Downhole tubular milling apparatus, especially suitable for deployment on coiled tubing

Abstract

An apparatus for cutting and/or milling of tubulars in a wellbore, especially using coiled tubing. An elongated main body has a longitudinal bore, with a piston slidably positioned in the bore. The piston is connected to one or more operating arms which are rotatably connected to the main body. The connection between the piston and the operating arms may be a pinned connection or a geared connection, both of which provide for a positive connection between the piston and the operating arms. Cutter bases are connected to the cutter arms, with a number of cutters mounted to the cutter bases. Fluid flow down the coiled tubing and through the main body bore pushes the piston downwardly, opening the operating arms and cutter bases and permitting the apparatus to be pulled up into the lower end of a tubular string for cutting and/or milling.

Claims

1. An apparatus for cutting and milling of downhole tubulars in a wellbore, comprising: a main body having a bore therein, the main body being configured for connection to a coiled tubing string; a piston slidably disposed in said main body bore and movable between an upper position and a lower position; a plurality of operating arms movable between a first, retracted position and a second, extended position, by movement of said piston in said main body bore; a plurality of cutter bases connected to said operating arms, and one or more cutters attached to each of said plurality of cutter bases; and one or more link members connecting each of said plurality of cutter bases to said main body, whereby each of said plurality of cutter bases is maintained substantially parallel to said main body in each of said first and second positions; wherein the apparatus is configured to be pulled upward by the coiled tubing string to mill in an uphole direction.

2. The apparatus of claim 1, wherein an upper section of each of said cutter bases has no cutters mounted thereon, forming a stabilizer section.

3. The apparatus of claim 1, whereby said piston is connected to said operating arms by a pinned connection.

4. The apparatus of claim 1, whereby said piston is connected to said operating arms by a toothed gear.

5. The apparatus of claim 1, further comprising a piston locking mechanism for locking said piston in said lower position, whereby said operating arms are locked in their second, extended position.

6. The apparatus of claim 1, wherein the lowermost or downhole ends of the cutter bases are configured for milling or cutting a tubular.

7. A tubular milling assembly, comprising: a length of coiled tubing string disposed in a wellbore; a tubular milling apparatus attached to said coiled tubing string and positioned at a desired depth in said wellbore, said tubular milling apparatus comprising: a main body having a bore therein; a piston slidably disposed in said main body bore and movable between an upper position and a lower position; a plurality of operating arms movable between a first, retracted position and a second, extended position by movement of said piston in said main body bore; a plurality of cutter bases connected to said operating arms, and one or more cutters attached to each of said plurality of cutter bases; one or more link members connecting each of said plurality of cutter bases to said main body, whereby each of said plurality of cutter bases is maintained substantially parallel to said main body in each of said first and second positions; and a device for rotating the apparatus; wherein the apparatus is configured to be pulled upward by the coiled tubing string to mill in an uphole direction.

8. The assembly of claim 7, wherein the tubular milling apparatus further comprises an upper section of each of said cutter bases has no cutters mounted thereon, forming a stabilizer section.

9. The assembly of claim 7, whereby said piston is connected to said operating arms by a pinned connection.

10. The assembly of claim 7, whereby said piston is connected to said operating arms by a toothed gear.

11. The assembly of claim 7, further comprising a piston locking mechanism for locking said piston in said lower position, whereby said operating arms are locked in their second, extended position.

12. The assembly of claim 7, wherein the device for rotating the apparatus comprises a downhole mud motor.

13. The assembly of claim 7, wherein the device for rotating the apparatus comprises a surface rotary device which is configured to rotate the coiled tubing string.

14. The assembly of claim 7, wherein the lowermost or downhole ends of the cutter bases are configured for milling or cutting a tubular.

15. A method for milling tubulars in a wellbore, comprising the steps of: a) providing a tubular milling assembly comprising: a tubular milling apparatus comprising: a main body having a bore therein, the main body being configured for connection to a coiled tubing string; a piston slidably disposed in said main body bore and movable between an upper position and a lower position; a plurality of operating arms movable between a first, retracted position and a second, extended position by movement of said piston in said main body bore; a plurality of cutter bases connected to said operating arms, and one or more cutters attached to each of said plurality of cutter bases; and one or more link members connecting each of said plurality of cutter bases to said main body, whereby each of said plurality of cutter bases is maintained substantially parallel to said main body in each of said first and second positions; b) lowering said tubular milling assembly to a desired position in said wellbore, below a lower end of a tubular to be milled; c) pumping fluid through said coiled tubing string to move the piston to a lower position and thereby move the operating arms into a second, extended position; d) rotating the apparatus; and e) lifting said tubular milling apparatus by said coiled tubing string so as to engage said lower end of said tubular, and maintaining fluid flow and tension on said apparatus.

16. The method of claim 15, further comprising rotating a downhole mud motor.

17. The method of claim 15, further comprising rotating a surface rotary device to rotate the coiled tubing string.

18. The method of claim 15, further comprising milling or cutting a tubular using lowermost or downhole ends of the cutter bases.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a side view in partial cross section of the apparatus, with the piston in an uphole position and the cutter bases in a first, closed position.

(2) FIG. 2 is a side view in partial cross section of the apparatus, with the piston in an downhole position and the cutter bases in a second, open position.

(3) FIG. 3 shows an exemplary bottom hole assembly comprising the apparatus on the bottom, a cross over sub, and a mud motor, connected as shown to a workstring, for example a coiled tubing string.

(4) FIG. 4 shows another embodiment of the apparatus, in an open position.

(5) FIG. 5 shows a gear type connection between the piston and the operating arms.

(6) FIG. 6 shows another embodiment of the apparatus, with a piston locking mechanism.

(7) FIG. 7 is a detailed view of the releasing sleeve seen in FIG. 6.

(8) FIG. 8 shows the releasing sleeve in its lower position.

DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENT(S)

(9) While various apparatus can embody the principles of the present invention, with reference to the drawings some of the presently preferred embodiments can be described.

(10) As can be seen in FIGS. 1 and 2, apparatus 10 comprises a main body 20, which is generally elongated with a longitudinal bore 22 therethrough. Main body 20 comprises a means for attachment to a tubular string, which may be a coil tubing string, at its upper or uphole end. Uphole/downhole relative direction and orientation is noted on the drawings.

(11) A plurality of cutter bases 30 are hingedly attached to main body 20 by a plurality of link arms 32, the uppermost of which comprises a plurality of operating arms 34 as will be later described. As readily understood from the drawings, link arms 32 and operating arms 34 are preferably of substantially equal length, so that cutter bases 30 are substantially parallel to main body 20, as cutter bases 30 move from a first, substantially retracted position as in FIG. 1, to a second, substantially extended position as in FIG. 2. Preferably cutter bases 30 have angled lower ends 31 covered with hardened cutting surfaces, to clean out metal, cement, etc. which may be encountered. Lower end 23 of main body 20 may be pointed.

(12) A piston 40 is disposed in bore 22 of main body 20. Piston 40 is slidably disposed, and is biased in an uphole or upward direction by spring 50. Piston 40 is connected to operating arms 34 by a pinned connection, as seen in FIG. 2, whereby operating arms 34 can rotate relative to piston 40, but as is readily understood movement of piston 34 necessarily results in rotation of operating arms 34 inwardly (as the piston moves uphole) or outwardly (as the piston moves downhole).

(13) Piston 40 has a central longitudinal bore 41. An interchangeable jet 48 may be provided to control fluid flow through bore 41. A seal 42 may be provided between piston 40 and bore 22. Fluid pumped down the coiled tubing string, and through bore 22 of main body 20, and the bore of piston 40, at a sufficient rate, will overcome the force exerted by spring 50 and force piston 40 downhole. As described, this will in turn rotate operating arms 34 outwardly, causing cutter bases 30 to move radially outward. When fluid flow ceases, spring 50 moves piston 40 uphole, and cutter bases 30 are moved to their first position as in FIG. 1.

(14) A plurality of cutters 60 are mounted on cutter bases 30, spaced in a desired pattern. Preferably, cutters 60 are covered with a hardened cutting material to enable efficient cutting/milling of tubulars. Preferably, a section on cutter bases 30, denoted as stabilizer section “SS” in the figures, generally at an upper or uphole end of the cutter bases, has no cutters mounted thereon, providing a stabilizer section as will be later described.

(15) FIG. 4 shows another embodiment of the apparatus in an open (cutting) position, with dimensions changed so as to yield a larger area between the end of main body 20 and cutter bases 30.

(16) FIG. 5 shows an embodiment of the present invention comprising a geared connection between piston 40 and operating arms 34. Gear teeth 43 on piston 40 engage gear teeth 33 on operating arms 32, such that movement upwardly and downwardly of piston 40 necessarily results in rotation of operating arms 34 inwardly and outwardly, as indicated by the arrows in FIG. 5. Note also the provision for a jetted sub 24 comprising jets 25, positioned above main body 20. Jets 25 permit diverting some portion of the total fluid flow into the annulus.

(17) Use of the Apparatus

(18) An exemplary use of the apparatus can now be described, with reference to the drawings. Although use is described in connection with coiled tubing as the workstring, it is understood that jointed tubulars can also be used as the workstring.

(19) Referring to FIG. 1, apparatus 10 is shown with cutter bases 30 in their first, substantially retracted position. Piston 40 is biased to an uphole position by spring 50, and operating arms 34 and cutter bases 30 are necessarily retracted. Apparatus 10 is attached to the end of a coiled tubing string as the workstring (shown) and run into a wellbore, and positioned typically as shown in FIG. 1, with cutters 60 below a lower end of a previously cut casing string, and with the stabilizer section SS positioned within the casing string.

(20) In FIG. 2, fluid circulation down the bore of the coiled tubing string has started, as indicated by the arrows, overcoming the uphole force from spring 50 and pushing piston 40 downhole. By the pin connection (or alternatively the geared connection) between piston 40 and operating arms 34, operating arms 34 are rotated outwardly, moving cutter bases 30 to their second, open position, with the stabilizer section SS of cutter bases 34 bearing against the inner wall of the casing string. Apparatus 10 is then pulled sufficiently uphole that cutters 60 contact the lower end of the casing string. Apparatus 10 is then rotated, for example by a mud motor downhole (see the exemplary bottomhole assembly shown in FIG. 3), while tension is applied to the coiled tubing and cutters 60 bear against and cut/mill the lower end of the tubing. FIG. 3 shows an exemplary bottomhole arrangement of apparatus 10, a crossover sub 12, and a downhole mud motor 14, for example a positive displacement mud motor. The mud motor may be arranged for left hand (counterclockwise) rotation, as are the appropriate downhole threaded connections, to avoid backing off the threaded connections of the casing string being milled. It is understood that any type of fluid powered rotary device may be used, including positive displacement motors (“mud motors”), turbines, or other suitable rotary devices. It is further understood that the apparatus may be used on workstrings rotated from the surface, by the rotary of a drilling/workover rig, power swivel, etc.

An Embodiment Comprising a Piston Locking Mechanism

(21) As can be readily understood from the foregoing description, when the apparatus is cutting in an upward direction (namely, being pulled upward by the coiled tubing, and thus pulled upward into the lowermost end of the cut casing string), the forces on the cutter bases/cutters tend to push them downward, thus tending to rotate the operating and link arms toward their retracted position, and to force the piston upward, thereby collapsing the apparatus. The force exerted on the piston by the fluid flow is what resists this movement.

(22) In another embodiment shown in FIG. 6, with further detail in FIG. 7, the apparatus comprises a piston locking mechanism which positively locks the piston in its downward position, in turn locking the operating and link arms in their outward position, and the cutter bases/cutters in their outer position.

(23) Referring to FIGS. 6 and 7, piston 40 comprises a chamber 44 at its upper end, above bore 41. Piston releasing sleeve 45 is releasably fixed in chamber 44 by means of a shear pin 200 or similar means. Piston releasing sleeve 45 has a ball seat 46 and a bore 47 therethrough, as can be seen in FIG. 6 and in more detail in FIG. 7. A jet 48 with a suitably sized hole therethrough is preferably positioned in the bore of the piston below the chamber, to control fluid flow through the bore. One or more dogs 100 are rotatably fixed to the piston, such that one end 101 (namely, an upper end) can rotate outwardly (typically under a spring bias, see exemplary spring 102 shown in schematical form), beyond the outer diameter of piston 40, while the other (lower) end 103 of the dogs extend into piston chamber 44. When piston 40 is moved (by fluid flow) to its lowermost position, dogs 100 (under influence of spring 102) toggle outwardly and engage recess 26 in bore 22 of main body 20, locking piston 40 in that lowermost position.

(24) To retrieve apparatus 10, it is necessary to release piston 40, allow the piston 40 to move upward in response to spring 50 (and/or force applied to cutter bases 30/cutters 60 by pulling upward into the casing), and operating arms 34/cutter bases 30 to move to their retracted position. To do so, a suitably sized ball 300 is released down the workstring bore, ball 300 ultimately seating on ball seat 46 and sealing thereon. Continued pressure shears shear pin 200 holding piston releasing sleeve 45 in place, forcing it downwardly in piston chamber 44. This movement of piston releasing sleeve 45 forces the lower ends 103 of dogs 100 radially outward, rotating locking ends 101 out of engagement with recess 26 in main body bore 22. Piston 40 then moves upwardly in response to the bias from spring 50, and the operating arms/cutter bases move to their retracted position. The tool can then be pulled up through the bore of the workstring and retrieved. FIG. 8 shows releasing sleeve 45 in its lowermost position, pushing the lower ends 103 of dogs 100 and rotating the upper ends 101 out of engagement with recess 26, thereby unlocking the mechanism.

(25) Release or Disconnect Mechanism

(26) In the event that the apparatus cannot be retrieved through the bore of the workstring (e.g. in the event that the operating arms/cutter bases are lodged in an open position), the scope of the invention further comprises a release mechanism, which may be employed in this instance to release the apparatus from the workstring. While different mechanisms may serve this purpose and are included within the scope of the invention, a hydraulic release or disconnect, various types of which are known in the relevant art, may be added to the assembly.

(27) Materials, Methods of Fabrication

(28) Materials suitable for the present invention are those well known in the relevant field, including high strength metals and alloys thereof, and resilient elements for seals and the like. Fabrication and assembly of the apparatus may be by processes well known in the relevant art.

CONCLUSION

(29) While the preceding description contains many specificities, it is to be understood that same are presented only to describe some of the presently preferred embodiments of the invention, and not by way of limitation. Changes can be made to various aspects of the invention, without departing from the scope thereof.

(30) Therefore, the scope of the invention is to be determined not by the illustrative examples set forth above, but by the appended claims and their legal equivalents.