Composite tool anchor for facilitated removal

Abstract

A tool anchor configured for installation and in a well casing includes a body constructed from a composite, non-metal material. The body has upper slip segment slots, lower slip segment slots and a central passage extending through the body. The anchor tool further includes an upper slip that has a plurality of upper slip segments constructed from a composite material, a plurality of inserts in each of the plurality of upper slip segments, and an upper slip retaining ring configured to hold the upper slip segments together before the tool anchor is set. The anchor tool also includes a lower slip that has a plurality of lower slip segments constructed from a composite material, a plurality of inserts in each of the plurality of lower slip segments, and a lower slip retaining ring configured to hold the lower slip segments together before the tool anchor is set.

Description

Composite Tool Anchor for Facilitated RemovalRelated Applications

[0001] This application claims the benefit of United States Provisional Patent Application Serial No. 63 / 549,420 entitled “Composite Tool Anchor for Facilitated Removal7’ and filed on February 2. 2024, the disclosure of which is herein incorporated by reference.Field of the Invention

[0002] This invention relates generally to tool systems deployed in subterranean wells, and more particularly, but not by way of limitation, to a system for preventing tools, tubulars and other components from falling deeper into the subterranean well.Background

[0003] In many cases, the production of hydrocarbons from a well requires the use of technical tools and tubulars that are deployed into a well that extends into a producing geologic formation. The well typically includes a casing that is perforated to permit the inflow of fluids from the producing formation to the well. The fluids can be recovered to the surface from the well using sophisticated tools. The well can substantially vertical or deviated in a manner that includes a lateral or horizontal section.

[0004] It is important to prevent tools or tubulars from falling into the well. To prevent tools or tubulars from falling into a position in the well that would frustrate efforts to retrieve the tools or tubulars, tool anchors have been used to block the unintended downward movement of tools inside the well. In the past the tool anchors or tool “catchers” have been constructed of cast iron. The tool anchor typically includes a pair of ring slips that are forced to expand radially outward over a pair of cones until the slips make contact with the interior wall of the well casing. The slips are often provided with hardened inserts that increase the frictional engagement between the slip and thewell casing. Once installed, the tool anchor has an inner diameter that is smaller than the outer diameter of the tools or tubulars that it is designed to block from further movement into the well.

[0005] Although generally effective, the use of cast iron tool anchors is undesirable for several reasons. In particular, the cast iron tool anchors are difficult to remove when the tool anchors are no longer needed. The cast iron tool anchors are typically removed using milling process in which a drill bit is used to destroy the tool anchor, which can take a significant amount of time. Accordingly, there is a need for an improved tool anchor that can be more quickly and easily removed when the tool anchor is no longer needed. It is to these and other objectives that the present invention is directed.Summary of the Invention

[0006] In exemplary embodiments, the present disclosure is directed to a tool anchor configured for installation and in a well casing. The tool anchor includes a body constructed from a composite, non-metal material. The body has upper slip segment slots, lower slip segment slots and a central passage extending through the body. The anchor tool further includes an upper slip that has a plurality of upper slip segments constructed from a composite material, a plurality of inserts in each of the plurality of upper slip segments, and an upper slip retaining ring configured to hold the upper slip segments together before the tool anchor is set. The anchor tool also includes a lower slip that has a plurality' of low er slip segments constructed from a composite material, a plurality of inserts in each of the plurality' of lower slip segments, and a lower slip retaining ring configured to hold the low er slip segments together before the tool anchor is set.

[0007] In another aspect, the present disclosure is directed to an installation system for setting a tool anchor inside a casing in a well. The installation system includes a drivemandrel extending through the tool anchor, wherein the drive mandrel comprises a drive mandrel shoulder and an engagement mechanism on a distal end of the drive mandrel, a lower sub connected to the distal end of the drive mandrel with the engagement mechanism, and a setting tool. The setting tool has an actuator connected to a proximal end of the drive mandrel and a setting tool sleeve extending over the drive mandrel shoulder. The anchor tool is captured between the setting tool sleeve and the lower sub. The anchor tool can have a body, upper slip segments, and lower slip segments constructed from composite, non-metal materials.Brief Description of the Drawings

[0008] FIG. 1 is a side view of a well with a tool connected to a tubular above a tool anchor constructed in accordance with exemplary embodiments.

[0009] FIG. 2 is a partial cross-sectional side view of the tool anchor, drive assembly and bottom sub.

[0010] FIG. 3 is a side view of a first embodiment of the drive mandrel.[OH] FIG. 4 is a partial cross-sectional view of the drive mandrel of FIG. 3 and bottom sub.

[0012] FIG. 5 is a partial cross-sectional view of the drive mandrel and bottom sub of FIG 4 after separation.

[0013] FIG. 6 is a partial cross-sectional side view of a second embodiment of the drive mandrel and bottom sub before assembly.

[0014] FIG. 7 is a partial cross-sectional side view of the drive mandrel and bottom sub after assembly.

[0015] FIG. 8 provides cross-sectional side and perspective views of the tool anchor body.

[0016] FIG. 9 provides side and perspective views of the upper and lower slips.

[0017] FIG. 10 is a partial cross-sectional side view of the tool anchor, drive mandrel, bottom sub and setting tool.

[0018] FIG. 11 is a partial cross-sectional side view of the tool anchor, drive mandrel, bottom sub and setting tool installed in the well casing.

[0019] FIG. 12 is a cross-sectional side view of the tool anchor installed in the well casing.Writen Description

[0020] FIG. 1 depicts a well 200 that includes a wellhead 202 and a casing 204. A downhole tool 206 is connected to the wellhead 202 with a tubular 208. Generally, the downhole tool 206 is designed to produce fluids such as liquid or gaseous petroleum products or water. As used herein, the term "petroleum" refers broadly to all mineral hydrocarbons, such as crude oil, natural gas and combinations of oil and gas. Although the well 200 is depicted as a conventional vertical well, it will be appreciated that the well 200 can include deviated or horizontal sections.

[0021] A tool anchor 100 has been installed inside the casing 204 below the downhole tool 206 and tubular 208. Generally, the tool anchor 100 is designed to prevent the downhole tool 206 or tubular 208 from falling deeper into the well 200 if the tubular 208 or downhole tool 206 are unintentionally released from attachment to the wellhead 202, casing 204 or from a surface-based support.

[0022] The tool anchor 100 includes a body 102, an upper slip 104 and a lower slip 106. Unless otherw ise indicated, each component of the tool anchor 100 is preferably manufactured from a composite (i.e., non-metal) material that can be easily milled for removal. As depicted in FIG. 8, the tool body 102 includes a plurality of upper slip segment slots 108, lower slip segment slots 110, and a central passage 112. The upper and lower slip segment slots 108, 110 each include a tapered planar surface such thatthe outboard ends of the upper and lower slip segment slots 108, 1 10 are closer to the central passage 112 than the inboard ends of the upper and lower slip segments slots 108, 110. In exemplary embodiments, the body 102 of the tool anchor 100 is manufactured as a single, unitary component.

[0023] As shown in FIG 9. the upper slip 104 includes a plurality of upper slip segments 114 and an upper slip retaining ring 116. Each of the upper slip segments 114 is configured to fit within a corresponding one of the upper slip segment slots 108. The upper slip retaining ring 116 is configured to hold the upper slip segments 114 together around the body 102 before the tool anchor 100 has been deployed. Each upper slip segment 114 can include one or more inserts 118 that are configured to penetrate the inner wall of the casing 204 to increase the frictional interface between the tool anchor 100 and the casing 204. The inserts 118 and the upper slip retaining ring 116 can be constructed from suitable metals.

[0024] The lower slip 106 includes a plurality of lower slip segments 120 and a lower slip retaining ring 122. Each of the lower slip segments 120 is configured to fit within a corresponding one of the lower slip segment slots 108. The lower slip retaining ring 122 is configured to hold the lower slip segments 120 together around the body 102 before the tool anchor 100 has been deployed. Each lower slip segment 120 can include one or more inserts 124 that are configured to penetrate the inner wall of the casing 204 to increase the frictional interface between the tool anchor 100 and the casing 204. The inserts 124 and the lower slip retaining ring 122 can be constructed from suitable metals.

[0025] Turning back to FIG. 2, the tool anchor 100 is configured for installation with a drive mandrel 126 and lower sub 128. The drive mandrel 126 includes a distal end 130, a proximal end 132, and an intermediate drive shoulder 136 between the distal andproximal ends 130, 132. The lower sub 128 is configured for connection to a distal end 130 of the drive mandrel 126. A proximal end 132 of the drive mandrel 126 is connected to a setting tool 134, as depicted in FIGS 10 and 11. The drive mandrel 126 supports the tool anchor 100 in an undeployed state between a drive mandrel shoulder 136 and the lower sub 128 while the tool anchor 100 is lowered into the well 200. When the tool anchor 100 is positioned in the proper location within the well 200, the drive mandrel 126 and setting tool 134 cooperate to deploy the tool anchor 100 in a locked position inside the casing 204.

[0026] The lower sub 128 can be connected to the drive mandrel 126 with one or more different engagement mechanisms. In a first embodiment depicted in FIGS. 2-5, the engagement mechanism is a threaded connection in which exterior threads 138 on the distal end 130 of the drive mandrel 126 engage with interior threads 140 in the lower sub 128. In this way, the lower sub 128 can be threaded into engagement over the distal end 130 of the drive mandrel 126. The drive mandrel 126 can include one or more lock screw bores 142 that each receive a corresponding lock screw 144 extending through the lower sub 128. The lock screws 144 and lock screw bores 142 prevent the lower sub 128 from unthreading from the drive mandrel 126 to ensure that the tool anchor 100 remains in an uncompressed, undeployed state in the spacing between the lower sub 128 and the drive mandrel shoulder 136. The lower sub 128 shields the tool anchor 100 from contact with debris or fluids in the well 200 while the tool anchor 100 is being lowered into the well 200.

[0027] When a sufficient tensional force is applied betw een the drive mandrel 126 and the lower sub 128, the lock screws 144 will shear and the exterior threads 138 will pull through the interior threads 140 of the lower sub 128. Thus, the engagement mechanismbetween the drive mandrel 126 and lower sub 128 is designed to fail when a threshold tensional force is applied between the drive mandrel 126 and lower sub 128.

[0028] In another embodiment, as depicted in FIG. 6, the lower sub 128 is attached to the distal end 130 of the drive mandrel 126 with an engagement mechanism that includes one or more shear screws 146 that each engaged a corresponding shear screw bore 148 on the drive mandrel 126. In yet other embodiments, as depicted in FIG. 7, the lower sub 128 is connected to the drive mandrel 126 with an engagement mechanism that includes a shear ring 150 that is initially captured in a shear ring groove 152 in the drive mandrel 126. Once the threshold tensional force is applied between the lower sub 128 and drive mandrel 126, the shear screws 146 and shear ring 150 are designed to shear, thereby allowing the lower sub 128 to separate from the drive mandrel 126.

[0029] In a preferred method of assembly, the upper slip 104 is placed over the distal end 130 of the drive mandrel 126 and moved into contact with the drive mandrel shoulder 136. Next, the body 102 of the tool anchor 100 is installed over the distal end 130 and placed in light contact with the upper slip 104. The lower slip 106 can then be installed over the distal end 130 of the drive mandrel 126 and brought into light contact with the body 102. The upper and lower slip segments 114, 120 should be aligned with the corresponding upper and lower slip segment slots 108, 110 on the body 102. Next, the lower sub 128 can be installed onto the distal end 130 of the drive mandrel 126 and locked into place with the selected engagement mechanism.

[0030] As illustrated in FIGS. 10 and 11, the setting tool 134 includes a setting tool sleeve 154 and an actuator 156. The setting tool sleeve 154 extends around the outside of the drive mandrel shoulder 136 so that it can contact the upper slip 104. The actuator156 is attached to the drive mandrel 126 and configured to pull the drive mandrel 126through the setting tool sleeve 154 while the setting tool sleeve 154 remains stationary. The actuator 156 can be a wireline-activated mechanism in which a wireline pulls the actuator 156 and drive mandrel 126. In other embodiments, the actuator 156 is hydraulically driven and configured to pull the drive mandrel 126 in response to an increase in hydraulic pressure in the actuator 156.

[0031] To deploy the tool anchor 100, the actuator 156 is activated to pull the drive mandrel 126 toward the setting tool 134. As the drive mandrel 126 is moved toward the setting tool 134, the lower sub 128 compresses the upper slip 104, lower slip 106 and body 102 against the setting tool sleeve 154. As the upper and lower slips 104, 106 are compressed over the body 102. the angled, conical geometry of the conical planar surfaces of the upper and lower slip segment slots 108, 110 force the corresponding upper and lower slip segments 114, 120 to expand radially outward until the outward force exerted by the upper and lower slips 104, 106 fractures the upper and lower slip retaining rings 116, 122.

[0032] Once the tool anchor 100 has been deployed or “set” within the casing 204, further compression between the upper and lower slips 104, 106 is prohibited and the lower sub 128 is blocked from further movement toward the setting tool 134. Once the tool anchor 100 has been deployed or “set” within the casing 204 and the lower sub 128 is prevented from further uphole movement by the low er slip 106 and body 102, the force applied by the actuator 156 will increase until the threshold “releasing force” is reached, at which time the engagement mechanism betw een the drive mandrel 126 and the lower sub 128 will fail and the drive mandrel 126 is pulled through the lower sub 128. The low er sub 128 will then fall aw ay from the balance of the tool anchor 100 and the drive mandrel 126 can be fully retracted within the setting tool 134. The setting tool134 can then be pulled away from the tool anchor 100 with the drive mandrel 126 passing through the central passage 112 of the tool anchor 100.

[0033] The setting tool 134 can then be removed from the wellbore 200 while the tool anchor 100 remains securely retained within the casing 204 by the outward, wedge- driven forces created by the engagement of the upper and lower slips 104, 106 over the body 102. In this way, the setting tool 134. drive mandrel 126 and lower sub 128 together present an installation system or installation kit for installing the tool anchor 100 in the casing 204 of the well 200. The tool anchor 100 and the setting tool, 134, drive mandrel 126 and lower sub 128 together form a tool anchor system.

[0034] Once set, the tool anchor 100 provides a robust fixture to hold tubing or downhole tools. The conical configuration of the upper and lower slips 104, 106 and the body 102 causes loads applied to the tool anchor 100 in either the uphole or downhole direction to be translated into outward radial forces that cause the upper and lower slips 104, 106 to further engage the casing 204, thereby increasing the holding force of the tool anchor 100. Unlike prior art metal tool anchors, the tool anchor 100 is manufactured primarily from composite materials that facilitate and expedite the removal of the tool anchor through milling operations. In most cases, the tool anchor 100 can be removed with a milling tool within a few minutes using standard bits and without causing any damage to the casing 204.

[0035] It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and functions of various embodiments of the invention, this disclosure is illustrative only, and changes may be made in detail, especially in matters of structure and arrangement of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the termsin which the appended claims are expressed. It will be appreciated by those skilled in the art that the teachings of the present invention can be applied to other systems without departing from the scope and spirit of the present invention.

Claims

What is claimed is:

1. A tool anchor configured for installation and in a well casing, the tool anchor comprising: a body constructed from a composite, non-metal material, wherein the body comprises upper slip segment slots, lower slip segment slots and a central passage extending through the body; an upper slip, wherein the upper slip comprises a plurality of upper slip segments constructed from a composite material; and a lower slip, wherein the lower slip comprises a plurality of lower slip segments constructed from a composite material.

2. The tool anchor of claim 1, wherein the upper slip further comprises a plurality of inserts in each of the plurality of upper slip segments.

3. The tool anchor of claim 2, wherein the upper slip further comprises an upper slip retaining ring configured to hold the upper slip segments together before the tool anchor is set.

4. The tool anchor of claim 1, wherein the lower slip further comprises a plurality of inserts in each of the plurality of lower slip segments.

5. The tool anchor of claim 4, wherein the lower slip further comprises a lower slip retaining ring configured to hold the lower slip segments together before the tool anchor is set.

6. An installation system for setting a tool anchor inside a casing in a well, the installation system comprising:a drive mandrel extending through the tool anchor, wherein the drive mandrel comprises a drive mandrel shoulder and an engagement mechanism on a distal end of the drive mandrel; a lower sub connected to the distal end of the drive mandrel with the engagement mechanism; and a setting tool, wherein the setting tool comprises an actuator connected to a proximal end of the drive mandrel and a setting tool sleeve extending over the drive mandrel shoulder; and wherein the anchor tool is captured between the setting tool sleeve and the lower sub.

7. A tool anchor system for installation in a well having a casing, the tool anchor system comprising: a tool anchor, wherein the tool anchor comprises: a body constructed from a composite, non-metal material, wherein the body comprises upper slip segment slots, lower slip segment slots and a central passage extending through the body; an upper slip, wherein the upper slip comprises a plurality of upper slip segments constructed from a composite material, a plurality’ of inserts in each of the plurality of upper slip segments, and an upper slip retaining ring configured to hold the upper slip segments together before the tool anchor is set: and a lower slip, wherein the lower slip comprises a plurality of lower slip segments constructed from a composite material, a plurality' of inserts in each of the plurality of lower slip segments, and alower slip retaining ring configured to hold the lower slip segments together before the tool anchor is set; and an installation system for setting the tool anchor inside the casing, the installation system comprising: a drive mandrel extending through the tool anchor, wherein the drive mandrel comprises a drive mandrel shoulder and an engagement mechanism on a distal end of the drive mandrel; a lower sub connected to the distal end of the drive mandrel with the engagement mechanism; and a setting tool, wherein the setting tool comprises an actuator connected to a proximal end of the drive mandrel and a setting tool sleeve extending over the drive mandrel shoulder; and wherein the anchor tool is captured between the setting tool sleeve and the lower sub.

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