computer can go into a hold action stopping the robotic rotary mill cutter and requiring operator intervention before resuming milling operations.

(27) The methods and systems described herein are not limited to specific sizes, shapes, or models. Numerous objects and advantages of the disclosure will become apparent as the following detailed description of the multiple embodiments of the apparatus and methods of the present disclosure are depicted in conjunction with the drawings and examples, which illustrate such embodiments.

(28) FIG. 1 depicts the robotic rotary mill cutter 1. The robotic rotary mill cutter 1, shows the position of the vertical Z-axis, and the 360-degree horizontal rotary W-axis, and the milling spindle swing arm pivotal Y-axis.

(29) FIGS. 2A and 2B, depict the upper and lower portions, respectively, of the robotic rotary mill cutter of the preferred embodiment.

(30) Referring to FIG. 2A, a collar 2 is used to attach the umbilical cord (not shown) and cable (not shown) to the body of robotic rotary mill cutter 1. Collar 2 may be exchanged to adapt to different size work strings (not shown). Additionally, the collar 2 provides a quick disconnect point in case emergency removal of the robotic rotary mill cutter 1 is necessary. After the robotic rotary mill cutter 1 is in the cut location, locking hydraulic cylinders 3 are energized to lock the robotic rotary mill cutter 1 into the well bore (not shown). In the preferred embodiment, after the locking hydraulic cylinders 3 have been energized, Z-axis hydraulic cylinder 6 is moved to a down position by extending piston rod 4 allowing the Z-axis slide 5 to extend. This permits the robotic rotary mill cutter 1 to begin cutting at the lowest point of the cut and be raised as needed to complete the severance.

(31) Referring to FIG. 2B, additional locking hydraulic cylinders 7 are available should additional stabilization (if energized) or movement (if not energized) are desired. W-axis servo motor 8 rotates the W-axis rotating body 10 under control of the computer (not shown). W-axis rotating body 10 houses the milling spindle swing arm 14 and the milling spindle swing arm 14 is driven by motor 11 also housed in the W-axis rotating body 10. Milling spindle swing arm 14 is driven by motor 11 through a half-shaft 12 such as Motorcraft modeI6L2Z-3A427-AA.

(32) Half-shaft 12 has a c.Y. joint (not shown) that allows milling spindle swing arm 14 to pivot in an arc from pivot bearing 13 that goes through W-axis rotating body 10. Milling spindle swing arm 14 is moved by Y-axis hydraulic cylinder 16. The rotation of W-axis rotating body 10 requires a swivel joint 9, such as Rotary Systems Model DOXX Completion, to allow power and sense lines (not shown) to motor 11, Y-axis hydraulic cylinder 16, and load cell 54 sense wires (not shown). Carbide cutter 15 is mounted to the milling spindle swing arm 14 and is moved by Y-axis hydraulic cylinder 16 into the cut under computer control.

(33) FIG. 3 depicts an expanded view of one embodiment of an inserted carbide mill 17 that could be attached to milling spindle swing arm 14. Other milling units with different material and/or cutting orientation could be utilized depending on the particular characteristics of the severance to be performed.

(34) FIG. 4A depicts a top view of nested multiple casings (tubulars) 18 that are positioned non-concentrically.

(35) FIG. 4B depicts an isometric view of nested multiple casings (tubulars) 18 that are positioned non-concentrically.

(36) FIG. 5A depicts a portion of the robotic rotary mill cutter 1 as it enters the nested multiple casings (tubulars) 18.

(37) FIG. 5B shows the nested multiple casings (tubulars) 18 with the void that has been created by the robotic rotary mill cutter 1. The profile generation system (not shown) simultaneously moved the robotic rotary mill cutter 1 in a vertical Z-axis, and a 360-degree horizontal rotary W-axis, and the milling spindle swing arm 14 in a pivotal Y-axis arc to allow cutting of the tubulars, cement (not shown), and formation rock (not shown) in any programmed shape or window profile(s) thereby cutting through the multiple casing (tubulars) 18, cement (not shown) or other encountered material in casing annuli (not shown).

(38) The disclosed subject matter covers the scope of functionality in a holistic way. Although described with reference to particular embodiments, those skilled in the art, with this disclosure, will be able to apply the teachings in principles in other ways. All such additional embodiments are considered part of this disclosure and any claims to be filed in the future.