Cutter for wellbore casing
A cutter for a wellbore casing is provided that includes a rotatable tubular support, at least one cutter blade supported on the rotatable tubular support, having a retracted position for insertion into the wellbore casing and having an expanded position for cutting engagement with the wellbore casing, and an actuator for moving the cutter blade from the retracted position to the expanded position for cutting engagement with the wellbore casing.
The present application is the National Stage patent application for PCT patent application serial number PCT/US2003/029858, attorney docket number 25791.112.02, filed on 22 Sep. 2003, which claimed the benefit of the filing dates of (1) U.S. provisional patent application Ser. No. 60/412,487, attorney docket no 25791.112, filed on Sep. 20, 2003, the disclosures of which are incorporated herein by reference.
The present application is a continuation-in-part of U.S. utility patent application serial number______, attorney docket number 25791.104.02, filed on______, which was the National Stage application for PCT application serial number PCT/US2003/014153, attorney docket number 25791.104.02, filed on May 6, 2003, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/380,147, attorney docket number 25791.104, filed on May 6, 2002, which was a continuation-in-part of U.S. utility patent application Ser. No. 10/507,567, attorney docket number 25791.95.03, filed on Sept. 13, 2004, which was the National Stage application for PCT application serial number PCT/US2003/004837, attorney docket number 25791.95.02, filed on Feb. 19, 2003, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/363,829, attorney docket number 25791.95, filed on Mar. 13, 2002, which was a continuation-in-part of both of: (1) U.S. utility patent application Ser. No. 10/495,347, attorney docket number 25791.87.05, filed on May 12, 2004, which was filed as the National Stage application for PCT application serial number PCT/US2002/036157, attorney docket number 25791.87.02, filed on Nov. 12, 2002, which claimed the benefit of the filing date of U.S. provisional application Ser. No. 60/338,996, attorney docket number 25791.87, filed on Nov. 12, 2001; and (2) U.S. utility patent application Ser. No. 10/495,344, attorney docket number 25791.88.05, filed on May 12, 2004, which was filed as the National Stage application for PCT application serial number PCT/US2002/036267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, which claimed the benefit of the filing date of U.S. provisional application Ser. No. 60/339,013, attorney docket number 25791.88, filed on Nov. 12, 2001, the disclosures of which are incorporated herein by reference.
The present application is related to the following: (1) U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, (4) U.S. Pat. No. 6,328,113, (5) U.S. patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, (10) PCT patent application Ser. No. PCT/US00/18635, attorney docket no. 25791.25.02, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, attorney docket no. 25791.45, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000, (20) U.S. provisional patent application Ser. No. 60/233,638, attorney docket no. 25791.47, filed on Sep. 18, 2000, (21) U.S. provisional patent application Ser. No. 60/237,334, attorney docket no. 25791.48, filed on Oct. 2, 2000, (22) U.S. provisional patent application Ser. No. 60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001, (23) U.S. provisional patent application Ser. No. 60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001, (24) U.S. provisional patent application Ser. No. 60/259,486, attorney docket no. 25791.52, filed on Jan. 3, 2001, (25) U.S. provisional patent application Ser. No. 60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001, (26) U.S. provisional patent application Ser. No. 60/313,453, attorney docket no. 25791.59, filed on Aug. 20, 2001, (27) U.S. provisional patent application Ser. No. 60/317,985, attorney docket no. 25791.67, filed on Sep. 6, 2001, (28) U.S. provisional patent application Ser. No. 60/3318,386, attorney docket no. 25791.67.02, filed on Sep. 10, 2001, (29) U.S. utility patent application Ser. No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, (30) U.S. utility patent application Ser. No. 10/016,467, attorney docket no. 25791.70, filed on Dec. 10, 2001, (31) U.S. provisional patent application Ser. No. 60/343,674, attorney docket no. 25791.68, filed on Dec. 27, 2001, (32) U.S. provisional patent application Ser. No. 60/346,309, attorney docket no 25791.92, filed on Jan. 7, 2002, (33) U.S. provisional patent application Ser. No. 60/372,048, attorney docket no. 25791.93, filed on Apr. 12, 2002, (34) U.S. provisional patent application Ser. No. 60/380,147, attorney docket no. 25791.104, filed on May 6, 2002, (35) U.S. provisional patent application Ser. No. 60/387,486, attorney docket no. 25791.107, filed on Jun. 10, 2002, (36) U.S. provisional patent application Ser. No. 60/387,961, attorney docket no. 25791.108, filed on Jun. 12, 2002, (37) U.S. provisional patent application Ser. No. 60/391,703, attorney docket no. 25791.90, filed on Jun. 26, 2002, (38) U.S. provisional patent application Ser. No. 60/397,284, attorney docket no. 25791.106, filed on Jul. 19, 2002, (39) U.S. provisional patent application Ser. No. 60/398,061, attorney docket no. 25791.110, filed on Jul. 24, 2002, (40) U.S. provisional patent application Ser. No. 60/405,610, attorney docket no. 25791.119, filed on Aug. 23, 2002, (41) U.S. provisional patent application Ser. No. 60/405,394, attorney docket no. 25791.120, filed on Aug. 23, 2002, (42) U.S. provisional patent application Ser. No. 60/412,177, attorney docket no. 25791.117, filed on Sep. 20, 2002, (43) U.S. provisional patent application Ser. No. 60/412,653, attorney docket no. 25791.118, filed on Sep. 20, 2002, (44) U.S. provisional patent application Ser. No. 60/412,544, attorney docket no. 25791.121, filed on Sep. 20, 2002, (45) U.S. provisional patent application Ser. No. 60/412,187, attorney docket no. 25791.128, filed on Sep. 20, 2002, (46) U.S. provisional patent application Ser. No. 60/412,187, attorney docket no. 25791.127, filed on Sep. 20, 2002, (47) U.S. provisional patent application Ser. No. 60/412,542, attorney docket no. 25791.102, filed on Sep. 20, 2002, and (48) U.S. provisional patent application Ser. No. 60/412,488, attorney docket no. 25791.114, filed on Sep. 20, 2002, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTIONThis invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration.
Conventionally, when a wellbore is created, a number of casings are installed in the borehole to prevent collapse of the borehole wall and to prevent undesired outflow of drilling fluid into the formation or inflow of fluid from the formation into the borehole. The borehole is drilled in intervals whereby a casing which is to be installed in a lower borehole interval is lowered through a previously installed casing of an upper borehole interval. As a consequence of this procedure the casing of the lower interval is of smaller diameter than the casing of the upper interval. Thus, the casings are in a nested arrangement with casing diameters decreasing in downward direction. Cement annuli are provided between the outer surfaces of the casings and the borehole wall to seal the casings from the borehole wall. As a consequence of this nested arrangement a relatively large borehole diameter is required at the upper part of the wellbore. Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings. Moreover, increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.
The present invention is directed to overcoming one or more of the limitations of the existing procedures for forming and/or repairing wellbore casings.
SUMMARY OF THE INVENTIONAccording to one aspect of the present invention, a cutter for an expandable wellbore casing is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
In the exemplary embodiment illustrated, the cutter tool 10 is a modular device including a tubular support 28 that can be attached at a conventional upper coupling 30 axially aligned with a conventional drill pipe or other portion of a down hole string (not shown). Similarly other conventional tools, other conventional expansion tools or other tubular expansion tools as described in patents and co-pending patent applications incorporated above by reference, may be connected at a conventional lower coupling 32. In the illustrated embodiment of the cutter tool 10, cutter blades 34 are expandably attached circumferentially space around the tubular support 28. An expander device 36 is attached to the tubular support for selectively moving the cutter blades 34 to expand or to retract.
With reference to
In the illustrative embodiment, shown in greater detail in
An activation device 76 is provided, for example, the activation device may include an opening dart 76A, that is ported to direct fluidic material 78 into and out of the opening and closing chambers 62 and 64. The opening dart 76 provides and entry fluidic passage 80 that is in fluid communication with the upstream fluid passage 72, and seats at seat 82 within the upstream fluid passage 72 axially aligned with the opening port 68 and an annulus 84 to provide a path for fluidic material 78 into the opening camber 62, regardless of the rotational orientation of the opening dart 76A. An exit fluidic passage 86 is also provided in the opening dart 76A. When the opening dart seats at seat 82, the fluidic passage 86 becomes aligned with the closing port 72 and an annulus 88 for allowing fluidic material 78 to escape from the closing chamber 64, and into the down stream passage 74 in the interior of the mandrel 48. Thus, a differential pressure results and the opening piston 56 is moved. Movement of the opening piston 56 causes the sliding sleeve 58 to slide, thereby causing the ramp surfaces 40 to move under and along the interior surfaces 42 of the cutter blades 34. The cutter blades 34 are thus pivoted outwardly thereby moving the cutting tips 52 radially outward to a cutting position. It will be understood based upon the present disclosure that a conventional actuating device for selectively directing fluidic material in a down hole tool may be used as an alternative to the illustrated activation device 76. It will also be understood that a conventional device for otherwise selectively actuating the cutter blades 34 to expand may also be used as an alternative to the actuator 50 without departing form certain aspects of the invention.
With reference also to
In
Thus what has been disclosed in the several exemplary embodiments is a cutter tool for a wellbore casing including a rotatable tubular support, at least one cutter blade supported on the rotatable tubular support, the cutter blade having a retracted position for insertion into the wellbore casing and an expanded position for cutting engagement with the wellbore casing and an actuator for moving the cutter blade from the retracted position to the expanded position for cutting engagement with the wellbore casing.
In one embodiment, the cutter tool further includes an expander device coupled to the actuator and the cutter blade is pivotably mounted on the expander device.
In another embodiment, the cutter blade includes an interior sliding surface and an expander device includes a ramp surface moveable by the actuator along the tubular support in sliding engagement with the interior sliding surface of the cutter blade to pivot the cutter blade between the retracted position and the expanded position.
In another embodiment, the cutter tool includes a plurality of cutter blades each pivotably mounted on a expander device and each having an interior sliding surface and wherein the expander device includes an expander cone supported on a mandrel portion of the tubular support and the expander device having a plurality of ramp surfaces slidingly engaged with each interior sliding surface of the plurality of cutter blades.
In another embodiment of the cutter tool, the actuator for moving the cutter device from the retracted position to the expanded position includes an activation device for selectively activating the actuator to move the cutter blades from the retracted position to the expanded position for cutting engagement with the wellbore casing.
In another embodiment the actuator includes a hydraulic cylinder attached to the tubular support and coupled to the expander device and wherein the activation device comprises an activation dart seatable within a fluid passage through the cutter tool for directing fluidic material into the hydraulic cylinder to cause relative sliding movement of the expander cone on the mandrel portion of the tubular support.
In another embodiment the actuator for moving the cutter device from the retracted position to the expanded position further includes means for selectively activating the actuator to move the cutter blades from the retracted position to the expanded position for cutting engagement with the wellbore casing and from the expanded position to the retracted position.
In another embodiment the actuator includes a hydraulic cylinder attached to the tubular support and coupled to the expander device, the hydraulic cylinder having an opening chamber for moving the cone in an axial direction for expanding the cutter blades and having a closing cylinder for moving the expander cone in an opposite axial direction for retracting the cutter blade and wherein the activation device comprises a first activation dart seatable in the tubular support for directing fluidic material into the opening chamber of the hydraulic cylinder and a second activation dart seatable in the tubular support for directing fluidic material into the closing chamber of the hydraulic cylinder.
In another embodiment the expander cone has a plurality of first cam arms each providing one a plurality of ramp surfaces each slidingly engaged with a separate one of a plurality of cutter blades and further comprising a second cone having a plurality of cam second arms each having a second ramp surface and interleaved with the first cam arms and a plurality of dummy blades interleaved with the plurality of cutter blades and in sliding engagement with the second ramp surfaces provided on the second cam arms, and wherein the dummy blades are expandable and retractable with the cutter blades and have insufficient thickness to contact the wellbore casing when expanded.
In another embodiment the cutter blade further includes a cutting tip secured to the cutter blade projecting radially outward when the cutter blade is in the expanded position for cutting engagement between the cutting tip and the wellbore casing .
In another embodiment the casing cutting tool includes an upper cam assembly further including a tubular base and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface, a plurality of upper cutting blade segments interleaved with the cam arms of the upper cam assembly and pivotally coupled to the upper tubular support member, a lower cam assembly comprising, a tubular base, and a plurality of cam arms extending from the tubular base in an upward longitudinal direction, each cam arm defining an inclined surface that mates with the inclined surface of a corresponding one of the upper cutter blade segments, wherein the cams arms of the upper cam assembly are interleaved with and overlap the cam arms of the lower cam assembly; and a plurality of lower dummy segments interleaved with cam arms of the lower cam assembly, each lower dummy segment pivotally coupled to the lower tubular support member and mating with the inclined surface of a corresponding one of the cam arms of the upper cam assembly.
One embodiment of a method for cutting a wellbore casing includes providing a plurality of cutter blades supported on a rotatable tubular support, placing the plurality of cutter blades in a retracted position, inserting the tubular support into the wellbore casing with the cutter blades supported in the retracted position, actuating the cutter blades in the wellbore to expand into a cutting position engage with the wellbore casing, and rotating the tubular support with the cutter blades supported thereon so that the wellbore casing is cut by the rotating cutter blades.
In another embodiment a method of radially expanding cutter blades for cutting a wellbore casing in a wellbore is disclosed including supporting the expandable tubular member using a tubular support member and an expandable cutter tool, injecting a fluidic material into the tubular support member, actuating the expandable cutter tool radially outwardly relative to the wellbore casing an into cutting engagement with the wellbore casing using the injected fluidic material.
In another embodiment a method of radially expanding cutter blades for cutting a wellbore casing in a wellbore further includes rotating the expandable cutter tool in cutting engagement with the wellbore casing when the expandable cutter tool is expanded radially outwardly relative to the wellbore casing.
In another embodiment, a method of radially expanding cutter blades for cutting a wellbore casing in a wellbore further includes continuing to rotate the expandable cuter tool in cutting engagement with the wellbore casing until an upper portion of the wellbore casing is severed from the wellbore casing, maintaining the expandable cutter tool in the radially expanded position after the upper portion of the wellbore casing is severed, and raising the expandable cutter tool with the severed casing portion supported thereon out of the wellbore.
In another embodiment a method of radially expanding cutter blades for cutting a wellbore casing in a wellbore is disclosed, wherein actuating the expandable cutter tool radially outwardly relative to the wellbore casing and into cutting engagement with the wellbore casing using the injected fluidic material, further includes directing the fluidic material from within a portion of the tubular support member to an actuator cylinder to cause the cutting tool to slide axially on ramp surfaces so that the cutting blades are moved radially outwardly.
Another embodiment of a method of radially expanding cutter blades for cutting a wellbore casing in a wellbore is disclosed, wherein actuating the expandable cutter tool radially outwardly relative the wellbore casing and into cutting engagement with the wellbore casing, wherein the tubular support member includes an upper tubular support member and a lower tubular support member; and wherein actuating the expandable cutter tool comprises displacing the upper tubular member relative to the lower tubular support member.
A further embodiment of a method of radially expanding cutter blades for cutting a wellbore casing in a wellbore is disclosed is disclosed, wherein the expandable cutting tool includes an upper cam assembly including a tubular base, and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface, a plurality of upper cutting blade segments interleaved with the cam arms of the upper cam assembly and pivotally coupled to the upper tubular support member, a lower cam assembly including a tubular base; and a plurality of cam arms extending from the tubular base in an upward longitudinal direction, each cam arm defining an inclined surface that mates with the inclined surface of a corresponding one of the upper cutter blade segments, wherein the cams arms of the upper cam assembly are interleaved with and overlap the cam arms of the lower cam assembly, and a plurality of lower dummy segments interleaved with cam arms of the lower cam assembly, each lower dummy segment pivotally coupled to the lower tubular support member and mating with the inclined surface of a corresponding one of the cam arms of the upper cam assembly.
It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, the teachings of the present illustrative embodiments may be used to provide a cutter for a wellbore casing, a pipeline, or a structural support.
In several alternative embodiments, a expander device 36 for expansion and/or retraction of the cutter blades 34 is described, a conventional rotary expander device, a conventional compliant expansion device and/or a conventional hydroforming expansion device may used instead of, or in combination with, the expander device 36 for expansion and/or retraction of the cutter blades 34.
In several alternative embodiments, one or more of the conventional commercially available expander devices available from Weatherford International, Baker Hughes, Halliburton Energy Services, Schlumberger, and/or Enventure Global Technology may be used instead of, or in combination with, the expander device 36 for expansion and/or retraction of the cutter blades 34.
Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
Claims
1. A cutter tool for a wellbore casing, comprising:
- a rotatable tubular support;
- at least one cutter blade supported on the rotatable tubular support, having a retracted position for insertion into the wellbore casing and having an expanded position for cutting engagement with the wellbore casing; and
- an actuator for moving the cutter blade from the retracted position to the expanded position for cutting engagement with the wellbore casing;
- wherein the cutter blade includes an interior sliding surface and the expander device includes a ramp surface moveable by the actuator along the tubular support in sliding engagement with the interior sliding surface of the cutter blade to pivot the cutter blade between the retracted position and the expanded position.
2. The cutter tool of claim 1, further comprising an expander device coupled to the actuator; and wherein the cutter blade is pivotably mounted on the expander device.
3. The cutter tool of claim 1, wherein the at least one cutter blade includes a plurality of cutter blades each pivotably mounted on the expander device and each having an interior sliding surface and wherein the expander device comprises an expander cone supported on a mandrel portion of the tubular support and having a plurality of ramp surfaces slidingly engaged with each interior sliding surface of the plurality of cutter blades.
4. The cutter tool of claim 3, wherein the actuator for moving the cutter device from the retracted position to the expanded position further comprises an activation device for selectively activating the actuator to move the cutter blade from the retracted position to the expanded position for cutting engagement with the wellbore casing.
5. The cutter tool of claim 4, wherein the actuator comprises a hydraulic cylinder attached to the tubular support and coupled to the expander device and wherein the activation device comprises an activation dart seatable in the tubular support for directing fluidic material into the hydraulic cylinder to cause relative sliding movement of the expander cone on the mandrel portion of the tubular support.
6. The cutter tool of claim 3, wherein the actuator for moving the cutter device from the retracted position to the expanded position further comprises means for selectively activating the actuator to move the cutter blades from the retracted position to the expanded position for cutting engagement with the wellbore casing and from the expanded position to the retracted position.
7. The cutter tool of claim 6, wherein the actuator comprises a hydraulic cylinder attached to the tubular support and coupled to the expander device, the hydraulic cylinder having an opening chamber for moving the cone in an axial direction for expanding the cutter blades and having a closing cylinder for moving the expander cone in an opposite axial direction for retracting the cutter blade and wherein the activation device comprises a first activation dart seatable in the tubular support for directing fluidic material into the opening chamber of the hydraulic cylinder and a second activation dart seatable in the tubular support for directing fluidic material into the closing chamber of the hydraulic cylinder.
8. The cutter tool of claim 3, wherein the expander cone has a plurality of first cam arms each providing one of the plurality of ramp surfaces and slidingly engaged with a separate one of the plurality of cutter blades and further comprising a second cone having a plurality of cam second arms each having a second ramp surface and interleaved with the first cam arms and a plurality of dummy blades interleaved with the plurality of cutter blades and in sliding engagement with the second ramp surfaces provided on the second cam arms, the dummy blades expandable and retractable with the cutter blades and having insufficient thickness to contact the wellbore casing when expanded.
9. The cutter tool of claim 1, wherein the cutter blade further comprises a cutting tip secured to the cutter blade projecting radially outward when the cutter blade is in the expanded position for cutting engagement between the cutting tip and the wellbore casing.
10. A casing cutting tool, comprising:
- an upper tubular support member;
- an upper cam assembly comprising: a tubular base; and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface;
- a plurality of upper cutting segments interleaved with the cam arms of the upper cam assembly and pivotally coupled to the upper tubular support member;
- a lower tubular support member;
- a lower cam assembly comprising: a tubular base; and a plurality of cam arms extending from the tubular base in an upward longitudinal direction, each cam arm defining an inclined surface that mates with the inclined surface of a corresponding one of the upper cutter blade segments;
- wherein the cams arms of the upper cam assembly are interleaved with and overlap the cam arms of the lower cam assembly; and
- a plurality of lower non-cutting segments interleaved with cam arms of the lower cam assembly and the upper cutting segments, each lower non-cutting segment pivotally coupled to the lower tubular support member and mating with the inclined surface of a corresponding one of the cam arms of the upper cam assembly.
11. A method for cutting a wellbore casing comprising:
- providing a plurality of cutter blades supported on a rotatable tubular support;
- placing the plurality of cutter blades in a retracted position;
- inserting the tubular support into the wellbore casing with the cutter blades supported in the retracted position;
- actuating the cutter blades in the wellbore to expand into a cutting position to engage with the wellbore casing by moving corresponding ramp surfaces into engagement with the cutter blades; and
- rotating the tubular support with the cutter blades supported thereon so that the wellbore casing is cut by the rotating cutter blades.
12. A method of radially expanding cutter blades for cutting a wellbore casing in a wellbore, comprising:
- supporting the expandable tubular member using a tubular support member and an expandable cutter tool;
- injecting a fluidic material into the tubular support member;
- actuating the expandable cutter tool radially outwardly relative to the wellbore casing and into cutting engagement with the wellbore casing using the injected fluidic material;
- rotating the expandable cutter tool in cutting engagement with the wellbore casing when the expandable cutter tool is expanded radially outwardly relative to the wellbore casing;
- continuing to rotate the expandable cuter tool in cutting engagement with the wellbore casing until an upper portion of the wellbore casing is severed from the wellbore casing;
- maintaining the expandable cutter tool in the radially expanded position after the upper portion of the wellbore casing is severed; and
- raising the expandable cutter tool with the severed casing portion supported thereon out of the wellbore.
13. The method of claim 12, wherein actuating the expandable cutter tool radially outwardly relative to the wellbore casing and into cutting engagement with the wellbore casing using the injected fluidic material, further comprises:
- directing the fluidic material from within a portion of the tubular support member to an actuator cylinder to cause the cutting tool to slide axially on ramp surfaces so that cutting blades are moved radially outwardly.
14. The method of claim 12, wherein actuating the expandable cutter tool radially outwardly relative to the wellbore casing and into cutting engagement with the wellbore casing, wherein the tubular support member comprises:
- an upper tubular support member and a lower tubular support member; and
- wherein actuating the expandable cutter tool comprises displacing the upper tubular support member relative to the lower tubular support member.
15. The method of claim 14, wherein the expandable cutting tool comprises:
- an upper cam assembly comprising: a tubular base; and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface;
- a plurality of upper cutting blade segments interleaved with the cam arms of the upper cam assembly and pivotally coupled to the upper tubular support member;
- a lower cam assembly comprising: a tubular base; and a plurality of cam arms extending from the tubular base in an upward longitudinal direction, each cam arm defining an inclined surface that mates with the inclined surface of a corresponding one of the upper cutter blade segments;
- wherein the cams arms of the upper cam assembly are interleaved with and overlap the cam arms of the lower cam assembly; and
- a plurality of lower dummy segments interleaved with cam arms of the lower cam assembly and the upper cutting blade segments, each lower dummy segment pivotally coupled to the lower tubular support member and mating with the inclined surface of a corresponding one of the cam arms of the upper cam assembly.
16. A cutter tool for a tubular member, comprising:
- a rotatable tubular support;
- at least one cutter blade supported on the rotatable tubular support, having a retracted position for insertion into the tubular member and having an expanded position for cutting engagement with the tubular member; and
- an actuator means for moving the cutter blade from the retracted position to the expanded position for cutting engagement with the tubular member.
17. The cutter tool of claim 16, further comprising an expander device means coupled to the actuator means for displacing the cutter blade outwardly; and wherein the cutter blade is pivotably mounted on the expander device means.
18. The cutter tool of claim 17, wherein the cutter blade includes an interior sliding surface and the expander device means includes a ramp surface moveable by the actuator means along the tubular support in sliding engagement with the interior sliding surface of the cutter blade to pivot the cutter blade between the retracted position and the expanded position.
19. The cutter tool of claim 18, wherein the at least one cutter blade includes a plurality of cutter blades each pivotably mounted on the expander device means and each having an interior sliding surface and wherein the expander device means comprises an expander cone means supported on a mandrel portion of the tubular support and having a plurality of ramp surfaces slidingly engaged with each interior sliding surface of the plurality of cutter blades.
20. The cutter tool of claim 19, wherein the actuator means for moving the cutter device from the retracted position to the expanded position further comprises an activation device means for selectively activating the actuator means to move the cutter blade from the retracted position to the expanded position for cutting engagement with the tubular member.
21. The cutter tool of claim 20, wherein the actuator means comprises a hydraulic cylinder attached to the tubular support and coupled to the expander device means and wherein the activation device means comprises an activation means in the tubular support for directing fluidic material into the hydraulic cylinder to cause relative sliding movement of the expander cone on the mandrel portion of the tubular support.
22. The cutter tool of claim 19, wherein the actuator means for moving the cutter device from the retracted position to the expanded position further comprises means for selectively activating the actuator to move the cutter blades from the retracted position to the expanded position for cutting engagement with the tubular member and from the expanded position to the retracted position.
23. The cutter tool of claim 22, wherein the actuator means comprises a hydraulic cylinder attached to the tubular support and coupled to the expander device means, the hydraulic cylinder having an opening chamber for moving the cone in an axial direction for expanding the cutter blades and having a closing cylinder for moving the expander cone in an opposite axial direction for retracting the cutter blade and wherein the activation device means comprises a first activation means seatable in the tubular support for directing fluidic material into the opening chamber of the hydraulic cylinder and a second activation means seatable in the tubular support for directing fluidic material into the closing chamber of the hydraulic cylinder.
24. The cutter tool of claim 19, wherein the expander cone has a plurality of first cam arms each providing one of the plurality of ramp surfaces and slidingly engaged with a separate one of the plurality of cutter blades and further comprising a second cone having a plurality of cam second arms each having a second ramp surface and interleaved with the first cam arms and a plurality of dummy blades interleaved with the plurality of cutter blades and in sliding engagement with the second ramp surfaces provided on the second cam arms, the dummy blades expandable and retractable with the cutter blades and having insufficient thickness to contact the tubular member when expanded.
25. The cutter tool of claim 16, wherein the cutter blade further comprises a cutting tip secured to the cutter blade projecting radially outward when the cutter blade is in the expanded position for cutting engagement between the cutting tip and the tubular member.
26. A system for cutting a tubular member comprising:
- means for providing a plurality of cutter blades supported on a rotatable tubular support;
- means for placing the plurality of cutter blades in a retracted position;
- means for inserting the tubular support into the tubular member with the cutter blades supported in the retracted position;
- means for actuating the cutter blades in the tubular member to expand into a cutting position to engage with the tubular member; and
- means for rotating the tubular support with the cutter blades supported thereon so that the tubular member is cut by the rotating cutter blades.
27. A system for radially expanding cutter blades for cutting a tubular member in a preexisting structure, comprising:
- means for supporting the expandable tubular member using a tubular support member and an expandable cutter tool;
- means for injecting a fluidic material into the tubular support member; and
- means for actuating the expandable cutter tool radially outwardly relative to the tubular member and into cutting engagement with the tubular member using the injected fluidic material.
28. The system of claim 27, further comprising:
- means for rotating the expandable cutter tool in cutting engagement with the tubular member when the expandable cutter tool is expanded radially outwardly relative to the tubular member.
29. The system of claim 28, further comprising:
- means for continuing to rotate the expandable cuter tool in cutting engagement with the tubular member until an upper portion of the tubular member is severed from the tubular member;
- means for maintaining the expandable cutter tool in the radially expanded position after the upper portion of the tubular member is severed; and
- means for raising the expandable cutter tool with the severed tubular member portion supported thereon out of the preexisting structure.
30. The system of claim 27, wherein means for actuating the expandable cutter tool radially outwardly relative to the wellbore casing and into cutting engagement with the wellbore casing using the injected fluidic material, further comprises:
- means for directing the fluidic material from within a portion of the tubular support member to an actuator cylinder to cause the cutting tool to slide axially on ramp surfaces so that cutting blades are moved radially outwardly.
31. The system of claim 27, wherein means for actuating the expandable cutter tool radially outwardly relative to the wellbore casing and into cutting engagement with the wellbore casing, wherein the tubular support member comprises:
- an upper tubular support member and a lower tubular support member; and
- wherein actuating the expandable cutter tool comprises means for displacing the upper tubular support member relative to the lower tubular support member.
32. A cutter tool for a tubular member, comprising:
- a rotatable tubular support;
- a plurality of cutting elements supported on the rotatable tubular support, having a retracted position for insertion into the tubular member and having an expanded position for cutting engagement with the wellbore casing;
- a plurality of non-cutting elements supported on the rotatable tubular support, having a retracted position for insertion into the tubular member and having an expanded position;
- an actuator for moving the cutting and non-cutting elements from the retracted positions to the expanded positions;
- wherein the cutting elements are interleaved with the non-cutting elements; and
- wherein, in the retracted positions, the cutting elements and the non-cutting elements are positioned away from one another in an axial direction; and
- wherein in the expanded positions, the cutting elements and the non-cutting elements are brought together in the axial direction.
33. A method of cutting a tubular member, comprising:
- interleaving a plurality of cutting elements with a plurality of non-cutting elements;
- positioning the cutting elements and non-cutting elements within the tubular member;
- rotating and translating the cutting elements and the non-cutting elements until the cutting elements engage the tubular member; and
- rotating the cutting elements relative to the tubular member to cut the tubular member.
34. The method of claim 33, further comprising:
- rotating and translating the cutting elements and the non-cutting elements after cutting the tubular member.
35. The method of claim 33, wherein positioning the cutting elements and non-cutting elements within the tubular member comprises:
- spacing apart the cutting elements from the non-cutting elements in an axial direction.
36. The method of claim 33, wherein rotating and translating the cutting elements and the non-cutting elements until the cutting elements engage the tubular member comprises:
- moving the cutting elements towards the non-cutting elements in an axial direction; and
- displacing the cutting elements and the non-cutting elements outwardly in a radial direction.
37. A system for cutting a tubular member, comprising:
- means for interleaving a plurality of cutting elements with a plurality of non-cutting elements;
- means for positioning the cutting elements and non-cutting elements within the tubular member;
- means for rotating and translating the cutting elements and the non-cutting elements until the cutting elements engage the tubular member; and
- means for rotating the cutting elements relative to the tubular member to cut the tubular member.
38. The system of claim 37, further comprising:
- means for rotating and translating the cutting elements and the non-cutting elements after cutting the tubular member.
39. The system of claim 37, wherein means for positioning the cutting elements and non-cutting elements within the tubular member comprises:
- spacing apart the cutting elements from the non-cutting elements in an axial direction.
40. The system of claim 37, wherein means for rotating and translating the cutting elements and the non-cutting elements until the cutting elements engage the tubular member comprises:
- means for moving the cutting elements towards the non-cutting elements in an axial direction; and
- means for displacing the cutting elements and the non-cutting elements outwardly in a radial direction.
Type: Application
Filed: Sep 22, 2003
Publication Date: Jun 29, 2006
Inventors: Brock Watson (CARROLTON, TX), David Brisco (Duncan, OK)
Application Number: 10/528,221
International Classification: E21B 29/00 (20060101);