Note: Descriptions are shown in the official language in which they were submitted.
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APPLICATION FOR LETTERS PATENT
INVENTORS:
MICHAEL C. ROBERTSON
DOUGLAS J. STREIBICH
ANTONY F. GRATTAN
CORY L. HUGGINS
TITLE:
SYSTEMS AND METHODS FOR SETTING AN
EXTREME-RANGE ANCHOR WITHIN A WELLBORE
1
SPECIFICATION
FIELD
[0002] Embodiments usable within the scope of the present disclosure
relate, generally,
to apparatus, systems, and methods for setting an anchor within a wellbore,
and
more specifically to apparatus, systems and methods usable to accurately
locate,
position, and actuate cutters, torches, perforators, setting tools, and/or
other types
of tools used downhole.
BACKGROUND
[0003] Many wellbore operations necessitate anchoring a tool downhole and
within a
wellbore. Such downhole tools include, for example, torches, perforators,
setting
tools, fracturing equipment, and the like (collectively referred to herein as
downhole tools).
[0004] A need exists, in the oil and gas industry, for the ability to
anchor, clock in
direction, and eventually release a transient tool or the tool string that
will allow
for precise and effective tool system performance. Enabling the precise
location
of: a force, an application of torque, a sensor, a perforation or cut, and a
drilling
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exit or other downhole operation, at an optimal position, further reduces the
requirement to reposition multiple-run, single location tools and tool
processes,
while reducing the chances of misguided or off-position deployments of the
tools.
[0005] Some
existing tool systems, deployed within a wellbore, are constructed with
control lines surrounding the periphery of a pipe or tubular string. Removal
of the
pipe requires cutting both the pipe at the target location, and the control
line or
lines. Without cutting both, operators cannot complete the required finishing
operations. Cutting operations that are powerful enough to cut through all the
elements, however, are restricted in their use due to the danger of causing
harm to
the backside infrastructure. Thus, having the ability to make multiple,
precise
cuts at a single target plane can enable all elements to be cut. A need exists
for
placing tools that enable precise energy delivery for cut effectiveness.
[0006] To precisely
position a tool, it is useful to place an anchor or anchoring system in
a single position, such that multiple tools may lock into that anchor or
anchoring
system for an exact placement and positioning of each tool. With the anchor
placed downhole, the tool does not have to rely on measurement or clocking
from
the surface.
Alternatively, anchoring systems are needed to enable the
positioning and repositioning of the same or multiple downhole tools, and to
enable the orienting or clocking of the tool while downhole. The clocking of
the
downhole tool enables future operations to be performed by the downhole tool
at
the same downhole location or at an offset. The offset can include an angular
offset (e.g., azimuthal, radial, polar, etc.) of the tool or a positional
offset of the
location of the downhole tool (e.g., a lower or higher depth within the
wellbore,
from the previous location within the wellbore at which the prior operations
were
conducted).
[0007] When screwed
together and properly torqued, joints between pipes within a
tubular string become relatively seamless, and the lack of distinguishable
features
makes the joints difficult to locate using conventional well logging devices.
While casing collar locators and similar devices can assist in positioning a
tool
within a tubular string, existing devices are limited in their accuracy, which
may
generally be, at best, in the range of a few feet. A joint target within a
tubular
string may be just inches in length, requiring far more precise placement of a
tool
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than current collar locators and similar devices can provide.
[0008] Completion processes taking place within a wellbore often require
placing
sensors, perforating a wall for communication, and perforating a casing such
that
contact with a geological feature is made. Operations such as gauge
integration,
cement squeezing, fracturing and jet drilling become subsequent processes.
[0009] Other positioning systems can include providing physical features
within the
interior of a tubular string that interact with corresponding physical
features of a
locating tool; however, these positioning systems require numerous, precisely
crafted features to ensure proper function and interaction, including various
moving parts to cause selective engagement between corresponding features.
[00010] A need exists for removable positioning apparatus and methods for
positioning a
tool with complementary mating integration capacity within a tubular string,
for
enabling precise positioning of anchorable tools at a preselected location,
including joints, within the tubular string to facilitate the effectiveness of
the
tools. Having the flexibility of a selectively placed locking feature within a
tubular member greatly enhances the tool's ability to positively fixate a
tool,
using pre-positioned anchoring profile mechanisms within a wellbore system.
[00011] A further need exists for positioning apparatus and methods usable
for
positioning a tool within a tubular string that are simple in construction and
function, able to incorporate reusable, machinable, and re-machinable parts
that
are able to accommodate a variety of latching and/or engaging orientations.
[00012] A need also exists for positioning apparatus and methods usable for
positioning a
tool within a tubular string that are conveyable and deployable utilizing
readily
available setting tools.
[00013] The present embodiments meet these needs.
SUMMARY
[00014] Embodiments of the present invention include apparatus, systems and
methods
usable to accurately locate, position, and actuate packers, cutters, torches,
perforators, setting tools, and/or other types of tools used downhole.
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[00015] The
disclosed embodiments include a system for providing a self-centering
reusable anchor location within a wellbore. The system includes an extreme
range anchor having a first extending assembly configured to engage the
wellbore. The first extending assembly can comprise a first set of arms that
can
connect to a first brace, a second set of arms that can connect to a second
brace,
and a set of footplates. Each footplate in the set of footplates can be
connected at
a first side to the first set of arms and can be connected at a second side to
the
second set of arms. Each footplate can comprise a fixator that can be coupled
to
a radially external face and configured to securely engage the wellbore. The
extreme range anchor can include a pull rod that can be rigidly coupled to the
first brace and slidably connected to the second brace. Forcing the pull rod
in an
axial direction can shorten the distance between the first brace and the
second
brace and can force the set of footplates to move in a radial direction toward
the
wellbore.
[00016] In certain
embodiments, the system may include a second extending assembly
configured to engage the wellbore. The second extending assembly may include
a third set of arms connected to the second brace, a fourth set of arms
connected
to a third brace, and a second set of footplates. Each footplate in the second
set
of footplates can be connected at a first side of the third set of arms and
connected at a second side to the fourth set of arms.
[00017] In certain
embodiments, the system may include a body and an engagement key.
The engagement key may be configured to engage with the body to maintain an
axial position of the pull rod relative to the body when the pull rod is
forced in
the axial direction. In certain embodiments, the engagement key may be
configured to disengage from within the body in response to the body being
forced in the axial direction at a disengage threshold of force.
[00018] In certain
embodiments, the set of footplates are configured to move a distance
up to fifteen (15) centimeters in the radial direction to engage with the
wellbore.
In certain embodiments, the fixators may include cone-shaped fixators, half
cone-
shaped fixators, serrated fixators, or other fixators to securely engage the
wellbore. In certain embodiments, the first extending assembly may include a
pull rod spring, securing pins, securing bands, or other securing implements
to
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prevent radial movement of the set of footplates, prior to the forcing of the
pull
rod.
[00019] In certain
embodiments, the system may include fixator covers configured to
cover the fixators. The fixator covers may prevent engagement between the
fixators and the wellbore while the extreme range anchor is being deployed to
a
depth within the wellbore. In certain embodiments, the extreme range anchor
may include a setting rod configured to connect to the pull rod with a tab at
a first
end, and to a setting tool at a second end. The setting tool may pull the
setting
rod to force the pull rod in the axial direction. In certain embodiments, the
tab
may be configured to shear the setting rod from the pull rod when pulled at a
set
force.
[00020] The
disclosed embodiments can include a method of performing a downhole
operation within a wellbore. The method can include lowering an extreme range
anchor into the wellbore, wherein the extreme range anchor may include a tool
connecting head. The method can include the step of actuating a setting tool
to
force a pull rod in an axial direction to extend a set of footplates in a
radial
direction. The footplates may be configured to securely engage the wellbore
with
fixators coupled to a radially external face of the footplates. The method can
further include the steps of lowering a first tool onto the tool connecting
head,
completing a first operation with the first tool, retrieving the first tool to
a surface
of the wellbore, lowering a second tool onto the tool connecting head,
completing
a second operation with the second tool at a second location, and retrieving
the
second tool to the surface of the wellbore.
[00021] The method
of the disclosed embodiments may also include pulling on the tool
connecting head in the axial direction to disengage the set of footplates from
the
wellbore. The step of completing the first operation, the second operation, or
combinations thereof, may include actuating an axial torch cutter, a radial
torch
cutter, a wellbore perforator, a production tubing cutter, or combinations
thereof.
Also, actuating the setting tool may include shearing a setting rod from the
pull
rod. The shearing may be configured to occur when the set of footplates are
engaged with the wellbore. In certain embodiments of the methods disclosed,
the
first operation may be completed at a target location and the second operation
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may be completed within three (3) centimeters (1.18 inches), or less than
three 3
centimeters of the target location. Also, the footplates may be configured to
extend in the radial direction up to fifteen (15) centimeters.
[00022] In certain
disclosed embodiments of a system for securely engaging a wellbore,
the system can include a first arm rotatably connected to a first brace at a
first end
of the first arm, a second arm rotatably connected to a second brace at a
first end
of the second arm, and a pull rod rigidly connected to the first brace and
slidably
connected to the second brace and configured to translate in a longitudinal
direction. When the pull rod translates the longitudinal direction, the first
arm
and the second arm may be configured to rotate so that a second end of the
first
arm and a second end of the second arm protrude in an axial direction
perpendicular to the longitudinal direction.
[00023] In certain
embodiments, the system can include a footplate rotatably connected to
the second end of the first arm and the second end of the second arm. The
system
can further include a protrusion attached at the second end of the second arm.
The protrusion can be configured to protrude into the wellbore after the pull
rod
translates in the longitudinal direction. The first arm may include a recess
configured to house the protrusion during transport of the system into the
wellbore, and the first arm, the second arm or combinations thereof can
comprise
flex features, as described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[00024] In the
detailed description of various embodiments usable within the scope of the
present disclosure, presented below, reference is made to the accompanying
drawings, in which:
[00025] FIG. 1
depicts a perspective view of an embodiment of an extreme range anchor
usable within the scope of the present disclosure.
[00026] FIG. 2
depicts a cross-sectional view of the embodiment of the extreme range
anchor of FIG. 1.
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[00027] FIG. 3 depicts a cross-sectional view of the embodiment of the
extreme range
anchor of FIG. 1.
[00028] FIG. 4 depicts a perspective view of an embodiment of a footplate
that may be
used as part of the extreme range anchor of FIG. 1.
[00029] FIG. 5 depicts a perspective view of an embodiment of a footplate
that may be
used as part of the extreme range anchor of FIG. 1.
[00030] FIG. 6 depicts a cross-sectional view of the embodiment of the
extreme range
anchor of FIG. 1.
[00031] FIG. 7 depicts a cross-sectional side view of an additional or
alternative lower
extending assembly 130.
[00032] FIG. 8 illustrates an embodiment of the extreme range anchor that
uses an
electromechanical anchor in the present invention.
[00033] One or more embodiments are described below with reference to the
listed FIGS.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[00034] Before describing selected embodiments of the present disclosure in
detail, it is to
be understood that the present invention is not limited to the particular
embodiments described herein. The disclosure and description herein is
illustrative and explanatory of one or more presently preferred embodiments
and
variations thereof, and it will be appreciated by those skilled in the art
that
various changes in the design, organization, means of operation, structures
and
location, methodology, and use of mechanical equivalents may be made without
departing from the spirit of the invention.
[00035] As well, it should be understood that the drawings are intended to
illustrate and
plainly disclose presently preferred embodiments to one of skill in the art,
but are
not intended to be manufacturing level drawings or renditions of final
products
and may include simplified conceptual views to facilitate understanding or
explanation. As well, the relative size and arrangement of the components may
differ from that shown and still operate within the spirit of the invention.
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[00036] Moreover, it
will be understood that various directions such as "upper", "lower",
"bottom", "top", "left", "right", and so forth are made only with respect to
explanation in conjunction with the drawings, and that components may be
oriented differently, for instance, during transportation and manufacturing as
well
as operation. Because many varying and different embodiments may be made
within the scope of the concept(s) herein taught, and because many
modifications
may be made in the embodiments described herein, it is to be understood that
the
details herein are to be interpreted as illustrative and non-limiting.
[00037] Referring
now to FIG. 1, a perspective view of an embodiment of an extreme
range anchor 10 that may be placed downhole in a wellbore. The extreme range
anchor 10 may be placed within the production tubing of the wellbore or the
drill
string, or in certain embodiments, may be secured within the casing of the
wellbore. The extreme range anchor 10 provides utility for anchoring within a
broad range of tubing. For example, as explained in detail below, the same
embodiment of the extreme range anchor 10 may be placed in 8.9 centimeters
(3.5 inch) production tubing, retrieved, and then later placed in 27.3
centimeters
(10.75 inch) production tubing. The anchor 10, as depicted, can include a
lower
section 12, which includes securing features as explained below, and an upper
section 14, which may include the electronic, mechanical, or chemical
deploying
features as explained below.
[00038] As shown in
FIG. 1, an alignment member 16, to which downhole tools may
connect, can be attached to the upper section 14. For example, the alignment
member 16 may include a fishneck, as illustrated, to connect to the downhole
tool. With such an alignment member 16, a downhole tool 17 can be lowered
onto the fishneck (surrounding the alignment member 16). The alignment
member 16 may include a nub 18 that can provide the downhole tool 17 with an
azimuthal direction into which the downhole tool 17 can clock. With the nub 18
providing the azimuthal direction, a precise directional operation may be
conducted multiple times with one or more tools. That is, the anchor 10 stays
within the wellbore and additional downhole tools 17 may he lowered onto the
alignment member 16, oriented on a nub 18, triggered, and retrieved. The
downhole tool 17 may be locked into place on the fishneck, on the alignment
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member 16, or locked onto the nub 18.
[00039] To lock the
extreme range anchor 10 into place, the lower section 12 can include
a number of extending assemblies that can be retracted while the extreme range
anchor 10 is lowered into the wellbore. Then, when the extreme range anchor 10
is in place the extending assemblies can extend outwardly, as explained in
detail
below.
[00040] The
embodiment illustrated in FIG. 1, shows a lower extending assembly 20 and
an upper extending assembly 22. Each of the assemblies 20, 22 include arms 24
and footplates 26 that are arranged as sets of arms 24 and sets of footplates
26.
FIG. 1 illustrates an embodiment in which each set includes three arms 24
(i.e.,
first set comprising three arms denoted as 24a (third arm 24a not shown in
FIG.
1), second set comprising three arms denoted as 24b (third arm 24b not shown
in
FIG. 1), third set comprising three arms denoted as 24c (third arm 24c not
shown
in FIG. 1), fourth set comprising three arms denoted as 24d (third arm 24d not
shown in FIG. 1)) and three footplates 26 (i.e., first set comprising three
footplates denoted as 26a (third footplate 26a not shown in FIG. 1), and
second
set comprising three footplates denoted as 26b (third footplate 26b not shown
in
FIG. 1)), respectively. The lower assembly 20 includes a set of lower arms
24a, a
set of footplates 26a, and a set of upper arms 24b. Likewise, the upper
assembly
22 includes a set of lower arms 24c, a set of footplates 26b, and a set of
upper
arms 24d. Each set of arms 24 or footplates 26 may contain as few as two
members or many more members. For example, the set may include 3 (as in the
illustrated embodiment), 4, 5, 6, 7, 8, 9, or more arms 24 or footplates 26,
or sets
of arms 24a-d and footplates 26a-b. Although the embodiment of the extreme
range anchor 10 shown in FIG. 1 includes two assemblies 20, 22, each assembly
comprising sets of arms 24a-d and sets of footplates 26a-b, the extreme range
anchor 10 can include any number of assemblies 20, 22 to ensure a secure
connection within the wellbore.
[00041] As shown in
FIG. 1, the arms 24 can connect the footplate 26 to braces that can
tie the assemblies 20, 22 together. For example, as further shown in FIG. 1,
the
lower arm 24a (for simplicity, each of the sets of arms 24a-d may be discussed
below as individual arms; it should be understood that "the lower arms 24a"
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should mean the lower arm in each set of the lower arms 24a) in the lower
assembly 20 can connect a first end of the first footplate 26a to a lower
brace 28,
and the upper arm 24b in the lower assembly 20 can connect a second end of the
first footplate 26a to a middle brace 29. With regard to the upper assembly
22,
the lower arm 24c in the upper assembly 22 can connect the second footplate
26b
to the middle brace 29, and the upper arm 24d of the upper assembly 22 can
connect the second footplate 26b to an upper brace 30. The connections between
the arms 24a-d and the braces 28, 29, 30 can be rotatably hinged so that the
arms
24a-d are free to change the angle at which they connect to each of the braces
28,
29, 30.
[00042] The
assemblies 20, 22 can extend radially outward in response to a pull rod 32,
which pulls on a bottom end 34 of the extreme range anchor 10 to shorten the
distance between the braces 28, 29, 30. That is, a
setting tool, an
electromechanical anchor, or other tool for pulling, urges the pull rod 32
(perhaps
through intermediary components, as explained below) in an upper direction 36;
and in response, the footplates 26 in the lower assembly 20 and the upper
assembly 22 simultaneously extend in a radially outward direction 44. The
simultaneous movement of all sets of arms 24a-d and footplates 26a-b self-
centers the extreme range anchor 10 within the wellbore, tubing, etc. A pull
rod
spring 40 can be used to exert a force in a downward direction 42 during the
time
that the extreme range anchor 10 travels down the wellbore to keep the
assemblies 20, 22 radially inward 38 and to prevent vibration or accidental
movement of the assemblies 20, 22 due to loose movement of the arms 24a-d
and/or the footplates 26a-b.
[00043] FIG. 2 is a
cross-sectional view of an embodiment of the extreme range anchor
shown in FIG. 1. In particular, FIG. 2 shows the lower assembly 20 in a
traveling or un-extended position with the pull rod 32 fully in the downward
radial direction 42. To further ensure stable travel conditions, the footplate
26a
may be secured into position with pins 46 that may be attached to the pull rod
spring 40 or other area of the extreme range anchor 10. The pins 46 can grip
the
footplate 26 at a gripping surface 48 that stably affixes until the pull rod
32 is
deployed in the upward radial direction 36. In other words, the lower assembly
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20, illustrated in FIG. 2, will maintain a traveling angle 50 for the arms 24a-
b
relative to the braces 28, 29 throughout the descent into the wellbore. The
traveling angle 50 may typically be near 90 degrees, meaning that the arms 24a-
b
are usually traveling parallel to the wellbore during descent. In some
embodiments, however, the traveling angle 50 may be greater than or less than
90
degrees, to accommodate more rapid deployment or other requirements for
deployment of the extreme range anchor 10.
[00044] To deploy
the extreme range anchor 10, the pull rod 32 is pulled in the upward
radial direction 36, as mentioned above. FIG. 2 shows that the pull rod 32 is
rigidly attached to the bottom end 34, so that when the pull rod 32 is pulled,
the
bottom end 34, the bottom brace 28, and the attached arm 24a are all pulled in
the
upward radial direction 36. The middle brace 29, in contrast, can travel along
the
outer diameter of the pull rod 32 such that the pull rod 32 is free to slide
through
the middle brace 29. Force from the upper assembly 22 urges the middle brace
29 downward (i.e., in the downward radial direction 42) relative to the bottom
end 34 and the arms 24a-b and the footplate 26a are thus forced radially
outward
44.
[00045] A deployed
embodiment of the extreme range anchor 10 of FIG. 2 is illustrated in
FIG. 3. As shown in FIG. 3, the bottom brace 28 (with the bottom end 34) has
been pulled closer to the middle brace 29, and the arms 24a-b and the
footplate
26a have moved radially outward 44. The arms 24a-b now make a deployed
angle 52 relative to the braces 28, 29, while the footplate 26a remains
parallel to
the pull rod 32 and, importantly, to a tubing wall 62. The deployed angle 52
is
generally less than the traveling angle 50 so that the extreme range anchor 10
travels down the wellbore with a smaller profile than when the anchor 10 is
deployed. The footplate 26a travels a distance 56 from the traveling position
(FIG. 2) to the deployed position (FIG. 3). The distance 56 may, in certain
embodiments, be any length up to 30 centimeters. For example, the range may be
between 1 centimeter and 15 centimeters, between 1 centimeter and 20
centimeters, between 1 centimeter and 25 centimeters, between 5 centimeters
and
15 centimeters, etc. Once the pull rod 32 is pulled and the anchor is
deployed, a
face 60 of the footplate 26a can abut the tubing wall 62 and fixators 64
(shown in
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FIGS. 4 and 5) can bite into the tubing wall 62 to ensure a secure fit. Since
the
arms 24a-b and footplate 26a can deploy or extend simultaneously, the
footplate
26a and/or the fixators 64 (shown in FIGS. 4 and 5), in each set or assembly
20,
22, can bite into the tubing wall 62 with the same force and timing. That is,
while one footplate 26a may contact the tubing wall 62 before the other
footplates
26a, the extreme range anchor 10 will center itself before any of the
footplates
26a apply any pressure that will actually set the fixators 64 into the tubing
wall
62. The fixators 64 decrease the likelihood of slipping or shifting after
deployment, and the fixators 64 can include any combination of shapes and
sizes
to securely bite into the tubing wall 62. The illustrated embodiments include
a
flat cone fixator 70, a pointed cone fixator 72, and a multipoint fixator 74,
as
shown in FIGS. 2 and 3.
[00046] FIG. 4 is an
embodiment of the footplate 26 that may be used in the extreme
range anchor 10 of FIGS. 1-3. As shown, the footplate 26 employs fixators 64
of
a uniform size and shape. In particular, FIG. 4 illustrates a two-by-three
pattern
of pointed cone fixators 72. The size, shape, and/or pattern of the fixators
64
may depend on the type of tubing wall 62 into which the fixators 64 will bite.
For example, a tubing wall 62 that is highly corroded and/or rusted, with
loose or
softened material on an inner surface 80 (shown in FIG. 3), may employ a
fixator
64 that penetrates deeper into the inner surface 80. On the other hand, if the
tubing wall 62 is made of a hard and/or polished surface, the fixators 64 may
employ smaller, sharper, and/or more plentiful points on the face 60 of the
footplate 26.
[00047] As an
additional but not limiting example, FIG. 5 shows an embodiment of a
footplate 26 having five fixators 64 arranged on the face 60 of the footplate
26.
Included on the embodiment of FIG. 5 is a larger multipoint fixator 74
positioned
in the center of the footplate 26 with several smaller flat cone fixators 70
positioned toward the corners of the footplate 26. Additionally, the footplate
26
in the embodiment illustrated in FIG. 5 includes chemical fixators 82 that may
employ glue, epoxy, adhesive, or other chemicals to attach the footplate 26 to
the
tubing wall 62.
[00048] To protect
the fixators 64 during travel down the wellbore, the footplate 26 may
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include a fixator cover 84 (shown in FIGS. 2 and 3). The fixator cover 84 can
be
attached to the face 60 during travel and, in certain embodiments, is made out
of
material that has a low coefficient of friction. For example, the fixator
cover 84
may include a polymer, a ceramic, a plastic, a silicone, a rubber, or other
protective material. The cover enables the footplate 26 and the extreme range
anchor 10 to traverse passed features within the wellbore that may otherwise
contact the fixators 64 and impede travel. Additionally, the fixator cover 84
protects the fixators 64 so that any sharp points of the fixators 64 maintain
their
sharpness until deployment. After deployment of the extreme range anchor 10,
the fixator cover 84 can deform, compress, or fracture so that the fixators 64
are
able to meet the inner surface 80 of the tubing wall 62. In the illustrated
embodiment of FIG. 3, the fixator cover 84 has fractured and will dissolve or
fall
down the wellbore.
[00049] FIG. 6 is an
embodiment of the upper section 14 of the extreme range anchor 10
illustrated in FIG. 1. As shown, the upper section 14 of the extreme range
anchor
can be used to house a body 98 that assists in keeping the extending
assemblies 20, 22 in the deployed position after deployment. FIG. 6 shows the
upper section 14 before the pull rod 32 has been pulled. As depicted, a collar
100
of the pull rod 32 sits at the bottom of a cavity 102 against a shoulder 120
which
rests in contact with the body seat 104. As explained above, the extreme range
anchor 10 can travel down the wellbore in this position. To deploy the extreme
range anchor 10, the pull rod 32 can be connected to a first end of a setting
rod
106 with a shear stud 108. The setting rod 106 can be connected at the other
end
to a setting tool, an electromechanical anchor, or other downhole pulling
device
that pulls on the setting rod 106. The setting rod 106, shear stud 108, and
pull
rod 32 can move upward 36 in relation to the body 98. Similar to the middle
brace 29 explained above, the upper brace 30 can be slidably coupled to the
pull
rod 32, which enables the pull rod 32 to move axially upwards 36 and, thus,
forces the arms 24 radially outward 44. To prevent deformation of the tubing
wall 62, the shear stud 108 can be calibrated to shear at a given deployment
force.
In certain embodiments, an electromechanical anchor may be calibrated or
programmed to cut off power once a deployment force (e.g., smaller than the
force that would deform the tubing wall 62) has been detected. In such
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embodiments, the extreme range anchor 10 possibly may not have a shear stud
108. The deployment force is large enough to set the fixators 64 into the
inner
surface 80 of the tubing wall 62, but small enough so that the extreme range
anchor 10 and the tubing wall 62 do not deform or otherwise suffer damage.
After deployment of the extreme range anchor 10, the setting tool (if used),
the
setting rod 106, and any part of the shear stud 108 attached to the setting
rod 106
can be retrieved back to the surface of the wellbore. In certain embodiments,
the
electromechanical anchor used to set the extreme range anchor 10 may remain
downhole until the extreme range anchor 10 is ready to be retrieved.
[00050] The pull rod
32 can be kept in place by a variety of securing devices. For
example, the upper section 14 may include an engagement key 110, retention
shear pin 122, and ridges 112 inside the cavity 102 of the body 98. The ridges
112 in the illustrated embodiment are shaped to enable the engagement key 110
to slide axially upward 36, but prevent the engagement key 110 from sliding
downward 42. A lower edge 114 of each ridge 112 can be angled slightly to
reduce the friction between a top edge 116 of the engagement key 110 and the
lower edge 114 of each ridge 112. An upper edge 118 of the ridges 112,
however, is angled to increase the retaining ability of a bottom edge 120 of
the
engagement key 110. The engagement key 110 may also include an engagement
spring 124 that increases the radially outward 44 force of the engagement key
110 against the ridges 112. The engagement key 110 may include embodiments
where the engagement spring 124 is a coil spring, or as illustrated, may
include a
resilient material, or an arc spring that forces the engagement key 110 toward
the
ridges 112.
[00051] After
deployment, the anchor 10 may stay in the deployed location for a number
of operations. One or more tools can be lowered downhole and onto the
alignment member 16 for operation. After all desired tool operations are
completed, an operator may retrieve the extreme range anchor 10 by returning
the
extending assemblies 20, 22 to the traveling position. For example, the
electromechanical may use a motor to move the pull rod 32 back down 42
relative to the upper section 14 and the upper brace 30. The pull rod 32 may
also
be released by fracturing or shearing the retention shear pin 122. The
retention
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shear pin 122 may be calibrated to fracture at a disengaged threshold of force
on
the extreme range anchor 10. Alternatively, a retrieving tool may be lowered
and
secured onto the alignment member 16 and pulled axially upward 36. At the
disengage threshold, the retention shear pin 122 shears, allowing the pull rod
32
to be disconnected from the engagement key 110. The downhole end of the
collar 100 will make contact with the uphole end of the shoulder 120 upon
retrieval. The pull rod spring 40 forces the pull rod 32 to stay in the
extended
position, which keeps the extending assemblies 20, 22 radially inward 38 so
the
anchor 10 can be fully retrieved. The retrieval operation may be completed by
the last tool to be oriented on the anchor 10. The last tool in that instance
would
be positioned to apply sufficient overpull to the anchor 10 so that the
retention
shear pin 122 breaks or shears.
[00052] FIG. 7
illustrates a cross-sectional side view of an additional or alternative lower
extending assembly 130. The lower extending assembly 130 includes a lower
arm 132a that may attach to the lower brace 28 in a similar manner to the
other
lower arm 24a. Likewise, an upper arm 132b may attach to the middle brace 29
in a similar way as described above. As illustrated, however, the lower
extending
assembly 130 may include embodiments that secure the anchor 10 to the wellbore
without the footplate 26 described above. Instead, the lower extending
assembly
130 may employ a securing protrusion 134 that protrudes from the upper end 142
of the upper arm 132b. The protrusion 134 includes ridges 136 that bite into
the
wellbore. The biting of the ridges 136 secures the positioning of the anchor
10
during orientation of the subsequently anchored tools. The ridges 136 may have
additional or alternative size, shape, and/or pattern to the ones shown in
FIG. 7,
depending on the material into which the ridges 136 will be biting. As with
the
fixators 64 (explained above), the size, shape, and/or pattern of the ridges
136
may penetrate deeper into the inner surface if the tubing wall 62 is highly
corroded, rusted, or has loose or softened material on an inner surface 80
thereof.
On the other hand, if the tubing wall 62 is made of a hard and/or polished
surface,
the ridges 136 may employ smaller, sharper, and/or more plentiful points.
[00053] During
transport of the anchor 10 down the wellbore, the lower arm 132a and the
upper arm 132b are substantially parallel to the pull rod 32, slimming the
profile
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of the extreme range anchor 10 in a similar manner to the embodiment shown in
FIG. 2 described above. The protrusion 134 is in line with the arms 132a.
132b.
The lower arm 132a includes a recess 138 cut out of the lower arm 132a; and
during transport, the protrusion 134 is located within the recess 138 to
protect the
ridges 136 and ensure a smooth descent of the anchor 10. The lower arm 132a
may attach to a left side 137 and a right side 140 of the upper arm 132b,
which
ensures an even and secure deployment of the protrusion 134 against the
wellbore. In certain embodiments, the lower arm 132a may include the
protrusion having the ridges on an upper end to further secure the anchor 10
into
the wellbore. In an additional or alternative embodiment, the upper arm 132b
and
lower arm 132a may switch roles. That is, the lower arm may include the
protrusion 134 while the upper arm 132b includes the recess 138.
[00054] The upper
arm 132b (or the lower arm 132a, in certain embodiments) may also
include flex features 144, or other cushioning features, that enable the upper
arm
132b to cushion or flex during deployment. Flex and cushion may be useful to
set and maintain connection between the protrusion 134 and the wellbore. For
example, as shown in FIG. 6, as the engagement key 110 slides upward 36 along
the ridges 112, each ridge 112 individually slides past the engagement key
110.
When the shear stud 108 shears, the engagement key 110 may experience a slide
back. This small slide may occur especially if the engagement key 110 is only
partially pulled from one ridge 112 to the next ridge 112. This may be a very
small amount (e.g., 0.006 inches or 0.152 mm) due to the small length of the
ridges 112, but can still cause the protrusion 134 to lose some traction with
the
wellbore.
[00055] To prevent
this traction loss, the flex features 144 (as shown in FIG. 7) provide
some spring potential energy to build up before the shear stud 108 shears.
That
is, the pull rod 32 pulls the braces 28, 29 to move the arms 132a, 132b
outward
44 until the protrusion 134 contacts the wellbore. Then, the upper arm 132b
can
flex to produce the spring potential between the wellbore and the pull rod 32.
Following the flexing of the upper arm 132b, the shear stud 108 shears and the
spring potential from the flexing absorbs any loss in traction caused by the
shift
of the engagement key 110 between ridges 112. The spring potential energy
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pushes the protrusion 134 against the wellbore with additional force, which
increases the frictional force and thus the overall ability of the extreme
range
anchor 10 to remain in a fixed location.
[00056] The flex
features 144 may include slots, striations, grooves, or other physical
changes to the arm (e.g., upper arm 132b) that enable an otherwise rigid arm
to
flex or arch without deforming or permanently bending. The flex features 144
may also include material differences to the arms. For example, the arms 132
may be constructed from a flexible metal, polymer, rubber, or other material
that
does not deform under a load. Furthermore, the flex features 144 may include
combinations of these or other features that enable the arms 132 to provide an
increased force normal to the interior surface of the wellbore.
[00057] In certain
embodiments, the anchor 10 may be purposefully offset from a center
of the wellbore. For example, the lower arms 132a and upper arms 132b may
vary in length from one set of the extending assembly 130 to another set. That
is,
the upper arm 132b of one set may be longer than the upper arms 132b of the
other sets of the particular extending assembly 130. This may result in the
shorter upper arm 132b being attached to the middle brace 29 while the longer
upper arm 132b is attached to a different middle brace. When the extending
assembly 130 is deployed, the longer arms of one set will force the anchor 10
away from the center of the wellbore before the shorter arms of another set
engage the wall of the wellbore. Alternatively or additionally, to offset the
anchor 10 from the center of the wellbore, a connection point 146 between the
lower arm 132a and the upper arm 132b may be adjusted. In the illustrated
embodiment of FIG. 7, both lower arms 132a and both upper arms 132b are of
substantially equal length, and the connection point 146 is near the ends of
these
arms 132a, 132h as shown. However, in certain embodiments, the lower arm
132a may be longer, with the recess 138 enveloping a greater proportion of the
upper arm 132b. That is, the lower arm 132a can extend on either side of the
upper arm 132b to any point of connection, for example see connection 148.
[00058] In
embodiments with longer recesses 138, the connection 148 may be located
closer to the middle brace 29 by an extended length 150, thus relocating the
connection point 146 to the connection 148. The lengths of the upper arms 132b
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may remain the same, however, the connection point 146 can be changed to any
connection 148 along the upper arm 132b. When the connection point 146 is
located at the connection 148, and is closer to the middle brace 29, the
deployment of the extending assembly 130 can cause the protrusion 134 to
extend further from the lower extending assembly 130. This would allow the
upper arm 132h, with the protrusion 134, to extend further away from the
extreme range anchor 10 for a given translation distance by the pull rod 32.
Thus, if the connection point 146 were located at different a different
connection
148 for each set of arms 132a, 132b, the extreme range anchor 10 would be
positioned at a non-central position within the wellbore.
[00059] FIG. 8
illustrates an embodiment of the extreme range anchor 10 that uses an
electromechanical anchor in the upper section 14. The electromechanical
section
which will be located uphole 36 from the upper brace 30. The electromechanical
section may include the engagement key 110, the shear pin 122, a rotation
device
(e.g., actuator, motor, extender, etc.) and a communication device (e.g.,
electronic
circuit board). A signal can be sent to the communication device to initiate a
setting procedure, or the retrieval procedure. The signal may be communicated
from the surface by sending a pressure wave that is detected by the
communication device, or by direct electronic communication through a wireline
connection. Additionally, the communication device may begin the deployment
procedure when a set of conditions is detected within the wellbore. The set of
conditions may include pressure, temperature, chemicals, orientation (e.g.,
only
deploys in a horizontal wellbore shaft), acceleration (e.g., does not deploy
while
moving), and time (e.g., will not deploy until a certain length of time has
elapsed
since being dropped into the wellbore). The communication device will send a
signal to the rotation device to initiate the setting sequence. Initiation of
the
rotation device will result in the uphole 36 movement of the pull rod 32 and
the
function of the system will react as outlined above. Additionally, the
retrieval
process may include a second signal or group of detected signals to reverse
the
motion of the rotation device. The retrieval process may also include a strong
upward 36 force applied to the system in order to shear the pin joining the
engagement key 110 and the pull rod 32. Shearing of the pin will result in
disengagement of the profiles from the casing and anchor arms will collapse to
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the travel angle 50.
[00060] While
various embodiments usable within the scope of the present disclosure
have been described with emphasis, it should be understood that within the
scope
of the appended claims, the present invention can be practiced other than as
specifically described herein.
