WELLBORE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/483,410 filed February 6, 2023 and U.S. Provisional Patent Application No. 63/345,994 filed May 26, 2022, the entire contents of which are incorporated herein by reference in their entireties.

BACKGROUND OF THE DISCLOSURE

[0002] Subsurface installations in a wellbore normally include one or more casing pipes coupled together to form a casing pipe assembly. With larger wellbore depths, casing pipes with smaller diameters may be installed in the well and may overlap each other vertically. The arrangement of the casing pipes may be different between different wells, due to the purpose of the well, its depth and the geological situation. Due to the arrangements of the casing pipes, it is common that smaller casing pipes (e.g. with smaller diameters) are installed inside of casing pipes of higher diameters. In other words, casing pipes with large diameters are concentrically disposed around other casing pipes of smaller diameters.

[0003] Hydraulic control lines are typically used to operate hydraulically-driven completion equipment from the surface of a wellbore. Such subsurface equipment could be for example subsurface safety valves or shutdown systems, a production tree, packers and the like. In some instances, the hydraulic control lines may be deployed with the inner casing pipes. In instances when these control lines should be removed, a commonly used method is to sever these lines with a cutting method to sever or cut through the casing pipe and the line. The lines can be severed using one or multiple shaped charges, a hydraulic cutting tool, or a mechanical cutter. Typical systems may sever the whole surrounding casing pipe. All these systems may affect the structural integrity of the casing pipe, which can include casing pipes that were previously damaged through erosion or degradation since the casing pipes may be decades old.

[0004] Accordingly, there is a need for a severing device that cuts control lines in a wellbore, while leaving an uncut vertical section of the casing pipe to maintain the structural integrity of the casing pipe. BRIEF DESCRIPTION

[0005] According to an aspect, the exemplary embodiments include a tool for cutting one or more control lines on an exterior of a pipe in a wellbore. The tool may include a holding structure configured to be disposed in the pipe and to retain and orient a plurality of shaped charges. In some embodiments, the holding structure may be configured to orient the plurality of shaped charges to each fire a perforating jet radially outward. In some embodiments, the holding structure may be configured to orient the plurality of shaped charges in a semi-spiral and/or zig-zag configuration. Upon firing of the plurality of shaped charges, a circumferential portion of the pipe may remain un-cut and may form an intact section.

[0006] In another aspect, the exemplary embodiments include a downhole well. The well may include an outer pipe disposed within a ground formation, an inner pipe disposed within the outer pipe, at least one control line extending axially on an exterior surface of the inner pipe, and a tool disposed in the inner pipe. In some embodiments, the tool may include one or more shaped charges and a holding structure configured to retain and orient the one or more shaped charges. In some embodiments, the holding structure may be configured to orient the one or more shaped charges to fire radially outward. In some embodiments, the holding structure may be configured to orient the one or more shaped charges so that, upon firing, the one or more shaped charges will form a continuous circumferential cut spanning less than 360 degrees circumferentially. In some embodiments, upon firing of the one or more shaped charges, a circumferential portion of the inner pipe may remain un-cut and may form an intact section.

[0007] In yet another aspect, exemplary embodiments include a method of severing one or more control lines in a wellbore. The wellbore may have an outer pipe within a ground formation and an inner pipe within the outer pipe, and the one or more control lines may extend axially on an exterior of the inner pipe. The exemplary method may include the steps of disposing/deploying a tool in the inner pipe of the wellbore and firing one or more shaped charges of the tool to form a continuous circumferential cut. By way of example, the tool may have one or more shaped charges and a holding structure configured to retain and orient the one or more shaped charges. In some embodiments, the holding structure may be configured to orient the one or more shaped charges to fire radially outward and to orient the one or more shaped charges so that, upon firing, the one or more shaped charges will form a continuous circumferential cut spanning less than 360 degrees circumferentially. In some embodiments, upon firing of the one or more shaped charges, a circumferential portion of the inner pipe may remain un-cut and may form an intact section. The continuous circumferential cut may sever the inner pipe and the one or more control lines. After firing of the one or more shaped charges, an intact section of the inner pipe may extend axially. For example, a vertical/axial strip of pipe may remain, which connects an upper portion of the pipe above the continuous circumferential cut to a lower portion of the pipe below the continuous circumferential cut. In some embodiments, the vertical strip or intact section may have no perforations.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A more particular description will be rendered by reference to exemplary embodiments that are illustrated in the accompanying figures. Understanding that these drawings depict exemplary embodiments and do not limit the scope of this disclosure, the exemplary embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0009] FIG. 1 is a partial cross-sectional, perspective view of a wellbore with an exemplary wellbore control line cutting tool deployed therein, according to an aspect;

[0010] FIG. 2a is a top cross-sectional view of the wellbore of FIG. 1, according to an aspect;

[0011] FIG. 2b is a top cross-sectional view illustrating the wellbore tool of FIG. 2a when activated, according to an aspect;

[0012] FIG. 3 is a perspective, partial cut-away view of an exemplary wellbore tool including linear (e.g. slotted) shaped charges, according to an aspect;

[0013] FIG. 4 is a perspective, partial cut-away view of an alternative exemplary wellbore tool, according to an aspect;

[0014] FIG. 5 is a side cross-sectional view of an exemplary shaped charge, according to an embodiment;

[0015] FIG. 6 is a perspective cross-sectional view of an exemplary shaped charge, according to an embodiment;

[0016] FIG. 7 is a side view of an exemplary wellbore tool including linear (e.g. slotted) shaped charges, according to an aspect;

[0017] FIG. 8 is a perspective view of an exemplary encapsulated shaped charge, according to an aspect;

[0018] FIG. 9 is a side view of an exemplary cap or cover for encapsulating a shaped charge similar to that shown in FIG. 8, according to an aspect; [0019] FIG. 10 is a side view of the encapsulated shaped charge of FIG. 8, according to an aspect;

[0020] FIG. 11 is a photograph of an exemplary casing pipe with a severed control line on its outer surface and a slotted perforating hole, according to an aspect; and

[0021] FIG. 12 is a perspective view of another exemplary wellbore tool, according to an aspect.

[0022] Various features, aspects, and advantages of the exemplary embodiments will become more apparent from the following detailed description, along with the accompanying drawings in which like numerals represent like components throughout the figures and detailed description. The various described features are not necessarily drawn to scale in the drawings but are drawn to emphasize specific features relevant to some embodiments.

[0023] The headings used herein are for organizational purposes only and are not meant to limit the scope of the disclosure or the claims. To facilitate understanding, reference numerals have been used, where possible, to designate like elements common to the figures.

DETAILED DESCRIPTION

[0024] Reference will now be made in detail to various embodiments. Each example is provided by way of explanation and is not meant as a limitation and does not constitute a definition of all possible embodiments.

[0025] For purposes of illustrating features of the embodiments, an exemplary embodiment will now be introduced and referenced throughout the disclosure. This example is illustrative and not limiting and is provided for illustrating the exemplary features of a method of non-circumferential shaped charge cutting to sever one or more control lines in a subsurface pipe as described throughout this disclosure

[0026] Embodiments of the disclosure are associated with a wellbore system/tool that includes one or more shaped charges. These shaped charges are designed to produce one or more holes / perforations /cuts in a wellbore pipe and cut not only through the thickness of the pipe, but also sever one or more control lines (e.g. disposed on the exterior of the pipe). For example, a wellbore tool may include shaped charges configured to sever a control line behind a wellbore pipe. In some embodiments, the perforations may be slot-shaped (e.g. elongate in the circumferential direction). The shaped charges may be arranged in a pattern so that they create perforations in the wellbore pipe in a circumferentially overlapping configuration. According to an aspect, the circumferentially overlapping configuration covers only a partial circumferential area of the pipe. It is contemplated that this may be done by arranging the shaped charges in a partial (e.g. semi) spiral or helix pattern, for example. Alternatively, a zig-zag pattern for arranging the shaped charges could be used. By not covering the total circumferential area of the wellbore pipe, a vertical section of the pipe remains intact and helps to maintain structural integrity of the pipe. According to an aspect, the wellbore tool may include a holding structure. In some embodiments, the holding structure may include a plurality of openings arranged in a semi-spiral and/or zig-zag configuration along the length of the holding structure, and the plurality of shaped charges may be positioned in the plurality of openings to orient the shaped charges. In some embodiments, the semi-spiral or zig-zag configuration of shaped charges may be configured to span the cutting arc multiple times (e.g. progressing across the circumferential cutting arc more than once, for example making more than one continuous circumferential cut, to help ensure that the control line is effectively cut). The more than one continuous circumferential cut may refer to a single cut or a plurality of cuts that do not span 100% of the circumference of a pipe in a single axial or radial plane. In some embodiments, the wellbore tool may be formed of two or more perforating guns, which may axially abut or may be axially spaced apart in a tool string (e g. the semi-spiral or zig-zag configuration may span more than one perforating gun, which may be used together to provide the control line cutting operation).

[0027] Turning now to FIG. 1 and FIG. 2a, an exemplary subsurface well is illustrated. The subsurface well is depicted as including an inner pipe 206 and a control line package 300. As would be understood by one of ordinary skill in the art, one or more control lines (e.g. of the control package) are typically disposed along the exterior of one or more wellbore pipes positioned in the wellbore to communicate between the wellbore surface location and a location within the wellbore, for example with the one or more control lines extending substantially axially/longitudinally. The control line package 300 may include various control lines, such as optical fibers, electrical conductors and/or hydraulic conduits, which may help to enable the transmission of signals, for example receiving downhole data and activating and controlling downhole devices. For example, command and control signals may be sent from the wellbore surface through the control line package 300 and to a downhole tool, such as a perforating gun, located within the wellbore. According to an aspect, the control line package 300 is surrounded by one or more outer pipes 202 inside a geological formation 200 of the wellbore (e.g. with the inner pipe 206 located within the outer pipe 202). Typically, the annulus 204 between the inner pipe 206 and the outer pipe 202 is filled with cement, to prevent a fluid flow (such as liquid flow or gas flow) through the annulus. Alternatively, other sealant material can be located in between the inner pipe 206 and outer pipe 202, such as epoxy or a polymeric material.

[0028] According to an aspect, a wellbore tool including shaped charges is deployed into the wellbore in order to sever the control line package 300. The wellbore tool may include a perforating gun / perforating gun assembly 100. In this context, the term “perforating gun”

100 is used as an oil and gas industry standard describing a wellbore tool that is deployed into a wellbore and is equipped with shaped charges to create detonation holes in the surrounding casing pipe. In typical usage, perforating guns 100 with shaped charges penetrate not only the casing, but also the cementation of the wellbore, as well as the surrounding geological formation. For example, in typical usage the perforating guns would form perforation tunnels that extend from the casing through to the surrounding geological formation.

[0029] Exemplary embodiments of a perforating gun 100 are illustrated in FIG. 3, FIG. 4, and FIG. 7. As shown in FIG. 3, the perforating gun 100 includes a perforating gun housing

101 The perforating gun housing 101 may be hollow and may extend longitudinally (e g. such as a tube). The perforating gun housing 101 may be configured to isolate one or more shaped charges 102 from fluids housed within the wellbore 208 (see, for example, FIG. 1, FIG. 2a, and FIG. 2b), providing a sealed environment for the shapes charges 102 In some embodiments, the perforating gun housing 101 may be a hollow member (such as a tube) which extends longitudinally and which has an open longitudinal bore configured to receive a holding structure 104. In some embodiments, the housing 101 may be hydraulically sealed. As understood by one of ordinary skill in the art, uncovered, uncapped or unencapsulated shaped charges would fail to form a perforating jet when initiated when exposed to wellbore fluids. Thus, a perforating gun housing 101 may be used to isolate the one or more shaped charges 102 when using un-encapsulated shaped charges. Alternatively, encapsulated shaped charges may be used without the need for enclosure and/or isolation within a housing. In some embodiments, each shaped charge 102 may be configured to form a perforating jet capable of cutting an inner pipe and the one or more control lines (but in some embodiment, not cutting the outer pipe). In some embodiments, each shaped charge

102 may be a slotted shaped charge (e.g. configured to produce an elongate perforation).

[0030] According to an aspect, a holding structure 104 may be provided within the perforating gun housing 101. The holding structure 104 may extend longitudinally and may, in some embodiments, be hollow (e.g. a tube). The holding structure 104 may be configured to be disposed in the inner pipe 206 of a well (and in embodiments with a housing, within the housing for the perforating gun). The holding structure 104 may be configured to retain and/or orient the one or more shaped charges 102, for example orienting the shaped charges 102 to fire radially outward (e.g. so as to form perforations in the inner pipe, the outer pipe, and/or the surrounding formation). In the embodiment of FIG. 3, the holding structure 104 may include a cylindrical structure or pipe that includes an opening for receiving a shaped charge 102. The holding structure 104 may be configured as a metal pipe having cut sections forming the openings within which the shaped charges 102 are positioned (for example, with each opening having a corresponding shaped charge 102). While the holding structure 104 may be formed from a metal, such as steel, it is contemplated that the holding structure 104 may be formed from other materials, such as plastics in some embodiments. [0031] The holding structure 104 may be configured to orient the one or more shaped charge 102 (e.g. within the openings) so that, upon firing/activating/detonating, they will form a continuous circumferential cut spanning less than 360 degrees circumferentially. In some embodiments, for example having a plurality of shaped charges 102 (e.g. at least 3 shaped charges, at least 4 shaped charges, at least 5 shaped charges, at least 6 shaped charges, at least 10 shaped charges, at least 20 shaped charges, at least 50 shaped charges, no more than 100 shaped charges, no more than 120 shaped charges, no more than 150 shaped charges, no more than 200 shaped charges, no more than 300 shaped charges, no more than 500 shaped charges, or 2 to 120 shaped charges), the holding structure 104 may be configured to orient the shaped charges 104 in a semi-spiral configuration. For example, the openings in the holding structure 104 may be arranged in a semi-spiral configuration along the length of the holding structure 104 (e.g. with the semi-spiral configuration of openings extending axially as well as extending circumferentially through less than 360 degrees). In this configuration, once shaped charges 102 are positioned in the openings, the shaped charges 102 are arranged in a semi-spiral pattern to produce circumferentially overlapping perforating jets. The shaped charges 102 may also be axially/vertically spaced, for example with circumferentially adjacent shaped charges 102 being axially spaced apart. While FIG. 3 illustrates the plurality of shaped charges 102 in a spiral configuration, in other embodiments the spacing of the shaped charges 102 need not be along a continuous path, so long as the shaped charges 102 are oriented to jointly form a continuous circumferential cut (e.g. with an arc no more than 90% of the circumference). In some embodiments, the axial spacing of adjacent shaped charges 102 may be approximately 3 inches, approximately 2 inches, or alternatively approximately 2-3 inches (e g. center-to- center). In some embodiments, the shaped charges may be distributed on the perforating gun at about 6 shots per foot and/or the perforating gun may be about 20 foot in length. In some embodiments, the amount of circumferential overlap (e g. for circumferentially adjacent shaped charges) may range between approximately 10% and 50% or from approximately 10% to 90%. For example, the perforating jets and/or perforations/cuts formed by the perforating jets may circumferentially overlap by between approximately 10-50%, approximately 10-40%, approximately 10-30%, approximately 10-20%, approximately 20- 50%, approximately 20-40%, approximately 20-30%, approximately 30-50%, approximately 30-40%, approximately 20-90%, approximately 30-90%, or approximately 50-90% in alternate embodiments. In some embodiments, each shaped charge 102 may be configured and oriented so that the resulting perforating jet overlaps circumferentially with at least two other (e.g. circumferentially adjacent) shaped charge resulting jets (e.g. 2-3).

[0032] As used herein, circumferentially overlapping means that, when viewed from above as in FIG. 2b, the perforating jets (e.g. from circumferentially adjacent shaped charges 102) and/or the perforations/cuts formed by those jets overlap about the circumference of the pipe to be cut (e.g. when projected from atop into a single plane to show the circumferential portion that is jointly cut), even if the jets and/or cuts are axially spaced along the length of the pipe. Typically, the shaped charges 102 would not entirely overlap with each other (e.g. adjacent shaped charges 102 may partially overlap circumferentially). In the embodiment shown in FIG. 2b, the plurality of shaped charges 102 form a continuous circumferential cut in the pipe, which when viewed from above has the resulting circumferential cuts formed by the jets of the plurality of shaped charges 102 circumferentially overlap to jointly cut a continuous portion of the circumference of the pipe. In some embodiments, the continuous circumferential cut may span less than the entire circumference (e.g. less than 360 degrees). In some embodiments, the continuous circumferential cut may not exceed about 90%, about 85%, or about 80% of the circumference of the pipe. In other embodiments, the continuous circumferential cut may exceed 90% of the circumference of the pipe, for example cutting from approximately 91% to approximately 99% (or alternately, 98%). In some embodiments, the continuous circumferential cut may be greater than about 10%, about 20%, about 30%, about 40%, about 50%, about 60%, about 70%, about 75%, about 80%, or about 85% of the circumference of the pipe. For example, the continuous circumferential cut may range from about 10% to about 90%. In some embodiments, upon firing/activating/discharge of the shaped charges, a circumferential portion of the pipe would remain un-cut, forming an intact section. For example, in FIG. 2b, the continuous circumferential cut extends for 360 degrees minus a, where a is the angle of the portion of the circumference that is uncut (e.g. has no penetrations from the shaped charges 102 of the tool). In some embodiments, a may correspond to about 10-90% of the circumference. In some embodiments, the intact section of pipe (represented as a in FIG. 2b) may be sufficiently strong to fully support the weight of the pipe below the cut formed by the plurality of shaped charges 102.

[0033] The cutting arc of each shaped charge 102 may be less than the entire circumference of the pipe (e.g. less than 360 degrees). For example, the circumferential width of the resulting cut from each shaped charge 102 may range from approximately 0.5 inches to approximately 1.5 inches or alternatively from approximately 0.2 inches to approximately 3 inches. In some embodiments, the circumferential width of the resulting cut from each shaped charge 102 may be approximately 1-2% of the circumference of the pipe (or alternately between 0.5 and 1%). In some embodiments, the plurality of shaped charges 102 may be spaced apart along the holding body 104 longitudinal axis and rotationally offset (e.g. angularly phased about the circumference, for example so as to fire outward at a different angle/direction around the circumference of the holding structure and/or the pipe). By being circumferentially overlapping, the angularly phased (e.g. circumferentially phased) shaped charges 102 may jointly form the continuous circumferential cut. The plurality of shaped charges 102 may be oriented so that the continuous circumferential cut is less than the entire circumference of the pipe, forming the intact section of the pipe. After firing of the shaped charges 102, the continuous circumferential cut may sever an arc of the circumference (which is less than the entire circumference), leaving the intact section, and in some embodiments, a spiral section support within the arc of the circumference of the continuous circumferential cut, for example due to longitudinal/axial spacing of the shaped charges 102 along the holding structure 104.

[0034] An alternative embodiment of the holding structure 104 is shown in FIG. 4. This embodiment of the holding structure 104 may include a plurality of shaped charge holders 418, each configured to hold a shaped charge 102. The shaped charge holders 418 may be linked together to form the elongate holding structure 104, for example with the plurality of shaped charge holders 418 jointly retaining and orienting the shaped charges 102 in the semi-spiral configuration. For example, adjacent shaped charge holders 418 of the holding structure 104 of FIG. 4 may be oriented so that the resulting jets from the adjacent shaped charges 102 overlap circumferentially. In some embodiments, the shaped charge holders 418 of the holding structure 104 of FIG. 4 may jointly be configured and/or oriented to form a continuous circumferential cut, which may span less than the entire circumference (e.g. less than 360 degrees). Typically, each shaped charge holder 418 may be configured to orient its shaped charge 102 radially outward. Further exemplary details regarding exemplary shaped charge holders and modular linking thereof are described in U.S. Patent No. 11,480,038, issued October 25, 2022, which is hereby incorporated by reference in its entirety to the extent that it is not inconsistent or incompatible with this disclosure.

[0035] According to an aspect and as illustrated in FIG. 3, for example, the shaped charges 102 each include a shaped charge housing 112, an explosive load / material (not shown) positioned in the shaped charge housing 112, and a shaped charge liner 114 disposed on top of the explosive material. Detonating the explosive load leads to a deformation of the shaped charge liner 114, which is accelerated and forms a projectile in the form of a shaped charge jet 108.

[0036] FIG. 5 to FIG. 6 illustrate an exemplary shaped charge in more detail. For example, the shaped charge 520, 530 may include a case / shell 540 having a plurality of walls 542. The plurality of walls may include a side wall 544 and a back wall 546’, 546”, that together define a hollow interior / cavity 550 within the case 540. The case 450 includes an inner surface 547 and an outer surface 548. An explosive load 560 may be positioned within the hollow interior 550 of the case 540, along at least a portion of the inner surface 547 of the shaped charge case 540. According to an aspect, the liner 510 is disposed adjacent the explosive load 560, so that the explosive load 560 is disposed adjacent the side walls 544 and the back walls 546’, 546” of the case 540.

[0037] The shaped charges 520, 530 of FIG. 5 to FIG. 6 have an open end 522, through which a jet is eventually directed, and a back end (closed end) 524, which is typically in communication with a detonating cord 570. Further details regarding exemplary shaped charges are described in PCT International Publication No. WO 2021/123041, published June 24, 2021, which is hereby incorporated by reference in its entirety to the extent that it is not inconsistent or incompatible with this disclosure.

[0038] FIG. 7 illustrates an alternative embodiment of a perforating gun 100 including shaped charges 102a. The perforating gun 100 includes a holding structure 104 (which is shown similar to the holding structure 104 of FIG. 3 for this example, but which in other embodiments could be similar to the holding structure 104 of FIG. 4), but is devoid of an outer housing 101. The holding structure 104 may include the shaped charges 102a arrange in a spiral or semi-spiral configuration along the length of the holding structure 104. To protect the shaped charges 102a from fluids in the wellbore, a lid or cap 116 is provided on the shaped charge housing 112 to prevent an inflow of wellbore fluid into the shaped charge 102a (e.g. encapsulated shaped charges may be used).

[0039] For example, FIG. 8 and FIG. 10 illustrate an exemplary encapsulated shaped charge 102a having a lid or cover 116. [0040] FIG. 9 illustrates an exemplary lid or cover 116. The presence of the lid of cover 116 for the encapsulated shaped charge 102a may allow for the holding structure 104 (having encapsulated shaped charges) to be used without a perforating gun housing. For example, the holding structure 104 with encapsulated shaped charges may be disposed directly in the well, so that it may come into contact with wellbore fluids. The lid or cover 116 may be sufficient to shelter the explosive of the shaped charge 102a from wellbore fluids. Further details regarding exemplary encapsulated shaped charges are described in U.S. Patent No. 11,492,877, issued November 8, 2022, which is hereby incorporated by reference in its entirety to the extent that it is not inconsistent or incompatible with this disclosure.

[0041] In the context of this disclosure, the perforating gun 100, is deployed in a designated depth into the wellbore and is activated from the wellbore surface in order to detonate the shaped charges 102, 102a (see, for example, 2B). The shaped charges 102, 102a of the perforating gun 100 are detonated and perforations (which may be slot shaped holes / perforations 110) are formed in at least the inner pipe 206. The shaped charges 102, 102a may also be designed to penetrate the control line package 300 on the outer surface of the inner pipe 206. According to an aspect, the shaped charges 102, 102a used in this method are designed to penetrate only the distance between the perforating gun 100 and the inner surface of the outer pipe 202 that surrounds the inner pipe 206 and/or to penetrate less than the radial distance between the perforating gun 100 and the outer pipe 202. By this method, the outer pipe 202 is not damaged by the shaped charge jet 108. In other embodiments, the shaped charges 102, 102a may be configured to penetrate the inner pipe 206 and the outer pipe 202 (and in some instances to penetrate into the surrounding formation as well).

[0042] Referring again to FIG. 2b, exemplary shaped charge jets 108 are displayed. FIG. 2b illustrates at least two features of this method: a circumferentially overlapping pattern of shaped charge jets 108 which forms a continuous circumferential cut and/or ensures that the control line package 300 is successfully severed (see FIG. 11); and that in a defined angle (a) an area of the inner surface of the perforated inner pipe 208 is still intact (e g. the inner pipe 208 is uncut in this defined angle area/strip, forming the intact section). The shaped charge jet (108) severs the control line package (300), which is displayed in the photograph of FIG. 11, including the control line 302 itself and, in some embodiments, the cover 304 of the control line 302.

[0043] The intact section of the inner pipe 206 (shown as a in FIG. 2b for example) may help to support the structural integrity of the pipe 206, as these pipes can be decades old, and could be damaged due to degradation, corrosion and/or erosion from producing basic hydrocarbons or from the pipe seeing acidizing events due to chemical treatment. Corrosive fluids from geological formation can also damage the pipe. Perforating the whole circumference of the pipe could cause a failure in damaged pipes, especially if the pipe sees a torsion in the case of a potential recovery to the surface. The intact section of pipe may provide sufficient structural integrity to the pipe to aid in successful recovery efforts. In some embodiments, the intact section of the pipe extends at least 10% of the circumference of the pipe (e.g. from about 10% to about 98% of the circumference of the pipe, from about 10% to about 90%, from about 10% to about 85%, from about 10% to about 50%, from about 10% to about 30%, from about 30% to about 50%, from about 50% to about 85%, or from about 50% to about 90% in alternate embodiments).

[0044] As shown in FIG. 12, alternate embodiments may include a holding structure 104 in which one or more shaped charges 102b are disposed in a single plane and configured with jets extending circumferentially for a portion (but not all) of the circumference of the holding structure 104 (e.g. spanning less than 360 degrees about the circumference). In some embodiments, the continuous circumferential cut may be disposed in a single plane. In some embodiments, the plane (of the circumferential cut and/or the one or more shaped charges) may be approximately perpendicular to the longitudinal axis of the holding structure and/or the pipe. When fired/detonated/activated, the shaped charge(s) 102b may produce a perforating jet that cuts the control line(s) (e g. the control line package 300), while leaving a section/ strip of uncut pipe (e.g. corresponding to the area a without shaped charges and/or corresponding perforations, and forming the intact section) connecting the portion of the pipe above the cut and the portion of the pipe below the cut and supporting the portion of the pipe below the cut. For example, the intact section may provide sufficient support to prevent separation of the lower portion of the pipe, even during removal/recovery operations

[0045] As shown in FIG. 12, some embodiments may also include an orientation sensor 1205. The orientation sensor 1205 may be configured to detect the orientation of the housing and/or the orientation of the holding structure 104. The orientation sensor 1205 may be used to determine the orientation of the area a and/or the shaped charges 102b. In some embodiments, the orientation sensor 1205 may be mounted to the housing. In some embodiments, the orientation sensor 1205 may be mounted to the holding structure 104. Exemplary orientation sensors may include a relative bearing sensor, a magnetic field sensor, an eddy current sensor or an ultrasonic sensor. Some embodiments may include a detector 1210 configured to detect the location of the one or more control lines with respect to the circumference of the pipe. In some embodiments, the detector 1210 may be mounted to the housing. In some embodiments, the detector 1210 may be mounted to the holding structure 104. In some embodiments, the detector 1210 may be mounted with a known relationship with respect to the shaped charges 102b and/or the area a (e.g. intact section). For example, the detector 1210 may be mounted approximately opposite the area a and/or approximately in the center of the circumferential portion at which the one or more shaped charges are directed (e.g. approximately in the center of the continuous circumferential cut formed by the shaped charges). Exemplary detectors may include coils, ultra sonic, or relative bearing. In some embodiments, the tool may further comprise an orienting device (not shown) configured to orient the one or more shaped charges (e.g. by orienting/rotating the holding structure or the tool as a whole). For example, an orienting sub (e.g. configured to allow rotation of the tool or perforating gun within the well) may be used with the perforating gun. Other exemplary orientation devices may include motorized devices, eccentric weight bars, or orientation fins. In other embodiments, the holding structure 104 may be configured to be oriented (e.g. within the housing), for example by rotation.

[0046] By using the detector 1210, the orientation sensor 1205, and/or the orienting device, the shaped charges 102b can be oriented effectively to cut the control lines (e g. the control package 300). For example, the shaped charges 102b may be oriented (e.g. by orienting the perforating gun or the holding structure) so that the detected control lines are positioned approximately in the center of the continuous circumferential cut and/or so that the area a is oriented approximately opposite the control lines. In some embodiments, the manufacturing tolerance for the arc of the perforating jet created by the one or more shaped charge may also be considered with respect to orientation and/or the creation of the continuous circumferential cut. For example, the minimum arc of the continuous cut may be based on tolerances of one or more of the following: the orientation sensor, the detector, the orienting device, and the cutting arc of the shaped charge(s). While the orientation sensor 1205 and the detector 1210 are shown here with respect to the tool of FIG. 12, similar sensors may be used with other disclosed tools.

[0047] Disclosed embodiments also relate to downhole wells within a ground formation, for example as shown in FIG. 1, 2a, and 2b. By way of example, the well may include an outer pipe 202 disposed within the ground formation, an inner pipe 206 disposed within the outer pipe 202, at least one control line (e.g. control package 300) disposed (e g. extending axially) on an exterior surface of the inner pipe 206, and a tool (e.g. perforating gun 100) disposed in the inner pipe 206. The one or more control line may extend longitudinally along an exterior surface of the inner pipe 206, typically parallel to longitudinal axis of the inner pipe 206 and/or the well, and may for example extend from the surface of the well downward. The tool may be similar to any embodiments described herein. For example, the tool may include one or more shaped charges 102, 102a, 102b and a holding structure 104 configured to retain and orient the one or more shaped charges. The holding structure 104 may be configured to orient the one or more shaped charges 102, 102a, 102b to fire radially outward (e.g. to project perforating jets radially outward so as to form perforations in the inner pipe, the outer pipe, and/or the surrounding formation), as well as orienting the one or more shaped charges 102, 102a, 102b so that, upon firing/initiation/activation/detonation, the one or more shaped charges will form a continuous circumferential cut spanning less than 360 degrees circumferentially (e.g. leaving a circumferential portion of the inner pipe un-cut to form an intact section).

[0048] In some embodiments, the outer pipe 202 and/or the inner pipe 206 may have previously been damaged (e.g. by erosion, corrosion, and/or degradation), for example due to being in service for at least a decade. The at least one control line (e.g. control package 300) may include optical fiber, electrical conductor, and/or hydraulic conduits. The tool (e.g. perforating gun 100) may be oriented so that the continuous circumferential cut severs the at least one control line. In some embodiments, the tool may have a plurality of shaped charges 102, 102a, 102b, which may be oriented so that resulting jets circumferentially overlap to form the continuous circumferential cut. In some embodiments, the holding structure may be configured to orient the plurality of shaped charges 102, 102a, 102b in a semi-spiral configuration. In some embodiments, the plurality of shaped charges 102, 102a, 102b may be axially/longitudinally spaced (e.g. along at least a portion of the length of the holding structure 104) and circumferentially overlapping. Once the shaped charges 102, 102a, 102b have been initiated/fired/detonated, a continuous circumferential cut may extend through at least the inner pipe 206 and the one or more control lines (e.g. the control package 300), while leaving an intact section which may support the portion of the pipe below the cut.

[0049] Disclosed embodiments also describe a method of severing one or more control lines (e.g. a control package). The one or more control lines may be located in a wellbore having an outer pipe within a ground formation and an inner pipe within the outer pipe, with the one or more control lines on an exterior of the inner pipe. The method may include the steps of disposing or deploying a tool in the inner pipe of the wellbore, and firing/activating/initiating/detonating the one or more shaped charges to form the continuous circumferential cut. The tool may be any of the disclosed tool embodiments herein. For example, the tool may have one or more shaped charges within a holding structure configured to retain and orient the one or more shaped charges. The holding structure may be configured to orient the one or more shaped charges to fire radially outward so that, upon firing, the one or more shaped charges will form a continuous circumferential cut spanning less than 360 degrees circumferentially; upon firing of the one or more shaped charges, a circumferential portion of the inner pipe may remain un-cut and may form an intact section. The continuous circumferential cut may sever the inner pipe and the one or more control lines (e.g. control package), but after firing, an intact section of the inner pipe may extend axially. Some method embodiments may include the step of leaving an intact section of the circumference uncut and/or supporting a lower portion of the pipe (below the cut) with the intact section.

[0050] The method may further include the step of selecting the one or more shaped charges to penetrate the inner pipe but not the outer pipe. In some embodiments, the holding structure may orient the one or more shaped charges so that the continuous circumferential cut has an arc extending from about 2% to about 90% of a circumference of the inner pipe (e.g. no more than about 90%), or alternately from about 10% to about 90%, from about 30% to about 90%, from about 50% to about 90%, from about 80% to about 90%, or from about 50% to about 80%. In some embodiments, the continuous circumferential cut may have an arc greater than 90%, for example from about 91% to about 98%. Some embodiments, of the tool may have a plurality of shaped charges. For example, the plurality of shaped charges may be oriented so that resulting jets circumferentially overlap to form the continuous circumferential cut. In some embodiments, the plurality of shaped charges may be axially spaced.

[0051] Some method embodiments may further include the step of using a detector to detect a circumferential location of the one or more control lines. Some embodiments may include orienting the tool so that the circumferential location of the one or more control lines is located in a circumferential cutting arc of the one or more shaped charges. In some embodiments, orienting the tool may include orienting a circumferential portion of the tool configured to produce the intact section (e.g. the portion of the circumference of the tool which will not be cut by the shaped charges) away from (e.g. opposite) the detected control line. In some embodiments, orienting the tool may include orienting a circumferential portion of the tool configured to produce the continuous circumferential cut so that the detected one or more control lines are located approximately centrally within the circumferential portion. Some method embodiments further include setting/selecting a minimum arc of the continuous circumferential cut based on one or more of the following: tolerance/accuracy of the detector, tolerance/accuracy of the orientation sensor, tolerance/accuracy of the orienting device, and tolerance/accuracy of the cutting arc formed by the shaped charges. In some embodiments, setting the arc of the continuous circumferential cut may include selecting and/or positioning the number, type, and/or orientation of the shaped charges (for example, so that the continuous circumferential cut they jointly produce exceeds the minimum arc). The holding structure may then be configured to orient the one or more shaped charges so that the continuous circumferential cut has an arc extending between about the minimum arc and 90% of a circumference of the inner pipe (e.g. greater than the minimum arc but no more than about 90% of the circumference of the inner pipe). In some embodiments, the shaped charges may be fired without detecting and/or orienting.

[0052] After severing/cutting the inner pipe, a lower portion of the inner pipe below the continuous circumferential cut may be supported by the intact section. In some embodiments, the lower portion of the inner pipe below the continuous circumferential cut may also be supported by an un-cut spiral section of the inner pipe (e.g. a spiral strip of the inner pipe connecting the upper portion of the inner pipe to the lower portion of the inner pipe after the shaped charges have been fired). In some embodiments, the intact section may be sufficiently strong to support lower section of pipe alone.

[0053] This disclosure, in various embodiments, configurations and aspects, includes components, methods, processes, systems, and/or apparatuses as depicted and described herein, including various embodiments, sub -combinations, and subsets thereof. This disclosure contemplates, in various embodiments, configurations and aspects, the actual or optional use or inclusion of, e.g., components or processes as may be well-known or understood in the art and consistent with this disclosure though not depicted and/or described herein.

[0054] The phrases "at least one", "one or more", and "and/or" are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B and C", "at least one of A, B, or C", "one or more of A, B, and C", "one or more of A, B, or C" and "A, B, and/or C" means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

[0055] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as "about" or “approximately” is not to be limited to the precise value specified. Such approximating language may refer to the specific value and/or may include a range of values that may have the same impact or effect as understood by persons of ordinary skill in the art field. For example, approximating language may include a range of +/-10%, +/-5%, or +/-3%. The term “substantially” as used herein is used in the common way understood by persons of skill in the art field with regard to patents, and may in some instances function as approximating language. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value.

[0056] In this specification and the claims that follow, reference will be made to a number of terms that have the following meanings. The terms "a" (or "an") and "the" refer to one or more of that entity, thereby including plural referents unless the context clearly dictates otherwise. As such, the terms "a" (or "an"), "one or more" and "at least one" can be used interchangeably herein. Furthermore, references to "one embodiment", "some embodiments", "an embodiment" and the like are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as "about" is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Terms such as "first," "second," "upper," "lower" etc. are used to identify one element from another, and unless otherwise specified are not meant to refer to a particular order or number of elements.

[0057] As used herein, the terms "may" and "may be" indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of "may" and "may be" indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances the modified term may sometimes not be appropriate, capable, or suitable. For example, in some circumstances an event or capacity can be expected, while in other circumstances the event or capacity cannot occur - this distinction is captured by the terms "may" and "may be."

[0058] As used in the claims, the word "comprises" and its grammatical variants logically also subtend and include phrases of varying and differing extent such as for example, but not limited thereto, "consisting essentially of and "consisting of." Where necessary, ranges have been supplied, and those ranges are inclusive of all sub-ranges therebetween. It is to be expected that the appended claims should cover variations in the ranges except where this disclosure makes clear the use of a particular range in certain embodiments.

[0059] The terms "determine", "calculate" and "compute," and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.

[0060] This disclosure is presented for purposes of illustration and description. This disclosure is not limited to the form or forms disclosed herein. In the Detailed Description of this disclosure, for example, various features of some exemplary embodiments are grouped together to representatively describe those and other contemplated embodiments, configurations, and aspects, to the extent that including in this disclosure a description of every potential embodiment, variant, and combination of features is not feasible. Thus, the features of the disclosed embodiments, configurations, and aspects may be combined in alternate embodiments, configurations, and aspects not expressly discussed above. For example, the features recited in the following claims lie in less than all features of a single disclosed embodiment, configuration, or aspect. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this disclosure.

[0061] Advances in science and technology may provide variations that are not necessarily express in the terminology of this disclosure although the claims would not necessarily exclude these variations.