Nose for a downhole tool

Abstract

A nose (10) for a downhole tool (1000), comprising a body (12) constructed from a composite material (14) including aramid is described.

Description

[0001] NOSE FOR A DOWNHOLE TOOL

[0002] FIELD

[0003] This relates to a nose for a downhole tool, such as a downhole reamer shoe, guide shoe, float shoe or the like; to a downhole tool comprising the nose; and a method of performing a downhole operation using the downhole tool.

[0004] BACKGROUND

[0005] In the oil and gas exploration and production industry, amongst others, a borehole (known in the oil and gas industry as a “wellbore” since it facilitates access to the hydrocarbon bearing formation) is drilled from surface, the borehole typically then being lined with metallic bore-lining tubing known as casing. Sections of casing are typically threaded together to form a casing string which is run into the borehole, the annulus between the casing string and the borehole then being filled with a settable material, typically cement, which amongst other things supports the casing string and the borehole and provides a seal which prevents uncontrolled fluid flow up the annulus between the outside of the casing string and the inside of the borehole.

[0006] Typically, the borehole construction and completion process involves a number of stages. For example, following the drilling, casing and cementing of a given section of the borehole, drilling equipment is directed through the cased section of the borehole and operated to extend the borehole. In some instances, the extended borehole section may be left in this “open hole” condition. In other instances, the extended borehole section is also cased.

[0007] The distal leading end of the casing string is often provided with a downhole tool, commonly known as a shoe, having a tapered nose which assists in guiding the casing towards the centre of the borehole, thereby reducing the risk that the casing string will hit ledges and / or washouts as it progresses through the borehole and which may otherwise impinge on the ability of the casing string to reach the desired total depth. In some instances, the downhole tool takes the form of a reamer shoe, having blades with cutting elements which facilitate reaming of the borehole as the casing string travels downhole. While used extensively, there are a number of technical challenges with the use of shoes.

[0008] For example, once the casing string has reached the desired depth, the casing string together with the shoe is cemented in place. As such, it is necessary to drill out the shoe in order to extend the borehole, this being achieved with a drill bit of smaller outer diameter than the casing string.

[0009] However, the drilling out of the shoe requires the removal of a significant amount of material, resulting in increased time and associated costs to complete the borehole completion operation.

[0010] Moreover, the requirement to remove the material of the shoe increases degradation of the drill bit, potentially reducing the working life of the bit to the extent that additional trips into and / or out of the borehole are required in order to reach total depth (at significant additional expense and loss of time to the operator). Degradation of the drill bit may also increase the likelihood of borehole irregularities being formed during drilling of the extended borehole portion, such that additional remedial operations must be carried out (again at significant additional expense and loss of time to the operator, where indeed these can be resolved at all).

[0011] The removal of the shoe material also results in the creation of drill cuttings which can be difficult to remove by drill fluid circulation and which can, amongst other things, result in the formation of drill cuttings beds on the low side of the borehole and / or other obstacles which may impinge on the ability to effectively case the extended borehole.

[0012] The above factors, amongst others, may in turn also detrimentally effect the ability to place and / or cement the casing in the extended portion of the borehole portion. In the oil and gas industry, for example, the quality of the cementing job is critical to the safe and efficient operation of the wellbore, in view of the cement being used to not only support the casing string and prevent collapse of the borehole but also to prevent uncontrolled fluid flow up the annulus between the outside of the casing string and the inside of the borehole. SUMMARY

[0013] Aspects of the present disclosure relate to a nose for a downhole tool, such as a downhole reamer shoe, guide shoe, float shoe or the like; to a downhole tool comprising the nose; and to a method of performing a downhole operation using the downhole tool.

[0014] According to a first aspect, there is provided a nose for a downhole tool, the nose comprising a body constructed from a composite material including aramid.

[0015] In use, the nose may form a distal leading end of a tubing string, e.g. a bore-lining tubing string such as a casing string, the nose facilitating progress of the tubing string through the borehole.

[0016] The nose provides a number of significant benefits in comparison to conventional equipment.

[0017] For example, in use, the nose may permit the tubing string to ride over obstructions in the borehole, beneficially reducing the risk that progress of the tubing string will be inhibited or prevented, e.g. via engagement with ridges, washouts or other bore irregularities which may otherwise impinge on the ability of the tubing string to reach the desired total depth.

[0018] In particular, but not exclusively, the nose may significantly reduce the amount of time required to carry out the borehole completion operation, since the nose is capable of being drilled out much more rapidly than conventional noses. For example, and as described further below, testing has demonstrated that the nose can be drilled out in approximately 2 minutes compared to approximately 17 minutes with a conventional aluminium nose.

[0019] The nose reduces wear of the surrounding bore-lining tubing (where the casing string is progressing through a cased section of the borehole) and / or the borehole wall (where the casing string is progressing though an open hole section of the borehole). For example, and as described further below, in testing steel casing material exhibited a 1 ,2g loss of mass following interaction with the nose material. In comparison, steel casing material exhibited a 118.1g loss of mass following interaction with steel nose material. Beneficially, a reduction in wear of the surrounding bore-lining tubing (where the casing string is progressing through a cased section of the borehole) and / or the borehole wall (where the casing string is progressing though an open hole section of the borehole) obviates the requirement for additional remedial operations at significant additional expense and loss of time to the operator.

[0020] The nose has a greater wear resistance than conventional noses. For example, in testing, the material of the nose exhibited a 1 ,2g loss of mass following interaction with an abrasive test surface. In comparison, steel nose material exhibited a 98.0g loss of mass following interaction with the same abrasive test surface.

[0021] Beneficially, the provision of a nose having a greater wear resistance than conventional noses may prolong operational effectiveness and / or working life, amongst other things reducing the likelihood that additional trips into the borehole are required.

[0022] The nose has a lower coefficient of friction than conventional noses. For example, in testing the material of the nose exhibited a friction factor of 0.171 in the borehole and 0.079 in casing (steel). In comparison, steel nose material exhibited a friction factor of 0.334 in the borehole and 0.178 in casing (steel).

[0023] Beneficially, this may reduce frictional torque and drag experienced by the tubing string, assisting tubular placement to the desired total depth.

[0024] The construction of the nose beneficially facilitates the formation of drill cuttings in a form which can be more readily removed from the borehole.

[0025] Moreover, the construction of the nose does not degrade the drill bit to a greater extent that conventional noses.

[0026] Beneficially, this, coupled with reduced drill out duration, facilitates increased working life of the bit and / or reduced likelihood of borehole irregularities being formed during drilling of the extended borehole portion. The above factors, amongst others, may in turn beneficially effect the ability to place and / or cement the casing in the extended portion of the borehole portion, facilitating high quality cementing of the casing, and consequential increased safety.

[0027] As described above, the nose comprises a body constructed from a composite material including aramid.

[0028] The aramid may comprise or take the form of a para-aramid, such as Kevlar (RTM) or like material.

[0029] The aramid may comprise or take the form of a meta-aramid, such as Nomex (RTM) or like material.

[0030] The composite material may comprise or take the form of a multi-layer composite material.

[0031] The multi-layer composite material may comprise a first layer, the first layer comprising the aramid. The first layer may form an outer layer of the body. The first layer may comprise a ceramic composite, for example a zirconia composite. The aramid may comprise or take the form of a mesh.

[0032] The composite material may further comprise carbon fibre, or like material.

[0033] For example, the multi-layer composite material may comprise one or more carbon fibre layers.

[0034] In particular embodiments, the multi-layer composite material may comprise two carbon fibre layers.

[0035] The carbon fibre may comprise or take the form of a carbon fibre matrix.

[0036] For example, at least one of the carbon fibre layers of the multi-layer composite may comprise or take the form of a carbon fibre matrix layer. In particular embodiments, the multi-layer composite material may comprise two carbon fibre matrix layers. The carbon fibre may comprise or take the form of woven carbon fibre.

[0037] For example, at least one of the carbon fibre layers of the multi-layer composite may comprise or take the form of a woven carbon fibre layer. In particular embodiments, the multi-layer composite material may comprise two woven carbon fibre layers.

[0038] The carbon fibre may comprise or take the form of a woven carbon fibre matrix. For example, at least one of the carbon fibre layers of the multi-layer composite may comprise or take the form of a woven carbon fibre matrix layer. In particular embodiments, the multi-layer composite material may comprise two woven carbon fibre matrix layers.

[0039] At least one of the carbon fibre layers may be disposed underneath the outer layer.

[0040] The composite material may further comprise chopped fibre.

[0041] For example, the multi-layer composite material may comprise one or more chopped fibre layers. In particular embodiments, the composite material may comprise a single chopped fibre layer.

[0042] The chopped fibre may comprise or take the form of a chopped fibre matrix.

[0043] For example, the multi-layer composite material may comprise one or more chopped fibre matrix layers. In particular embodiments, the composite material may comprise a single chopped fibre matrix layer.

[0044] The chopped fibre layer may be disposed underneath the outer layer.

[0045] The chopped fibre layer may be interposed between the carbon fibre layers.

[0046] The composite material may comprise chopped carbon fibre.

[0047] As described above, the nose comprises a body. The body may take a variety of different shapes and / or forms.

[0048] The body may be conical or substantially conical in shape.

[0049] The body may be symmetrical or substantially symmetrical about a central longitudinal axis of the body.

[0050] In particular embodiments, the body may be eccentrically shaped.

[0051] Beneficially, the provision of a nose having an eccentrically shaped body permits the tubing string to more readily ride over obstructions in the borehole, beneficially reducing the risk that progress of the tubing string will be inhibited or prevented, e.g. via engagement with ridges, washouts or other bore irregularities which may otherwise impinge on the ability of the tubing string to reach the desired total depth.

[0052] The body may be hollow. The body may comprise or define an axial flow passage, e.g. a throughbore.

[0053] The nose may comprise a coupling arrangement.

[0054] In use, the coupling arrangement may be configured and / or operable to couple the nose to the downhole tool.

[0055] The body and the coupling arrangement may form a unitary construction.

[0056] The coupling arrangement may comprise or take the form of a threaded connection.

[0057] Alternatively, or additionally, the coupling arrangement may comprise or take the form of a j-slot, bayonet-type fitting, push fit connection, a weld connection, an adhesive bond or other suitable connection.

[0058] The nose may comprise a male portion. The male portion may be hollow. The male portion may comprise or take the form of a boss portion. The coupling arrangement may be provided on the male portion. Alternatively or additionally, the nose may comprise a female portion. The coupling arrangement may be provided on the female portion.

[0059] The nose may comprise a flow port arrangement.

[0060] In use, the flow port arrangement may be configured and / or operable to facilitate fluid flow through the nose.

[0061] The flow port arrangement may be configured and / or operable to provide 360 degree or substantially 360 degree flow area coverage.

[0062] Beneficially, the flow port arrangement aids borehole cleaning and / or cement placement.

[0063] The flow port arrangement may comprise one or more flow ports.

[0064] In particular embodiments, the flow port arrangement may comprise a plurality of the flow ports.

[0065] In use, at least one of the flow ports may define an outlet.

[0066] At least one of the flow ports may be aligned or substantially aligned with the longitudinal axis of the nose. Said at least one flow port may comprise or define an axial flow port. In particular embodiments, the flow port arrangement may comprise a single flow port aligned or substantially aligned with the longitudinal axis of the nose. The at least one axial flow port may communicate with the axial flow passage of the body.

[0067] At least one of the flow ports may comprise or take the form of a lateral flow port. The lateral flow ports may be oriented at an angle to the longitudinal axis of the nose. At least one of the lateral flow ports may be oriented at 90 degrees or substantially 90 degrees. However, in particular embodiments at least one of the lateral flow ports may be oriented at an acute angle to the longitudinal axis. The flow port arrangement may comprise a plurality of the lateral flow ports. In particular embodiments, the flow port arrangement may comprise three lateral flow ports.

[0068] The lateral flow ports may be circumferentially arranged and / or spaced.

[0069] At least one of the lateral flow ports may communicate with the axial flow passage of the body.

[0070] The one or more flow ports may take a variety of different shapes and / or forms. In particular embodiments, at least one of the flow ports may be circular or substantially circular.

[0071] The nose may comprise, may be coupled to or operatively associated with a valve arrangement.

[0072] The valve arrangement may be configured and / or operable to control fluid flow through the body of the nose. More particularly, the valve arrangement may be configured and / or operable to prevent or at least mitigate flow of borehole fluid in an uphole direction through the downhole tool as the downhole tool is run downhole and / or the flow of unset cement slurry / settable material from the annulus into the casing.

[0073] The valve arrangement may comprise a valve, e.g. a non-return valve.

[0074] The valve arrangement may comprise a valve member.

[0075] The valve arrangement may comprise a valve seat.

[0076] The valve may be configurable from a first, closed, configuration, e.g. in which the valve member engages the valve seat and a second, open, configuration, e.g. in which the valve member is offset from the valve seat.

[0077] The valve may be configured so that the valve member is biased towards the first, closed, configuration. The valve arrangement may be disposed in the body of the nose, more particularly in the axial flow passage of the body of the nose. The valve arrangement may be coupled to the body of the nose.

[0078] Beneficially, the positioning of the valve arrangement may permit the downhole tool to be shorter than conventional equipment.

[0079] According to a second aspect, there is provided a downhole tool comprising the nose of the first aspect.

[0080] The downhole tool may comprise or take the form of a shoe, e.g. a reamer shoe, a float shoe, a pilot guide shoe or the like.

[0081] The downhole tool may be configured for attachment to a casing string. For example, the downhole tool may be utilised as a float shoe, a casing shoe, a pilot guide shoe etc.

[0082] The downhole tool may comprise a body. The body of the downhole tool may comprise or take the form of a tubular body. The body of the downhole tool may be hollow. The body of the downhole tool may comprise or define an axial flow passage, e.g. a throughbore. The axial flow passage of the body of the downhole tool may communicate with the axial flow passage of the body of the nose.

[0083] The downhole tool may comprise one or more radially extending members.

[0084] The one or more radially extending members may comprise or take the form of one or more blades.

[0085] The one or more radially extending members may be configured and / or operable to engage a wall of the borehole, e.g. surrounding bore-lining tubing (where the casing string is progressing through a cased section of the borehole) and / or the borehole wall (where the casing string is progressing though an open hole section of the borehole).

[0086] In particular embodiments, the downhole tool may comprise a plurality of radially extending members. At least one of the radially extending members may be formed or disposed on the body of the downhole tool. Alternatively or additionally, at least one of the radially extending members may be formed or disposed on the body of the nose.

[0087] At least one of the radially extending members may comprise one or more cutting elements. The cutting elements may be configured and / or operable to ream the borehole. Beneficially, the cutting elements offer the capability to ream past obstructions with rotation and / or by reciprocation.

[0088] For example, at least one of the cutting elements may be constructed from Tungsten Carbide, polycrystalline diamond compact (PDC) or the like.

[0089] At least one of the radially extending members may extend axially, e.g. along at least a part of the length of the body of the downhole tool and / or the body of the nose.

[0090] At least one of the radially extending members may extend at least partially circumferentially. For example, at least one of the radially extending members may extend helically.

[0091] The nose may be integrally formed with the body of the downhole tool.

[0092] Alternatively, the nose may be configured for coupling to the body of the downhole tool.

[0093] The body of the downhole tool may comprise a coupling arrangement.

[0094] The coupling arrangement of the downhole tool may comprise a first coupling portion.

[0095] The first coupling portion may be configured and / or operable to couple the body of the downhole tool to the nose, in particular the coupling arrangement of the nose. The first coupling portion may be located at a first, downhole, end of the body of the downhole tool. Beneficially, the first coupling portion facilitates switch-out of the nose, e.g. for repair, replacement and / or in order to couple a different nose.

[0096] The first coupling portion may comprise or take the form of a threaded connection.

[0097] Alternatively, or additionally, the first coupling portion may comprise or take the form of a j-slot, bayonet-type fitting, push fit connection, a weld connection, an adhesive bond or other suitable connection.

[0098] The body of the downhole tool may comprise a female portion. The first coupling portion may be provided on the female portion of the body of the downhole tool.

[0099] Alternatively, the body of the downhole tool may comprise a male portion. The first coupling portion may be provided on the male portion of the body of the downhole tool.

[0100] The coupling arrangement of the downhole tool may comprise a second coupling portion.

[0101] The second coupling portion may be configured and / or operable to couple the body of the downhole tool to the tubing string, e.g. casing string. The second coupling portion may be located at a second, uphole, end of the body of the downhole tool.

[0102] The second coupling portion may comprise or take the form of a threaded connection.

[0103] Alternatively, or additionally, the second coupling portion may comprise or take the form of a push fit connection, a weld connection, an adhesive bond or other suitable connection.

[0104] The body of the downhole tool may comprise a female portion (“second female portion”). The second coupling portion may be provided on the second female portion of the body of the downhole tool. Alternatively, the body of the downhole tool may comprise a male portion (“second male portion”). The second coupling portion may be provided on the second male portion of the body of the downhole tool.

[0105] The downhole tool may comprise, may be coupled to or operatively associated with a valve arrangement.

[0106] The valve arrangement may be configured and / or operable to control fluid flow through the body of the downhole tool. More particularly, the valve arrangement may be configured and / or operable to prevent or at least mitigate flow of borehole fluid in an uphole direction through the downhole tool as the downhole tool is run downhole and / or the flow of unset cement slurry / settable material from the annulus into the casing.

[0107] The valve arrangement may comprise a valve, e.g. a non-return valve.

[0108] The valve arrangement may comprise a valve member.

[0109] The valve arrangement may comprise a valve seat.

[0110] The valve may be configurable from a first, closed, configuration, e.g. in which the valve member engages the valve seat and a second, open, configuration, e.g. in which the valve member is offset from the valve seat.

[0111] The valve may be configured so that the valve member is biased towards the first, closed, configuration.

[0112] The valve arrangement may be disposed in the body of the downhole tool, more particularly in the axial flow passage of the body of the downhole tool. The valve arrangement may be coupled to the body of the downhole tool.

[0113] Beneficially, the positioning of the valve arrangement may permit the downhole tool to be shorter than conventional equipment.

[0114] A third aspect relates to use of the downhole tool of the second aspect to guide a tubing string into a borehole and / or ream a borehole. According to a fourth aspect, there is provided a method of manufacture of a nose for a downhole tool, wherein the nose is constructed from a composite material, and wherein the nose is constructed by moulding, e.g. compression moulding.

[0115] The nose may comprise or take the form of the nose of the first aspect.

[0116] The method may comprise forming a first layer, e.g. the first layer of the first aspect.

[0117] The method may comprise forming one or more carbon fibre layers, e.g. the one or more carbon fibre layers of the first aspect. In particular embodiments, the method may comprise forming two carbon fibre layers.

[0118] The method may comprise forming one or more chopped fibre layers, e.g. the one or more chopped fibre layers of the first aspect.

[0119] The method may comprise disposing the first layer on top of the one or more carbon fibre layers. Where the composite material comprises two or more carbon fibre layers, the method may comprise forming the first layer on top of the two or more carbon fibre layers.

[0120] Where the composite material comprises the one or more chopped fibre layers, the method may comprise interposing the one or more chopped fibre layers in between the two or more carbon fibre layers. The step of interposing the one or more chopped fibre layers in between the one or more carbon fibre layers may be carried out before the step of disposing the outer layer on top.

[0121] In particular embodiments, the method may comprise: providing a first carbon fibre layer; disposing the chopped fibre layer on top of the first carbon fibre layer; disposing a second carbon fibre layer on top of the chopped fibre layer; and disposing the first layer on top of the second carbon fibre layer. The method may comprise compression moulding the first layer and the one or more carbon fibre layers to form a multi-layer composite, e.g. the multi-layer composite of the first aspect.

[0122] In particular embodiments, the method may comprise compression moulding the first layer, the one or more carbon fibre layers and the chopped fibre layer to form a multilayer composite, e.g. the multi-layer composite of the first aspect.

[0123] The method may comprise the step of forming the composite material, e.g. the multi-layer composite, into the shape of a nose, e.g. the nose of the first aspect.

[0124] According to a fifth aspect, there is provided a method of manufacture of a nose for a downhole tool or a downhole tool comprising the nose, wherein the nose is constructed from a composite material, and wherein the nose or downhole tool is constructed by additive manufacturing.

[0125] The nose may comprise or take the form of the nose of the first aspect.

[0126] The method of manufacturing via additive manufacturing may include the steps of obtaining a design file representing the nose and / or downhole tool and instructing an additive manufacturing apparatus to manufacture the nose and / or downhole tool according to the design file. The additive manufacturing apparatus may include a processor that is configured to automatically convert the design file into computer executable instructions for controlling the manufacture of the nose and / or downhole tool. The design file itself may automatically cause the production of the nose and / or downhole tool once input into the additive manufacturing device. Accordingly, the design file itself may be considered computer executable instructions that cause the additive manufacturing apparatus to manufacture the nose and / or downhole tool. Alternatively, the design file may be converted into instructions by an external computing system, with the resulting computer executable instructions being provided to the additive manufacturing device.

[0127] Given the above, the design and manufacture of the nose and / or downhole tool may be realised using digital electronic circuitry, or in computer software, firmware, or hardware. Hardware may include processors, microprocessors, electronic circuitry, electronic components, integrated circuits, etc. Implementations of the method of manufacturing via additive manufacturing may be realised using one or more computer programs, i.e., one or more modules of computer program instructions, encoded on computer storage medium for execution by, or to control the operation of, data processing apparatus. Alternatively or in addition, the program instructions may be encoded on an artificially generated propagated signal, e.g., a machine-generated electrical, optical, or electromagnetic signal that is generated to encode information for transmission to suitable receiver apparatus for execution by a data processing apparatus. A computer storage medium may be, or be included in, a computer-readable storage device, a computer-readable storage substrate, a random or serial access memory array or device, or a combination of one or more of them. Moreover, while a computer storage medium is not a propagated signal, a computer storage medium may be a source or destination of computer program instructions encoded in an artificially generated propagated signal. The computer storage medium may also be, or be included in, one or more separate physical components or media (e.g., multiple CDs, disks, or other storage devices).

[0128] According to a sixth aspect, there is provided computer software, firmware or hardware for controlling the manufacture of a nose for a downhole tool or a downhole tool comprising the nose, wherein the nose is constructed from a composite material.

[0129] The nose may comprise or take the form of the nose of the first aspect.

[0130] The structure of the nose and / or downhole tool may be represented digitally in the form of a design file. The design file may be produced using modelling (e.g. CAD modelling) software. The design file, e.g. a computer aided design (CAD) file, may be a configuration file that encodes one or more of the surface or volumetric configuration of the shape of the nose and / or downhole tool. That is, the design file may represent the geometrical arrangement or shape of the nose and / or downhole tool.

[0131] The design files may take any now known or later developed file format. For example, the design file may be in the Stereolithography or “Standard Tessellation Language” (.stl) format which was created for stereolithography CAD programs of 3D Systems, or the Additive Manufacturing File (.amf) format, which is an American Society of Mechanical Engineers (ASME) standard that is an extensible markup-language (XML) based format designed to allow any CAD software to describe the shape and composition of any three-dimensional object to be fabricated on any additive manufacturing printer. Further examples of design file formats include AutoCAD (.dwg) files, Blender (.blend) files, Parasolid (,x_t) files, 3D Manufacturing Format (,3mf) files, Autodesk (3ds) files, Collada (.dae) files and Wavefront (.obj) files, although many other file formats exist.

[0132] Once obtained, the design file may be converted into a set of computer executable instructions that, once executed by a processer, cause the processor to control an additive manufacturing apparatus to produce the nose and / or downhole tool according to the geometrical arrangement specified in the design file. The conversion may convert the design file into slices or layers that are to be formed sequentially by the additive manufacturing apparatus. The instructions (otherwise known as geometric code or “G-code”) may be calibrated to the specific additive manufacturing apparatus and may specify the precise location and amount of material that is to be formed at each stage in the manufacturing process. The formation may be through deposition, through sintering, or through any other form of additive manufacturing method.

[0133] The code or instructions may be translated between different formats, converted into a set of data signals and transmitted, received as a set of data signals and converted to code, stored, etc., as necessary. The instructions may be an input to the additive manufacturing system and may come from a part designer, an intellectual property (IP) provider, a design company, the operator or owner of the additive manufacturing system, or from other sources. An additive manufacturing system may execute the instructions to fabricate the nose and / or downhole tool using any of the technologies or methods disclosed herein.

[0134] The design file or computer executable instructions may be stored in a (transitory or non-transitory) computer readable storage medium (e.g., memory, storage system, etc.) storing code, or computer readable instructions, representative of the product to be produced. As noted, the code or computer readable instructions defining the nose and / or downhole tool may be used to physically generate the nose and / or downhole tool, upon execution of the code or instructions by an additive manufacturing system. For example, the instructions may include a precisely defined 3D model of the nose and / or downhole tool and may be generated from any of a large variety of well-known computer aided design (CAD) software systems such as AutoCAD®, TurboCAD®, DesignCAD 3D Max, etc. Alternatively, a model or prototype of the nose and / or downhole tool may be scanned to determine the three-dimensional information of the component. Accordingly, by controlling an additive manufacturing apparatus according to the computer executable instructions, the additive manufacturing apparatus may be instructed to print out the nose and / or downhole tool.

[0135] The invention is defined by the appended claims. However, for the purposes of the present disclosure it will be understood that any of the features defined above or described below may be utilised in isolation or in combination. For example, features described above in relation to one of the above aspects or below in relation to the detailed description below may be utilised in any other aspect, or together form a new aspect.

[0136] BRIEF DESCRIPTION OF THE DRAWINGS

[0137] Figure 1 shows a perspective view of a nose for a downhole tool;

[0138] Figure 2 shows a diagrammatic view of a multi-layer composite material from which the nose shown in Figure 1 is constructed;

[0139] Figure 3 shows a side view of the nose shown in Figure 1 ;

[0140] Figure 4 shows a front view of the nose shown in Figure 1 ;

[0141] Figure 5 shows a longitudinal section view of the nose shown in Figure 1 ;

[0142] Figure 6 shows a perspective view of a downhole tool comprising the nose shown in Figure 1 , coupled to a tubing string;

[0143] Figure 7 shows a cross-sectional view of the downhole tool shown in Figure 6 coupled to the tubing string;

[0144] Figure 8A is a photograph of a 9.625” (244.48 mm) eccentric machined Aluminium nose;

[0145] Figure 8B is a photograph of a 9.625” (244.48 mm) nose according to the present disclosure;

[0146] Figure 9A is a photograph of the nose shown in Figure 8A cemented in a section of casing;

[0147] Figure 9B is a photograph of the nose shown in Figure 8B cemented in a section of casing;

[0148] Figure 10A shows the nose shown in Figure 8A located on the test bed just prior to the drill bit drilling out the nose;

[0149] Figure 10B shows the nose shown in Figure 8B located on the test bed just prior to the drill bit drilling out the nose;

[0150] Figure 11A shows the nose shown in Figure 8A after the drill out operation has been completed;

[0151] Figure 11 B shows the nose shown in Figure 8B after the drill out operation has been completed;

[0152] Figure 12A shows the drill cuttings created during the drill out operation on the nose shown in Figure 8A;

[0153] Figure 12B shows the drill cuttings created during the drill out operation on the nose shown in Figure 8B;

[0154] Figure 13A shows a graph showing the results of the drill out operation on the nose shown in Figure 8A;

[0155] Figure 13B shows a graph showing the results of the drill out operation on the nose shown in Figure 8B; Figure 14 shows a graph showing friction factor exhibited by a specimen of steel of the same grade as conventional noses (line A) and the material of the nose 10 (line B) in relation to a specimen of formation material;

[0156] Figure 15 shows a graph showing friction factor exhibited by a specimen of steel of the same grade as conventional noses (line A) and the material of the nose 10 (line B) in relation to a specimen of steel of the same grade as casing (representative of when the nose passes through a cased section of the borehole;

[0157] Figure 16 shows an alternative downhole tool comprising the nose shown in Figure 1 ; and

[0158] Figure 17 shows a further alternative downhole tool comprising the nose shown in Figure 1.

[0159] DETAILED DESCRIPTION OF THE DRAWINGS

[0160] Referring first to Figure 1 of the accompanying drawings, there is shown a perspective view of a nose, generally denoted 10, for a downhole tool, generally denoted 1000 (as best shown in Figure 6), the nose 10 comprising a body 12 constructed from a composite material, generally denoted 14 (as best shown in Figure 2), including aramid.

[0161] In use, the nose 10 forms a distal leading end of a tubing string, generally denoted S (as best shown in Figure 6), e.g. a bore-lining tubing string such as a casing string, the nose 10 facilitating progress of the tubing string S through a borehole B (shown in Figure 6).

[0162] The nose 10 provides a number of significant benefits in comparison to conventional equipment.

[0163] For example, in use, the nose 10 permits the tubing string S to ride over obstructions in the borehole B, beneficially reducing the risk that progress of the tubing string Swill be inhibited or prevented, e.g. via engagement with ridges, washouts or other bore irregularities which may otherwise impinge on the ability of the tubing string S to reach the desired total depth.

[0164] In particular, but not exclusively, the nose 10 significantly reduces the amount of time required to carry out the borehole completion operation, since the nose 10 is capable of being drilled out much more rapidly than conventional noses. For example, and as described further below, testing has demonstrated that the nose 10 can be drilled out in approximately 2 minutes compared to approximately 17 minutes with a conventional aluminium nose.

[0165] The nose 10 reduces wear of the surrounding bore-lining tubing (where the tubing string S is progressing through a cased section of the borehole B) and / or the borehole wall (where the tubing string S is progressing though an open hole section of the borehole B). For example, and as described further below, in testing steel casing material exhibited a 1.2g loss of mass following interaction with the nose 10 material. In comparison, steel casing material exhibited a 118.1g loss of mass following interaction with steel nose material.

[0166] Beneficially, a reduction in wear of the surrounding bore-lining tubing (where the tubing string S is progressing through a cased section of the borehole B) and / or the borehole wall (where the tubing string S is progressing though an open hole section of the borehole B) obviates the requirement for additional remedial operations at significant additional expense and loss of time to the operator.

[0167] The nose 10 has a greater wear resistance than conventional noses. For example, in testing, the material of the nose 10 exhibited a 1.2g loss of mass following interaction with an abrasive test surface. In comparison, steel nose material exhibited a 98.0g loss of mass following interaction with the same abrasive test surface.

[0168] Beneficially, the provision of the nose 10 having a greater wear resistance than conventional noses prolongs operational effectiveness and / or working life, amongst other things reducing the likelihood that additional trips into the borehole B are required.

[0169] The nose 10 has a lower coefficient of friction than conventional noses. For example, in testing the material of the nose 10 exhibited a friction factor of 0.171 in the borehole B and 0.079 in casing (steel). In comparison, steel nose material exhibited a friction factor of 0.334 in the borehole B and 0.178 in casing (steel).

[0170] Beneficially, this reduces frictional torque and drag experienced by the tubing string S, assisting tubular placement to the desired total depth. The construction of the nose 10 beneficially facilitates the formation of drill cuttings in a form which can be more readily removed from the borehole B.

[0171] Moreover, the construction of the nose 10 does not degrade the drill bit to a greater extent than conventional noses.

[0172] Beneficially, this, coupled with reduced drill out duration, facilitates increased working life of the bit and / or reduced likelihood of borehole irregularities being formed during drilling of the extended borehole portion.

[0173] The above factors, amongst others, may in turn beneficially effect the ability to place and / or cement a bore-lining casing in the extended portion of the borehole portion, facilitating high quality cementing of the bore-lining casing, and consequential increased safety.

[0174] As described above, the nose 10 comprises a body 12 constructed from a composite material 14 including aramid.

[0175] Referring now in particular to Figure 2 of the accompanying drawings, the composite material 14 is shown to comprise or take the form of a multi-layer composite material.

[0176] In the illustrated embodiment, the multi-layer composite material 14 comprises a first layer 16, the first layer 16 comprising the aramid. The first layer 16 forms an outer layer of the body 12, the first layer 16 comprising a ceramic composite, for example a zirconia composite.

[0177] The multi-layer composite material 14 comprises two carbon fibre layers 18, 20, the carbon fibre layers 18, 20 of the multi-layer composite 14 comprising or taking the form of woven carbon fibre matrix layers.

[0178] As shown, the carbon fibre layers 18, 20 are disposed underneath the first layer

[0179] 16. In the illustrated embodiment, the composite material 14 comprises a single chopped fibre layer 22 comprising a single chopped fibre matrix layer.

[0180] As shown, the chopped fibre layer 22 is disposed underneath the first layer 16 and interposed between the carbon fibre layers 18, 20.

[0181] Referring now to Figures 3 to 5 of the accompanying drawings, the body 12 is shown to be eccentrically shaped.

[0182] Beneficially, the provision of the nose 10 having an eccentrically shaped body 12 permits the tubing string S to more readily ride over obstructions in the borehole B, beneficially reducing the risk that progress of the tubing string S will be inhibited or prevented, e.g. via engagement with ridges, washouts or other bore irregularities which may otherwise impinge on the ability of the tubing string S to reach the desired total depth.

[0183] As is best shown in Figure 5 of the accompanying drawings, the body 12 is hollow, the body 12 comprising or defining an axial flow passage, generally denoted 24, e.g. a throughbore.

[0184] As is best shown in Figure 3 of the accompanying drawings, the nose 10 comprises a coupling arrangement, generally denoted 26.

[0185] In use, the coupling arrangement 26 is configured and / or operable to couple the nose 10 to the downhole tool 1000.

[0186] In the illustrated embodiment, the body 12 and the coupling arrangement 26 form a unitary construction, the coupling arrangement 26 comprising or taking the form of a threaded connection. In addition, the nose 10 comprises a male portion 28. The male portion 28 is hollow, the coupling arrangement 26 being provided thereon.

[0187] Referring now in particular to Figures 4 and 5 of the accompanying drawings, the nose 10 comprises a flow port arrangement, generally denoted 30. In use, the flow port arrangement 30 is configured and / or operable to facilitate fluid flow through the nose 10, the flow port arrangement 30 being configured and / or operable to provide 360 degree or substantially 360 degree flow area coverage.

[0188] Beneficially, the flow port arrangement 30 aids borehole cleaning and / or cement placement.

[0189] In the illustrated embodiment, the flow port arrangement 30 comprises a single flow port 32 and a plurality of flow ports 34, the flow ports 32, 34 each defining an outlet.

[0190] The flow port 32 is aligned or substantially aligned with the longitudinal axis A of the nose 10, the flow port 32 comprising or defining an axial flow port. The axial flow port 32 communicates with the axial flow passage 24 of the body 12.

[0191] In addition, the flow port arrangement 30 comprises three lateral flow ports 34, the lateral flow ports 34 being oriented at an acute angle to the longitudinal axis A of the nose 10 (as is best shown in Figure 5 of the accompanying drawings). The lateral flow ports 34 are circumferentially arranged and / or spaced, and each communicates with the axial flow passage 24 of the body 12.

[0192] In the illustrated embodiment, the flow ports 32, 34 are circular or substantially circular.

[0193] Referring now in particular to Figure 6 of the accompanying drawings, there is shown a perspective view of the downhole tool 1000 comprising the nose 10.

[0194] In the illustrated embodiment, the downhole tool 1000 comprises or takes the form of a reamer shoe.

[0195] The downhole tool 1000 is configured for attachment to the tubing string S.

[0196] The downhole tool 1000 comprises a body 1036, the body 1036 comprising or taking the form of a tubular body. As is best shown in Figure 5 of the accompanying drawings, the body 1036 is hollow, the body 1036 comprising or defining an axial flow passage, generally denoted 1038, e.g. a throughbore. The axial flow passage 1038 communicates with the axial flow passage 24 of the body 12 of the nose 10.

[0197] In the illustrated embodiment, the downhole tool 1000 comprises a plurality of radially extending members 1040, the radially extending members comprising or taking the form of blades. The radially extending members 1040 are formed or disposed on the body 1036.

[0198] The radially extending members 1040 are configured and / or operable to engage a wall of the borehole B, e.g. surrounding bore-lining tubing (where the tubing string S is progressing through a cased section of the borehole B) and / or the borehole wall (where the tubing string S is progressing though an open hole section of the borehole B).

[0199] The radially extending members 1040 each comprise a plurality of cutting elements 1042, the cutting elements 1042 being configured and / or operable to ream the borehole B.

[0200] Beneficially, the cutting elements 1042 offer the capability to ream past obstructions with rotation and / or by reciprocation.

[0201] In the illustrated embodiment, the cutting elements 1042 are constructed from Tungsten Carbide.

[0202] Referring still to Figure 6 of the accompanying drawings, each of the radially extending members 1040 is shown to extend axially along a part of the length of the body 1036, the radially extending members 1040 extending helically thereon.

[0203] In the illustrated embodiment, the nose 10 is configured for coupling to the body 1036.

[0204] As is best shown in Figures 5 and 7 of the accompanying drawings, the body 1036 comprises a coupling arrangement, generally denoted 1044. In the illustrated embodiment, the coupling arrangement 1044 comprises a first coupling portion, generally denoted 1046.

[0205] The first coupling portion 1046 is configured and / or operable to couple the body 1036 to the nose 10, in particular the coupling arrangement 26 of the nose 10. The first coupling portion 1046 is located at a first, downhole, end of the body 1036.

[0206] Beneficially, the first coupling portion 1046 facilitates switch-out of the nose 10, e.g. for repair, replacement and / or in order to couple a different nose.

[0207] In the illustrated embodiment, the first coupling portion 1046 comprises or takes the form of a threaded connection.

[0208] The body 1036 comprise a female portion 1048, the first coupling portion 1046 being provided on the female portion 1048 of the body 1036.

[0209] Referring now in particular to Figure 7 of the accompanying drawings, the coupling arrangement 1044 comprises a second coupling portion 1050.

[0210] The second coupling portion 1050 is configured and / or operable to couple the body 1036 to the tubing string S, the second coupling portion being located at a second, uphole, end of the body 1036.

[0211] In the illustrated embodiment, the second coupling portion comprises or takes the form of a threaded connection.

[0212] The body 1036 comprises a second female portion 1052, the second coupling portion 1050 being provided on the second female portion 1052 of the body 1036.

[0213] As described above, the nose 10 provides a number of significant benefits in comparison to conventional equipment.

[0214] In particular, the nose 10 significantly reduces the amount of time required to carry out the borehole completion operation, since the nose 10 is capable of being drilled out much more rapidly than conventional noses. A drill out test was carried out comparing the performance of a 9.625” (244.48 mm) eccentric machined Aluminium nose (Figure 6A) chosen as a suitable benchmark and a 9.625” (244.48 mm) nose 10 (see Figure 6B) according to the present disclosure.

[0215] Details of the test are provided below.

[0216] A horizontal test bed was selected as the best facility to conduct the drill out test as it best replicates drilling out in the horizontal position, as this is most likely where most orientation that the nose will be deployed and then drilled through. The chosen horizontal test bed was a 60ft long rigid adjustable bed having a push-pull capability of 1 ,200,000 Ibf and rotation of 120 RPM @ 15,000ft.bf.

[0217] The chosen drill bit was an 8.500” DB616 (ORCA) PDC Bit designed and manufactured in Aberdeen, UK by ZerdaLab.

[0218] The chosen drill-out parameters for the test were: 60 RPM, 5-1 OK Weight-on-Bit, a flow rate of 100 GPM. For the purposes of the test, fresh water was used in place of drilling fluid.

[0219] In order to best replicate downhole conditions and guard against slippage when the nose sections were being drilled, each of the Aluminum nose and the nose 10 were set into a 13.375” casing section and cemented in place (see Figures 7A, 7B).

[0220] Firstly, the Aluminium nose was loaded into the test bed and the drill out operation was carried out (see Figure 8A).

[0221] Figure 9A shows the Aluminium nose after completion of the drill out test.

[0222] Figure 10A shows the drill cuttings and shavings produced during the drill out of the Aluminium nose.

[0223] The same test was repeated for the 9.625” (244.48 mm) nose 10 according to the present disclosure. The nose 10 was loaded into the test bed and the drill out operation was carried out (see Figure 8B).

[0224] Figure 9B shows the nose 10 after completion of the drill out test.

[0225] Figure 10B shows the drill cuttings produced during the drill out of the nose 10. As shown, the cuttings are smaller and so would be easily circulated in comparison to the cuttings shown in Figure 10A.

[0226] Figures 11A and 11 B respectively show the results of the drill out operations carried out on the Aluminium nose (Figure 11A) and the nose 10 (Figure 11 B).

[0227] As shown in Figure 11A, the test recorded a completion time of 17 minutes and 19 seconds for completion of the drill out operation.

[0228] As shown in Figure 11 B, the test recorded a completion time of 2 minutes and 6 seconds for the bit to remove the nose 10.

[0229] As described above, the nose 10 provides a number of additional benefits.

[0230] For example, the nose 10 reduces wear of the surrounding bore-lining tubing (where the tubing string S is progressing through a cased section of the borehole) and / or the borehole wall (where the tubing string S is progressing though an open hole section of the borehole B).

[0231] In order to simulate casing wear, a test was carried out whereby a rotating wheel of the composite material of the nose 10 was forced against a steel plate of the same grade used in casing. The same test was applied using a rotating wheel of steel of the same grade typically used in conventional noses. In order to simulate downhole conditions, the wheel was rotated at 60 RPM and with a force of 110kg at a bath temperature of 65 degrees C.

[0232] On completion of the test, the steel casing material exhibited a 118.1g loss of mass following interaction with the steel wheel. On completion of the test, the steel casing material exhibited a 1.2g loss of mass following interaction with the material of the nose 10.

[0233] Beneficially, a reduction in wear of the surrounding bore-lining tubing (where the tubing string S is progressing through a cased section of the borehole B) and / or the borehole wall (where the tubing string S is progressing though an open hole section of the borehole B) obviates the requirement for additional remedial operations at significant additional expense and loss of time to the operator.

[0234] The nose exhibits a greater wear resistance than conventional noses.

[0235] In order to test wear resistance in downhole conditions, a test was carried out whereby a rotating wheel of carborundum (AL203) material was forced against a plate of the composite material of the nose 10. The wheel diameter was 140 mm. The wheel width was 50 mm. The same test was applied with a plate of steel of the same grade typically used in conventional noses. In order to simulate downhole conditions, the wheel was rotated at 60 RPM and with a force of 110kg with brine at a bath temperature of 65 degrees C. The test duration was 240 minutes.

[0236] On completion of the test, the material of the nose 10 exhibited a 1.2g loss of mass.

[0237] On completion of the test, the steel material exhibited a 98.0g loss of mass.

[0238] Beneficially, the provision of a nose having a greater wear resistance than conventional noses may prolong operational effectiveness and / or working life, amongst other things reducing the likelihood that additional trips into the borehole B are required.

[0239] The nose exhibits a lower coefficient of friction than conventional noses.

[0240] For example, Figure 12 is a graph showing friction factor exhibited by a specimen of steel of the same grade as conventional noses (line A) and the material of the nose 10 (line B) in relation to a specimen of formation material (representative of when the nose passes through open hole section of the borehole B). In each case, the test duration was 10 minutes. On completion of the test, the material of the nose 10 exhibited an average friction factor relative to the formation material of 0.171. In comparison, the steel material of conventional noses exhibited an average friction factor relative to the formation material of 0.334.

[0241] Figure 13 is a graph showing friction factor exhibited by a specimen of steel of the same grade as conventional noses (line A) and the material of the nose 10 (line B) in relation to a specimen of steel of the same grade as casing (representative of when the nose passes through a cased section of the borehole B). Again, in each case the test duration was 10 minutes.

[0242] On completion of the test, the material of the nose 10 exhibited an average friction factor relative to the formation material of 0.079. In comparison, the steel material of conventional noses exhibited an average friction factor relative to the formation material of 0.178.

[0243] Beneficially, the nose may reduce frictional torque and drag experienced by the tubing string, assisting tubular placement to the desired total depth.

[0244] Beneficially, the above factors, coupled with reduced drill out duration, facilitate increased working life of the bit and / or reduced likelihood of borehole irregularities being formed during drilling of the extended borehole portion.

[0245] Various modifications may be made without departing from the scope of the invention as defined by the appended claims.

[0246] For example, Figures 16 and 17 of the accompanying drawings show alternative downhole tools 2000, 3000 comprising the nose 10 according to the present disclosure.

[0247] The downhole tools 2000, 3000 are identical to the downhole tool 1000 described above, with the exception that the downhole tools 2000, 3000 comprise a valve arrangement, generally denoted 2054, 3054, as will be described further below. As shown in Figure 16, the valve arrangement 2054 is configured and / or operable to control fluid flow through the body 12 of the nose 10. More particularly, the valve arrangement 2054 is configured and / or operable to prevent or at least mitigate flow of borehole fluid in an uphole direction through the downhole tool 2000 as the downhole tool 2000 is run downhole and / or the flow of unset cement slurry / settable material from the annulus into the tubing string S.

[0248] The valve arrangement 2054 comprises a valve 2056, which in the illustrated downhole tool 2000 takes the form of a non-return valve. As shown, the valve 2056 comprises a valve member 2058 and a valve seat 2060.

[0249] The valve 2056 is configurable from a first, closed, configuration in which the valve member 2058 engages the valve seat 2060 and a second, open, configuration, in which the valve member 2058 is offset from the valve seat 2060. The valve 2056 is configured so that the valve member 2058 is biased towards the first, closed, configuration.

[0250] In the illustrated downhole tool 2000, the valve arrangement 2054 is disposed in the body 12 of the nose 10, more particularly in the axial flow passage 24 of the body 12 of the nose 10, the valve arrangement 2054 being coupled to the body 12 of the nose 10.

[0251] As shown in Figure 17, the valve arrangement 3054 is configured and / or operable to control fluid flow through the body 12 of the nose 10. More particularly, the valve arrangement 3054 is configured and / or operable to prevent or at least mitigate flow of borehole fluid in an uphole direction through the downhole tool 3000 as the downhole tool 3000 is run downhole and / or the flow of unset cement slurry / settable material from the annulus into the tubing string S.

[0252] The valve arrangement 3054 comprises a valve 3056, which in the illustrated downhole tool 3000 takes the form of a non-return valve. As shown, the valve 3056 comprises a valve member 3058 and a valve seat 3060.

[0253] The valve 3056 is configurable from a first, closed, configuration in which the valve member 3058 engages the valve seat 3060 and a second, open, configuration, in which the valve member 3058 is offset from the valve seat 3060. The valve 3056 is configured so that the valve member 3058 is biased towards the first, closed, configuration. In the illustrated downhole tool 3000, the valve arrangement 3054 is disposed in the body 3036 of the downhole tool 3000, more particularly in the axial flow passage 3038 of the body 3036, the valve arrangement 3054 being coupled to the body 3036 of the downhole tool 3000. The invention is defined by the appended claims. However, for the purposes of the present disclosure it will be understood that any of the features defined above or described below may be utilised in isolation or in combination. For example, features described above in relation to one of the above aspects or below in relation to the detailed description below may be utilised in any other aspect, or together form a new aspect.

Claims

CLAIMS1. A nose for a downhole tool, the nose comprising a body constructed from a composite material including aramid.

2. The nose of claim 1 , wherein the aramid comprises or takes the form of a paraaramid, e.g. Kevlar (RTM).

3. The nose of any preceding claim, wherein the composite material comprises or takes the form of a multi-layer composite material.

4. The nose of claim 3, wherein the multi-layer composite material comprises a first layer, the first layer comprising aramid.

5. The nose of claim 4, wherein at least one of: the first layer forms an outer layer of the body; and / or the first layer comprises a ceramic composite, e.g. a zirconia composite.

6. The nose of any one of claims 3 to 5, wherein the composite material comprises one or more carbon fibre layers.

7. The nose of claim 6, wherein at least one of the carbon fibre layers comprises or takes the form of a carbon fibre matrix layer.

8. The nose of claim 6, wherein at least one of the one or more carbon fibre layers comprises or takes the form of a woven carbon fibre layer.

9. The nose of claim 8, wherein at least one of the carbon fibre layers comprises or takes the form of a woven carbon fibre matrix layer.

10. The nose of any one of claims 6 to 9, wherein at least one of the carbon fibre layers is disposed underneath the first layer.

11. The nose of any one of claims 3 to 10, wherein the composite material comprises one or more chopped fibre layers.

12. The nose of claim 11 , wherein at least one of the chopped fibre layers comprises or takes the form of a chopped fibre matrix layer.

13. The nose of claim 11 or 12, wherein at least one of the chopped fibre layers is disposed underneath the first layer.

14. The nose of claim 13, wherein one of the chopped fibre layers is interposed between two carbon fibre layers.

15. The nose of any preceding claim, wherein the body is eccentrically shaped.

16. The nose of any preceding claim, wherein the body comprises or defines an axial flow passage.

17. The nose of any preceding claim, wherein the nose comprises a coupling arrangement.

18. The nose of any preceding claim, wherein the nose comprises a flow port arrangement.

19. The nose of any preceding claim, wherein the nose comprises, is coupled to or operatively associated with a valve arrangement.

20. A downhole tool comprising the nose of any of claims 1 to 19.

21. The downhole tool of claim 20, wherein the downhole tool further comprises a body.

22. The downhole tool of claim 20 or 21 , wherein the downhole tool further comprises one or more radially extending members, e.g. blades.

23. The downhole tool of claim 20, 21 or 22, wherein the downhole tool comprises, is coupled to or operatively associated with a valve arrangement.

24. Use of the downhole tool of any one of claims 20 to 23 to guide a tubing string into a borehole and / or ream a borehole.

25. A method of manufacture of a nose for a downhole tool, wherein the nose is constructed from a composite material and wherein the nose is constructed by moulding, e.g. compression moulding.

26. A method of manufacture of a nose for a downhole tool or a downhole tool comprising the nose, wherein the nose is constructed from a composite material, and wherein the nose or downhole tool is constructed by additive manufacturing.

27. The method of claim 25 or 26, wherein the nose comprises or takes the form of the nose of any of claims 1 to 19.

28. Computer software, firmware or hardware for controlling the manufacture of a nose for a downhole tool or a downhole tool comprising the nose, wherein the nose is constructed from a composite material.

29. The computer software, firmware or hardware of claim 28, wherein the nose comprises or takes the form of the nose of any of claims 1 to 19.

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