DOWNHOLE TOOLS

INVENTORS(S): ADAM, Mark K.; MARZOUK, Mahmoud M.; and

HERN, Christopher R.

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure

[0001] The disclosure relates generally to systems and methods for actuating downhole tools.

2. Description of the Related Art

[0002] Hydrocarbons such as oil and gas are recovered from a subterranean formation using a borehole drilled into the formation. During all phases of well construction and production, a variety of downhole tools are deployed into the borehole to perform any number of tasks. Some tools have components that are temporarily coupled or connected to one another. By temporarily, it is meant that at some point, the components are to be separated from one another. Because a mechanical assembly is often used to connect such components, a mechanical force (e.g., compression, tension or torsion) is used as an actuation force to separate the components. Traditionally, the mechanical assembly must be strong enough to resist the various forces that are applied to the downhole tool while the downhole tool is conveyed to a target location in the borehole. As a consequence, the actuation force is conventionally required to be at least as great as the forces encountered during initial tool deployment.

[0003] This disclosure provides, in part, actuation devices and methods that do not have these and other drawbacks of the prior art in the oil and gas field as well as other applications. SUMMARY OF THE DISCLOSURE

[0004] In aspects, the present disclosure provides an apparatus for temporarily connecting a first tool part to a second tool part of a tool. The apparatus may include a plurality of frangible members connecting the first tool part to the second tool part. The frangible members may be configured to break only after being subjected to a predetermined applied force. The frangible members cooperate to differentially resist loading applied to the tool.

[0005] In aspects, the present disclosure also provides a downhole tool having a first tool part and a second tool part. The first tool part has a plurality of slots formed thereon, wherein a dimension of at least two slots is different. The second tool part has a plurality of frangible members configured to break only after being subjected to a predetermined actuation force, wherein at least one frangible member of the plurality of frangible members is received in one slot of the plurality of slots.

[0006] In further aspects, the present disclosure provides a method for temporarily connecting a first tool part to a second tool part of a tool. The method may include connecting the first tool part to the second tool part by using a plurality of frangible members. The frangible members may be configured to break only after being subjected to a predetermined applied force. The frangible members cooperate to differentially resist loading applied to the tool.

[0007] It should be understood that examples of certain features of the disclosure have been summarized rather broadly in order that detailed description thereof that follows may be better understood, and in order that the contributions to the art may be appreciated. There are, of course, additional features of the disclosure that will be described hereinafter and which will form the subject of the claims appended hereto. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The advantages and further aspects of the disclosure will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing and wherein:

Fig. 1 is a schematic side view of an actuation assembly in accordance with one embodiment of the present disclosure that includes frangible elements and associated slots that differentially resist axial loading while non- differentially resisting torsional loading;

Fig. 1A is a sectional view of a frangible element co-acting with an outer tool assembly and the mandrel;

Fig. 2 is a schematic end view of an actuation assembly in accordance with one embodiment of the present disclosure;

Fig. 3 is a schematic side view of an actuation assembly in accordance with one embodiment of the present disclosure that includes multiple rows and columns of frangible elements and associated slots arranged to differentially resist axial loadings while non-differentially resisting torsional loadings;

Fig. 4 is a schematic side view of an actuation assembly in accordance with one embodiment of the present disclosure that includes frangible elements and associated slots that differentially resist torsional loading while non- differentially resisting axial loadings;

Fig. 5 is a schematic side view of an actuation assembly in accordance with one embodiment of the present disclosure that includes frangible elements and associated slots that differentially resist axial and torsional loadings in two discrete stages; Fig. 6 is a schematic side view of an actuation assembly in accordance with one embodiment of the present disclosure that includes frangible elements and associated slots that differentially resist axial and torsional loading; and

Fig. 7 is a schematic view of an actuation assembly in accordance with one embodiment of the present disclosure that includes non-tubular members, frangible elements, and associated variegated slots that differentially resist axial and torsional loading;

Fig. 8 is a schematic view of an actuation assembly that utilize various arrangements in with the present disclosure that includes frangible elements and associated variegated slots that differentially resist axial and /or torsional loading;

Fig. 9 is a schematic view of an embodiment of an actuation assembly in accordance with the present disclosure that utilizes a plurality of frangible elements and an associated slot that differentially resist axial and /or torsional loading; and.

Figs. 10A-F are schematic views of embodiments actuation assemblies having differential load between the different load modes.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0009] The present disclosure relates to devices and methods for providing differential resistance for tools. In one non-limiting use, such tools may be actuators for downhole tools. Such actuation may be needed during any stage of well construction or production (e.g. , drilling, logging, completion, workover, remediation, etc.). The term "actuate" or "actuation" refers to action that changes a status, condition, position, and / or orientation of a tool. Embodiments of the present disclosure differentially control the torsional and / or axial force resistance capacities of a downhole tool. Illustrative non-limiting embodiments are discussed below.

[0010] Referring now to Figs. 1 and 2, there is shown one embodiment of an actuation assembly 10 for actuating a downhole tool 11. The actuation assembly 10 may be conveyed along a borehole 12 via a suitable conveyance device, such as drill pipe or coiled tubing (not shown). In one embodiment, the actuation assembly 10 may be used to temporarily connect two discrete parts of the downhole tool 11, such an inner mandrel 14 and an outer tool assembly 16. As further discussed below, the connection is differential because the amount of resistance to an applied axial force varies with the direction or orientation of such a force; e.g. , a greater / less resistance to an axial force is provided if that force is applied in an uphole direction as opposed to a downhole direction or greater / less resistance is provided if a torsional force is applied in a clockwise direction as opposed to a counter-clockwise direction. In Fig. 1, the actuation assembly 10 provides differential resistance to axial loadings and non- differential resistance to torsional loadings as described in detail below.

[0011] In one non-limiting embodiment, the actuation assembly 10 includes a plurality of frangible elements 40a,b disposed in the outer tool assembly 16 and associated slots 42a,b formed in the inner mandrel 14. As used herein, a "frangible element" is an element that is specifically constructed to fracture, crack, or otherwise lose structural integrity (or generally "break") once a predetermined force level is encountered. Thus, the breaking is an intended and desired function of a frangible element. The predetermined force may be an actuation force, such an axial force applied by putting the conveyance device, such as a drill string or coiled tubing in tension or compression. The actuation force may also be torsional. As used herein a loading "mode," refers to the type of loading, namely, tension, compression, torsion.

[0012] The slots 42a,b are each defined by lateral surfaces and parallel surfaces. By "lateral," it is meant transverse or perpendicular to the direction of movement of the inner mandrel 14 and / or the outer assembly 16 during actuation. By "parallel," it is meant aligned with the direction of movement of the inner mandrel 14 and / or the outer assembly 16 during actuation. The parallel surfaces 46a,b of slots 42a,b have similar dimensions; i.e. , they have the same width. However, the slot 42a is elongated relative to slot 42b. Thus, the distance separating lateral surfaces 44a,c of slot 42a is greater than the distance separating the lateral surfaces 44b,d of slots 42b. For tubular components, the surfaces 46a,b may be considered axially aligned surfaces and the lateral surfaces 44a,b may be considered circumferentially aligned surfaces.

[0013] The frangible elements 40a,b are positioned to simultaneously contact a first set of lateral surfaces and sequentially contact a second set of lateral surfaces. Specifically, the frangible elements 40a,b contact the uphole lateral surfaces 44a,b, respectively, at the same time. Thus, the axial loading on the downhole tool 11 is distributed among both of the frangible elements 40a,b. In contrast, the frangible elements 40a,b contact the downhole lateral surfaces 44c,d, respectively, at different times. Thus, all of the axial loading on the downhole tool 11 is borne by one of the frangible elements 40a,b at any given time. As will be apparent below, this arrangement provides a differential, or asymmetric, resistance to loading that reduces the actuation force needed to actuate the downhole tool 11.

[0014] While conveying the downhole tool 11 into the borehole 12, which is the downhole direction 30, both frangible elements 40a,b physically contact the mandrel 14 at the lateral surfaces 44a,b, respectively. This is due to the presence of a drag force 31 acting in the uphole direction 32, which resists the downhole movement of the outer tool assembly 16. As best seen in Fig. 1A, to overcome the drag force on the outer tool assembly 16, the mandrel 14 has to effectively pull the outer tool assembly 16 using the frangible elements 44a,b. Thus, both frangible elements 40a,b, which are fixed to the outer tool assembly 16, bear the axial loading applied to the downhole tool 11 and thereby cooperate to provide resistance to the drag force 31. As used herein, "cooperate" means a sharing or dividing of the applied loading.

[0015] Actuation occurs by first fixing the inner mandrel 14 a surface in the borehole, and then placing the tool assembly 16 into compression, which moves the tool assembly 16 in the downhole direction 30. Initially, only the frangible element 40b physically contacts and resists loading caused by the tool assembly 16, which occurs at the lateral surface 44d. The frangible element 40a does not provide any meaningful resistance because it does not contact the lateral surface 44c as shown in Fig. 1A. Once the applied actuation force is reached, the frangible element 40b breaks and the tool assembly 16 moves in the downhole direction 30 until the frangible element 40a contacts the lateral surface 44c. The applied actuation force then breaks the frangible element 40a and the mandrel 14 is released from the tool assembly 16.

[0016] It should be appreciated that the actuation force is only a fraction of resistance force present while conveying a downhole tool. That is, for actuation of the illustrated embodiment, the sequential breaking of the frangible elements 40a,b reduces the available resistance to applied loading resulting from axial loading in the downhole direction 30. The use of more frangible elements 40,b would further reduce the fraction of force needed to disconnect the tool assembly 16 and the mandrel 14. Thus, the actuation assembly 14 advantageously has a locking strength sufficient to withstand the drag forces encountered by a downhole tool being conveyed into a borehole, but reduces the load resistance when it is desired to release the tool assembly 16 from the mandrel 14. It should be noted that while the resistance to axial loading is differential, the resistance to torsional loading is non-differential. That is, the frangible elements 40a,b have the same resistance to torsional loading regardless of direction. Thus, the differential resistance depends on the mode of loading.

[0017] It should be understood that the actuation assembly 10 is susceptible to numerous variants. For instance, while the mandrel 14 is shown disposed inside the tool assembly 16, it should be understood that two parts need only overlap sufficiently to interpose the actuation assembly 10. Also, the illustrated embodiment has frangible elements 40a,b fixed to the outer tool assembly 16 and the openings 42a,b formed in a section or body 15 associated with the inner mandrel 14. However, a reverse arrangement may also be used; i.e. , the frangible elements 40a,b may be fixed to the inner mandrel 14 and the openings 42a,b are formed in outer tool assembly 16. Additionally, while two frangible elements and associated openings are shown, other embodiments may include three or more axially and / or circumferentially distributed frangible elements and associated openings. Still other variants are discussed below.

[0018] Referring to Fig. 3, the actuation assembly 10 includes a plurality of frangible elements 40 and associated slots 42 arranged in rows 50a,b,c and columns 52a,b,c. In each row 50a,b,c, the frangible elements 40 and associated slots 42 are arranged to provide cooperative resistance to applied force. In each column 52a,b,c, the frangible elements 40 and associated slots 42 are arranged to sequentially break the frangible elements 40. While being conveyed downhole in the direction 30, all of the frangible elements 40 resist the load applied by drag forces 31 (Fig. 1), which is in direction 32. During actuation, the compression on the outer tool assembly 16 (Fig. 1) applies a force in the direction 30 to the frangible elements 40. frangible elements in row 50a must break before the frangible elements in row 50b take up the applied loading. Similarly, the frangible elements in row 50b must break before the frangible elements in row 50c take up the applied loading. Thus, the resistance to axial load is differential because only a fraction of frangible elements 40 resist loading when it is applied in direction 30. It should be noted that while the resistance to axial loading is differential, the resistance to torsional loading is non-differential. Because the width of the slots 42 are the same, the frangible elements 40 have the same resistance to torsional loading regardless of the rotational direction 64, 44 in which the torsional loading is applied.

[0019] Referring to Fig. 4, the actuation assembly 10 includes a plurality of frangible elements 40a,b,c and associated slots 62a,b,c arranged to differentially resist torsional loading. In this arrangement, the slots 62a,b,c are elongated circumferentially as opposed to the axially elongated slots 42a,b, of Fig. 1. When the tool assembly 16 (Fig. 1) and connected frangible elements 40a,b,c are rotated in the second direction 66, all of the frangible elements 40a,b,c cooperatively resist the applied torsional loading because all the frangible elements 40a,b,c abut a surface that is lateral to and blocks the direction of motion. Actuation occurs when the tool assembly 16 (Fig. 1) is rotated in a first direction 64 opposite to the second direction 66. During this rotation, the actuation force sequentially breaks the frangible elements 40a,b,c because of the staggered contact with blocking lateral surfaces. It should be noted that while the resistance to torsional loading is differential, the resistance to axial loading is non-differential. Because the axial length of the slots 62a,b,c, are the same, the frangible elements 40 have the same resistance to axial loading regardless of direction of the axial loading. Because the width of the slots 62a,b,c are the same, the frangible elements 40a,b,c have the same resistance to axial loading regardless of the axial directions 30,32 in which the axial loading is applied.

[0020] Referring to Fig. 5, the actuation assembly 10 includes a plurality of frangible elements 40a,b,c and associated slots 72a,b,c arranged to resist torsional loading. In this arrangement, at least one of the slots 72a,b,c is elongated in a helical direction. When the tool assembly 16 (Fig. 1) is rotated in the second direction 66, all of the frangible elements 40a,b,c resist the applied torsional loading. When the tool assembly 16 (Fig. 1) is rotated in a first direction 64 opposite to the first direction 66, the frangible elements 40a,c resist the applied torsional loading and break at the same time. However, frangible element 40b slides along the slot 72b and resists loading after reaching a terminal end 74 of the slot 72b. Thus, the tool assembly 16 (Fig. 1) may move axially a predetermined distance before being completely released from the mandrel 14.

[0021] Similarly, when the tool assembly 16 (Fig. 1) is axially loaded in the first direction 30 by drag force 31 (Fig. 1) , all of the frangible elements 40a,b,c resist the applied axial loading. When the tool assembly 16 (Fig. 1) is loaded in the second direction 32 opposite to the first direction 30, the frangible elements 40a,c resist the applied axial loading and break at the same time. However, frangible element 40b slides along the slot 72b and resists loading after reaching a terminal end 74 of the slot 72b. Thus, the tool assembly 16 (Fig. 1) may move axially a predetermined distance before being completely released from the mandrel 14.

[0022] Referring to Fig. 6, the actuation assembly 10 includes a plurality of frangible elements 40a,b,c and associated slots 82a,b,c arranged to differentially resist both torsional and axial loading. In this arrangement, the slots 82b,c are elongated axially and circumferentially relative to the slot 82a.

[0023] Thus, while moving in the downhole direction 30, all frangible elements 40a,b,c physically contact the mandrel 14 and provide resistance to applied axial loadings as previously discussed. However, when moving in uphole direction 32, the frangible elements 40a,b,c break sequentially as discussed in connection with Fig. 1. Similarly, when the tool assembly 16 (Fig. 1) is rotated in the second direction 66, all of the frangible elements 40a,b,c resist the applied torsional loading. When the tool assembly 16 is rotated in the first direction 64, the frangible elements 40a,b,c break sequentially as described in connection with Fig. 4.

[0024] Referring to Fig. 7, there is illustrated still another arrangement in accordance with the present disclosure that illustrates the application of the present teachings to non-tubular components. In Fig. 7, a plurality of frangible elements 40 a,b,c,d are fixed to a first platen member 90 and a plurality of associated slots 92 formed in a second platen member 94. It should be noted that the slots 92a,b,c,d doe not all share a common shape. Slots 92a,b are rectangular with different lengths. Slot 92c is square. Slot 92d is oval and directs the frangible element 40d along a direction that is angled relative to the slots 92a,b. The platen members 90, 92 may have any geometrical shape, included, but not limited to, circular, rectangular, square, oval, hexagonal, etc. Further, the platen members 90, 92 may rotate and / or translate in one or more dimensions. For example, platen member 90 may spin about a central axis and / or platen member 92 may slide along one or more different axes. Thus, the present teachings are not limited to any particular shapes or types of motion.

[0025] Referring to Figs. 8-9, there are illustrated other arrangements in accordance with the present disclosure that illustrate the present teachings.

[0026] Referring to Fig. 8, frangible elements 140 a,b,c are used in a differential resistance arrangement wherein one of the slots includes multiple frangible elements. Slot 142a has two frangible elements 140a,b. Slot 142b has one frangible element 140c. Slots 142a and 142b have the same width, but different lengths. Thus, the Fig. 8 arrangement provides a non-differential resistance to axial loadings 30, 32. The resistance to torsional loading is differential. Specifically, two frangible elements 140a,c simultaneously resist torsional loading in the first direction 64. In the opposite direction 66 of torsional loading, the smaller length of slot 142b causes frangible element 140c to be sheared first. Thereafter, frangible elements 140a,b are sequentially sheared. Thus, only one frangible element resists loading in the second direction 66. The arrangement may also be re-oriented by ninety degrees to provide differential resistance to axial loading. Of course, any intermediate angles and other variations described above may also be used.

[0027] Referring to Fig. 9, there is an arrangement in accordance with the present disclosure that uses multiple frangible elements 140 d,e,f circumferentially, or laterally, distributed in one slot 142c. The slot 142c includes staggered edges 145a,b,c. The Fig. 9 arrangement provides differential resistance to axial loadings 30, 32 and non-differential resistance to torsional loadings 64, 66. Specifically, all three frangible elements 140d,e,f simultaneously resist axial loading 30. During the opposite direction axial loading 32, the frangible elements 140 d,e,f are sequentially sheared by the staggered edges 145a,b,c. That is, frangible element 140f is first sheared by edge 145c, thereafter frangible elements 140e and 140d are sheared by edges 145b and 145a, respectively. The arrangement may also be re-oriented by ninety degrees to provide differential resistance to torsional loading. Of course, any intermediate angles and other variations described above may also be used.

[0028] Figs. 10A-F illustrate embodiments of actuation assemblies that may utilize the differential loading arrangements (e.g. , different slot sizes and configurations) as discussed above to provide different resistance to loadings depending on the direction of the loading within the same loading mode (e.g., axial or torsional). The embodiments of Figs. 10A-F illustrate how the previously described actuation assemblies may also be configured to provide differential resistance to loading depending on the mode of the loading; e.g., greater resistance to torsional loading than axial loading, or vice versa.

[0029] Referring to Fig. 10A, there is shown an embodiment of an actuation assembly 100 wherein a resistance to axial loading 33 is a fraction of the resistance to torsional loading 35. Specifically, all of the frangible elements 40 simultaneously resist torsional loading 35 irrespective of direction because the widths of the slots 42 are the same. However, only a fraction of the frangible elements 40 simultaneously resist axial loading 33, depending on direction, because the axial lengths of the slots 42 are different.

[0030] Referring to Fig. 10B, there is shown another embodiment of an actuation assembly 100 wherein a resistance to axial loading 33 is a fraction of the resistance to torsional loading 35. Specifically, all of the frangible elements 40 simultaneously resist torsional loading 35 irrespective of direction because the widths of the slots 42 are the same. However, only a fraction of the frangible elements 40 simultaneously resist axial loading 33, depending on direction, because the lateral edges of the slots 42 are staggered to prevent simultaneously contact with their respective frangible elements 40.

[0031] Referring to Fig. IOC, there is shown an embodiment of an actuation assembly 100 wherein a resistance to axial loading 33 is a fraction of the resistance to torsional loading 35. Specifically, all of the frangible elements 40 simultaneously resist torsional loading 35 irrespective of direction whereas only a fraction of the frangible elements 40 simultaneously resist axial loading 33.

[0032] Referring to Fig. 10D, there is shown an embodiment of an actuation assembly 100 wherein a resistance to torsional loading 35 is a fraction of the resistance to axial loading 33. Specifically, all of the frangible elements 40 simultaneously resist axial loading 33 irrespective of direction because the axial lengths of the slots 42 are the same. However, only a fraction of the frangible elements 40 simultaneously resist axial loading 33, depending on direction, because the widths of the slots 42 are different.

[0033] Referring to Fig. 10E, there is shown another embodiment of an actuation assembly 100 wherein a resistance to torsional loading 35 is a fraction of the resistance to axial loading 33. Specifically, all of the frangible elements 40 simultaneously resist axial loading 33 irrespective of direction because the axial lengths of the slots 42 are the same. However, only a fraction of the frangible elements 40 simultaneously resist torsional loading 35, depending on direction, because the frangible elements 40 have staggered positions in their respective slots 42 to prevent simultaneously contact.

[0034] Referring to Fig. 10F, there is shown an embodiment of an actuation assembly 100 wherein a resistance to torsional loading 35 is a fraction of the resistance to axial loading 33. Specifically, all of the frangible elements 40 simultaneously resist axial loading 33 irrespective of direction whereas only a fraction of the frangible elements 40 simultaneously resist torsional loading 35.

[0035] Referring to Fig. 1, the downhole tool 11 may be any tool configured for use in a borehole 12. By way of illustration, and not limitation, the downhole tool 11 may be a drilling assembly, a reamer, a steering assembly, a downhole motor, formation evaluation tool, a thruster, liner assembly, a completion tool, a cementing tool, a well packer, a bridge plug, an inflow control device, a perforating tool, etc.

[0036] From the above, it should be appreciated that what has been described includes, in part, a downhole tool that may include at least two discrete components, such as a mandrel disposed within an assembly, and an actuation assembly that maintains the mandrel and the assembly in specified axial and rotational relationships prior to tool actuation. The actuation assembly maintains these relationships stronger in one or more loading scenarios versus others. In embodiments, the actuation assembly includes frangible elements and openings that are combined using varying dimensions such as length and width and / or orientations to allow dissimilar loading conditions in different load cases.

[0037] The present disclosure is susceptible to embodiments of different forms. For instance, while the present disclosure is discussed in the context of a hydrocarbon producing well, it should be understood that the present disclosure may be used in any borehole environment (e.g. , a geothermal well). Moreover, the present teachings may be used for actuators and other tools in any industry; e.g., automotive, aerospace, construction, etc. There are shown in the drawings, and herein will be described in detail, specific embodiments of the present disclosure with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure and is not intended to limit the disclosure to that illustrated and described herein.