Motor cooling and debris management during milling
12486720 ยท 2025-12-02
Assignee
Inventors
Cpc classification
E21B4/006
FIXED CONSTRUCTIONS
E21B10/60
FIXED CONSTRUCTIONS
International classification
Abstract
In the drilling of oil and gas wells, some fluid isolation valves may be stuck in a closed position and may need to be milled out. Provided are methods and systems to dissipate heat and remove cuttings and shavings generated during milling of these fluid isolation barrier. The methods may include conveying a milling tool into a borehole, wherein the milling tool comprises a motor, a gear box coupled to the motor; a pump coupled to the gear box, and a mill bit coupled to the pump, milling a fluid isolation barrier positioned in the borehole using the milling tool, wherein heat is generated at the mill bit and by the motor during the milling of the fluid isolation barrier, and removing at least a portion of the heat by pumping fluid past the motor and the mill bit using the pump.
Claims
1. A milling tool comprising: a motor; a gear box coupled to the motor; a pump coupled to the gear box; a mill bit coupled to the pump; wherein the pump generates flow past the motor and the mill bit to at least partially remove generated heat; and wherein the pump comprises a housing having a pump inlet and a pump outlet designed to orient flow towards the motor, and wherein the pump outlet is smaller than the pump inlet.
2. The milling tool of claim 1, further comprising a second gear box coupled to the pump, wherein the pump is positioned between the gear box and the second gear box.
3. The milling tool of claim 1, wherein the pump comprises a progressive cavity pump, a centrifugal pump, or any combination thereof.
4. The milling tool of claim 1, wherein the pump comprises a housing having the pump inlet and the pump outlet on one side of the housing.
5. The milling tool of claim 1, wherein the pump comprises a housing having the pump inlet and the pump outlet arranged radially on the housing.
6. The milling tool of claim 1, wherein the motor turns the gear box which turns the pump which turns the mill bit.
7. The milling tool of claim 1, wherein the pump comprises a housing having the pump inlet and the pump outlet with one or more screens positioned with respect to at least the pump inlet to prevent cuttings and shavings from entering the housing.
8. The milling tool of claim 7, wherein the screens have a mesh size from about 0.1 inch to about 1 inch wide and from about 0.5 inch to about 2 inches long.
9. A method comprising: conveying a milling tool into a borehole, wherein the milling tool comprises a motor, a gear box coupled to the motor; a pump coupled to the gear box, and a mill bit coupled to the pump, wherein the pump comprises a housing having a pump inlet and a pump outlet designed to orient flow towards the motor, and wherein the pump outlet is smaller than the pump inlet; milling a fluid isolation barrier positioned in the borehole using the milling tool, wherein heat is generated at the mill bit and by the motor during the milling of the fluid isolation barrier; and removing at least a portion of the heat by pumping fluid past the motor and the mill bit using the pump.
10. The method of claim 9, wherein the milling tool further comprises a second gear box coupled to the pump, wherein the pump is positioned between the gear box and the second gear box.
11. The method of claim 9, wherein the pump comprises a progressive cavity pump, a centrifugal pump, or any combination thereof.
12. The method of claim 9, wherein the pump comprises a housing having the pump inlet and the pump outlet on one side of the housing.
13. The method of claim 9, wherein the pump comprises a housing having the pump inlet and the pump outlet arranged radially on the housing.
14. The method of claim 9, wherein the pump is designed to orient a flow towards the mill bit.
15. The method of claim 9, wherein the pump is designed to orient a flow towards the motor.
16. The method of claim 9, wherein the pump comprises a housing having a pump inlet and a pump outlet with one or more screens positioned with respect to at least the pump inlet to prevent cutting and shaving from entering the housing.
17. The method of claim 16, wherein the screens have a mesh size from about 0.1 inch to about 1 inch wide and from about 0.5 inch to about 2 inches long.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) These drawings illustrate certain aspects of some examples of the present disclosure and should not be used to limit or define the disclosure.
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DETAILED DESCRIPTION
(9) The present disclosure relates to the field of well operations, and more specifically to methods and systems to dissipate heat and remove cuttings and shavings generated during milling of a fluid isolation barrier. The fluid isolation barrier may be defined as any barrier controlling the flow of formation fluid or treatment fluid into the casing including a valve or a plug such as a frac plug, a bridge plug, or a non-sealing plug, for example. The fluid isolation barrier may also be defined as any deposit preventing at least partial flow through the casing such as organic scale, inorganic scale, or any deposit accumulated during the production of the reservoir fluid. Alternatively, or additionally, the deposit may come from any human-made treatment fluid such as a fracturing fluid treatment, for example. The systems may include a milling tool comprising power electronics, a motor coupled to the power electronics, a gear box coupled to the motor, a compensation chamber coupled to the gear box, a pump coupled to the compensation chamber through a flexible joint, and a mill bit coupled to the pump through a flexible joint. Optionally, the systems may include power electronics, a motor coupled to the power electronics, a gear box coupled to the motor, a compensation chamber coupled to the gear box, a pump coupled to the gear box through a flexible joint, a second gear box coupled to the pump through a second flexible joint, and a mill bit coupled to the second gear box through a second compensation chamber and a flexible joint. Further, the pump may be configured to generate flow past the motor to at least partially remove the heat generated by the motor, and also to generate flow past the mill bit to at least partially remove the generated heat, cuttings, and shaving. The pump may be any pump capable of generating fluid flow including progressive cavity pump, centrifugal pump, or any combination thereof, for example.
(10) The centrifugal pump may connect the motor to the mill bit. The centrifugal pump may be designed to act as a pump moving fluid past the mill bit, dissipating heat, and removing cuttings and shavings generated during milling of the fluid isolation barrier. The centrifugal pump may be a multistage centrifugal pump. The centrifugal pump may be housed inside a housing, for example. The centrifugal pump is designed to generate flow with a clearance between the centrifugal pump and the housing such that there is enough space for cuttings and shavings to flow through in case there is no screen to prevent any solid from entering housing or the screen is broken. The clearance may be from about 0.005 inch to about 0.2 inch, or from about 0.02 inch to about 0.08 inch, for example. In embodiments, the systems may include a milling tool comprising a motor, a gear box coupled to the motor, a centrifugal pump coupled to the gear box, and a mill bit coupled to the centrifugal pump. In some embodiments, a second gear box may be coupled between the centrifugal pump and the mill bit. In some embodiments, the centrifugal pump may be added to another pump. In embodiments, the centrifugal pump may have 1 to 20 stages, or from 2 to 8 stages, for example. In some embodiments, the centrifugal pump may produce flow rates from about 1 gallon per minute to about 15 gallons per minute, or from about 2 gallons per minute to about 8 gallons per minute. In embodiments, the centrifugal pump may work at downhole pressures ranging from about 100 psi to about 30,000 psi, or from about 5,000 psi to about 25,000 psi, for example. In embodiments, the centrifugal pump may work at downhole temperatures ranging from about 35 F (4 C.) to about 350 F (177 C.), or from about 150 F (66 C.) to about 300 F (149 C.), for example. The centrifugal pump may be able to handle fluid with viscosity ranging from about 1 cP to about 1,000 cP, or from about 1 cP to about 10 cP, for example.
(11) The progressive cavity pump may be any positive displacement pump capable of generating flow past the motor to at least partially remove the heat generated by the motor, and also generating flow past the mill bit to at least partially remove the generated heat, cuttings, and shaving. The progressive cavity pump may generate flow using any design of sealed cavities and any number of adjacent cavities per stage. The progressive cavity pump may have from one to 10 stages, or from 2 to 8 stages, for example. Further, the progressive cavity pump may have a single lobe design or a multi lobe designs (1:1, 2:1, 3:2, 4:3, 5:4 up to 6:5 lobe designs, for example). The progressive cavity pump may have clearances with its housing ranging from about 0.002 inch to about 0.05 inch, or from about 0.005 inch to about 0.02 inch, for example. In some embodiments, the progressive cavity pump may produce flow rates from about 1 gallon per minute to about 15 gallons per minute, or from about 2 gallons per minute to about 8 gallons per minute. In embodiments, the progressive cavity pump may work at downhole pressures ranging from about 100 psi to about 30,000 psi, or from about 5,000 psi to about 25,000 psi, for example. In embodiments, the progressive cavity pump may work at downhole temperatures ranging from about 35 F (4 C.) to about 350 F (177 C.), or from about 150 F (66 C.) to about 300 F (149 C.), for example. The progressive cavity pump may be able to handle fluid with a viscosity ranging from 1 about cP to about 1,000 cP, or from about 1 cP to about 10 cP, for example.
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(13) Casing 108 may extend along a full length of wellbore 104 as shown in
(14) Fluid isolation barrier 110 may be set within wellbore 104, and in some embodiments may facilitate the use of the stimulation fluid in fracturing formation 106. In this particular embodiment, fluid isolation barrier 110 may hydraulically seal a portion of wellbore 104 below fluid isolation barrier 110 (i.e., section 122 in
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(16) Power electronics 202 may be any power electronics capable of controlling motor 204, gear box 206, second gear box 302, compensation chamber 208, pump 212, mill bit 216, and any other equipment needed in system 200. Motor 204 may be any motor that may be placed downhole capable of generating rotations of mill bit 216 through gear box 206. Gear box 206 may be any gear arranged to reduce the rotational output from motor 204 to mill bit 216 through compensation chamber 208. Compensation chamber 208 may be any compensation chamber capable of handling high pressures and high temperatures typically found downhole as well as any pressure surge and helping in controlling flow rate through pump 212. Flexible joints 210, 214 may be any flexible joint capable of connecting at least two components including pin joint, cardan joint, flexible shaft, gear type joint, or any combination thereof, for example.
(17) Pump 212 may be designed to act as a pump moving fluid past mill bit 216, dissipating heat, and removing cuttings and shavings generated during milling of fluid isolation barrier 110. Pump 212 also pumps fluid past motor 204 to dissipate at least partially the heat generated by motor 204. Pump 212 may be any pump capable of generating fluid flow including progressive cavity pump, centrifugal pump, or any combination thereof, for example. The progressive cavity pump, centrifugal pump, or any combination thereof may be housed inside a housing, for example. The centrifugal pump is designed to generate flow as it rotates with a clearance between the impeller and the housing such that there is enough space for cuttings and shavings to flow through in case there is no screen to prevent any solid from entering housing or the screen is broken. The progressive cavity pump may be any positive displacement pump capable of generating flow past motor 204 to at least partially remove the heat generated by motor 204, and generating flow past mill bit 216 to at least partially remove the generated heat, cuttings, and shaving. The progressive cavity pump may generate flow using any design of sealed cavities and any number of adjacent cavities per stage including from 1 to 10 stages as described above, for example.
(18) Mill bit 216 may include a bit body having one or more blades, knives, or other cutting structure thereon. These blades or other cutting structures may further include or be coupled to cutting elements configured to grind, mill, degrade, or break-up fluid isolation barrier 110 (referring to
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(20) Power electronics 202 may be any power electronics capable of controlling motor 204, gear box 206, compensation chamber 208, pump 212, second gear box 302, second compensation chamber 304, mill bit 216, and any other equipment needed on system 100, 200, or 300. Motor 204 may be any motor that may be placed downhole. Motor 204 may be any motor that may be placed downhole capable of generating rotation of mill bit 216 through gear box 206. Gear box 206 may be any gear arranged to reduce the rotational output from motor 204 to second gear box 302 to mill bit 216 through compensation chamber 208. Gear box 206 and second gear box 302 may be any gear arranged to reduce the rotational output from motor 204 to mill bit 216 through compensation chamber 208 and second compensation chamber 304. Compensation chamber 208 and second compensation chamber 304 may be any compensation chamber capable of handling high pressures and high temperatures typically found downhole as well as any pressure surge and helping in controlling flow rate through pump 212. Flexible joints 210, 214 may be any flexible joint capable of connecting at least two components including pin joint, cardan joint, flexible shaft, gear type joint, or any combination thereof, for example.
(21) Pump 212 is added to remove at least partially the heat generated by motor 204, and also to generate flow past mill bit 216 to at least partially remove the generated heat, cuttings, and shaving. Pump 212 may be any pump capable of generating fluid flow including progressive cavity pump, centrifugal pump, or any combination thereof, for example. Pump 212 may connect motor 204 to mill bit 216. Pump 212 may be designed to act as a pump moving fluid past mill bit 216, dissipating heat, and removing cuttings and shavings generated during milling of fluid isolation barrier 110. Pump 212 may be placed in between gear box 206 and second gear box 302 as illustrated in
(22) Mill bit 216 may be operated using information handling system (not shown) that sends commands through power electronics 202 to motor 204 that engages gear box 206 that reduces the rotational output from motor 204 to mill bit 216 through compensation chamber 208 and second gear box 302 through second compensation chamber 304. Mill bit 216 may include a bit body having one or more blades, knives, or other cutting structure thereon. These blades or other cutting structures may further include or be coupled to cutting elements configured to grind, mill, degrade, or break-up fluid isolation barrier 110 (referring to
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(24) System 200 may be configured to grind, mill, degrade, or break-up fluid isolation barrier 110 (e.g., referring to
(25) System 200 in
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(29) In embodiments, the two pump inlets 402 may be spaced apart by from about 5 to about 355 and any angle in-between including from about 15 to about 345, from about 30 to about 330, from about 45 to about 300, from about 60 to about 270, from about 90 to about 245, from about 120 to about 210, from about 150 to about 180, for example.
(30) In embodiments, the two pump outlets 404 may be spaced apart by from about 5 to about 355 and any angle in-between including from about 15 to about 345, from about 30 to about 330, from about 45 to about 300, from about 60 to about 270, from about 90 to about 245, from about 120 to about 210, from about 150 to about 180, for example.
(31) In alternative embodiments, pump 212 may comprise three pump inlets 402 and two pump outlets 404 on pump housing 406 or vice versa, two pump inlets 402 and three pump outlets 404, for example. In embodiments, pump 212 may comprise three pump inlets 402 and three pump outlets 404. In embodiments, pump 212 may comprise four or more pump inlets 402 and/or three or more pump outlets 404. In embodiments, pump 212 may comprise three or more pump inlets 402 and four or more pump outlets 404. In embodiments, pump 212 may comprise one pump inlet 402 and two or more pump outlets 404 or vice versa.
(32) The preceding description provides various examples of the systems and methods of use disclosed herein which may contain different method steps and alternative combinations of components. It should be understood that, although individual examples may be discussed herein, the present disclosure covers all combinations of the disclosed examples, including, without limitation, the different component combinations, method step combinations, and properties of the system. It should be understood that the compositions and methods are described in terms of comprising, containing, or including various components or steps, the compositions and methods may also consist essentially of or consist of the various components and steps. Moreover, the indefinite articles a or an, as used in the claims, are defined herein to mean one or more than one of the elements that it introduces. The systems and methods may comprise any of the various features disclosed herein, comprising one or more of the following statements.
(33) Statement 1. A milling tool comprising: a motor; a gear box coupled to the motor; a pump coupled to the gear box; a mill bit coupled to the pump; and wherein the pump generates flow past the motor and the mill bit to at least partially remove generated heat
(34) Statement 2. The milling tool of statement 1, further comprising a second gear box coupled to the pump, wherein the pump is positioned between the gear box and the second gear box
(35) Statement 3. The milling tool of statement 1 or statement 2, wherein the pump comprises a progressive cavity pump, a centrifugal pump, or any combination thereof.
(36) Statement 4. The milling tool of any one of statements 1-3, wherein the pump comprises a housing having a pump inlet and a pump outlet on one side of the housing.
(37) Statement 5. The milling tool of any one of statements 1-4, wherein the pump comprises a housing having a pump inlet and a pump outlet arranged radially on the housing.
(38) Statement 6. The milling tool of any one of statements 1-5, wherein the motor turns the gear box which turns the pump which turns the mill bit.
(39) Statement 7. The milling tool of any one of statements 1-6, wherein the pump comprises a housing having a pump inlet and a pump outlet designed to orient flow towards the motor, and wherein the pump outlet is smaller than the pump inlet.
(40) Statement 8. The milling tool of any one of statements 1-7, wherein the pump is designed to orient one flow from the motor to the mill bit on one side of the milling tool and another flow from the mill bit to the motor on another side of the milling tool.
(41) Statement 9. The milling tool of any one of statements 1-8, wherein the pump comprises a housing having a pump inlet and a pump outlet with one or more screens positioned with respect to at least the pump inlet to prevent cuttings and shavings from entering the housing.
(42) Statement 10. The milling tool of any one of statements 1-9, wherein the screens have a mesh size from about 0.1 inch to about 1 inch wide and from about 0.5 inch to about 2 inches long.
(43) Statement 11. A method comprising: conveying a milling tool into a borehole, wherein the milling tool comprises a motor, a gear box coupled to the motor; a pump coupled to the gear box, and a mill bit coupled to the pump; milling a fluid isolation barrier positioned in the borehole using the milling tool, wherein heat is generated at the mill bit and by the motor during the milling of the fluid isolation barrier; and removing at least a portion of the heat by pumping fluid past the motor and the mill bit using the pump.
(44) Statement 12. The method of statement 11, wherein the milling tool further comprises a second gear box coupled to the pump, wherein the pump is positioned between the gear box and the second gear box.
(45) Statement 13. The method of statement 11 or statement 12, wherein the pump comprises a progressive cavity pump, a centrifugal pump, or any combination thereof.
(46) Statement 14. The method of any one of statements 11-13, wherein the pump comprises a housing having a pump inlet and a pump outlet on one side of the housing.
(47) Statement 15. The method of any one of statements 11-14, wherein the pump comprises a housing having a pump inlet and a pump outlet arranged radially on the housing.
(48) Statement 16. The method of any one of statements 11-15, wherein the pump is designed to orient a flow towards the mill bit.
(49) Statement 17. The method of any one of statements 11-16, wherein the pump is designed to orient a flow towards the motor.
(50) Statement 18. The method of any one of statements 11-17, wherein the pump is designed to orient one flow from the motor to the mill bit on one side of the milling tool and another flow from the mill bit to the motor on another side of the milling tool.
(51) Statement 19. The method of any one of statements 11-18, wherein the pump comprises a housing having a pump inlet and a pump outlet with one or more screens positioned with respect to at least the pump inlet to prevent cutting and shaving from entering the housing.
(52) Statement 20. The method of any one of statements 11-19, wherein the screens have a mesh size from about 0.1 inch to about 1 inch wide and from about 0.5 inch to about 2 inches long.
(53) For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, from about a to about b, or, equivalently, from approximately a to b, or, equivalently, from approximately a-b) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.
(54) Therefore, the present examples are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular examples disclosed above are illustrative only, and may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual examples are discussed, the disclosure covers all combinations of all of the examples. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative examples disclosed above may be altered or modified and all such variations are considered within the scope and spirit of those examples. If there is any conflict in the usages of a word or term in this specification and one or more patent(s) or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.