Casing patches and related methods

Abstract

An embodiment of a casing patch includes a receptacle (102) and one or more seals (116) positioned in the receptacle that are configured to engage with a radially outer surface of a casing stump (20) in a subterranean borehole. In addition, the casing patch includes a gripping mechanism (114) positioned in the receptacle that is configured to grip onto the radially outer surface of the casing stump. Further, the casing patch includes a dressing assembly (130) positioned in the receptacle that is configured to dress the radially outer surface of the casing stump as the casing stump is received into the receptacle.

Description

PATENTAttorney Docket No.: WBRE / 0017PCCASING PATCHES AND RELATED METHODSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application Serial Number 63 / 757,866, filed February 13, 2026, and entitled “One-Trip Casing Patch,” the entire contents of which are incorporated by reference.BACKGROUND

[0002] In a subterranean borehole, such as a borehole used in the production of oil, gas, or other resources, a casing pipe (or casing) may be installed for a myriad of reasons. For instance, the casing may be used to reinforce the borehole against the fluid pressure of the surrounding formation, to isolate the borehole from fluids within the formation, and to provide a passageway for fluids or equipment.

[0003] In some circumstances, a portion of a casing in a borehole may become damaged. Such damage may result from mechanical wear caused by repeated passage of tools and equipment, impact from dropped or stuck objects, or deformation due to excessive axial or radial loads. Corrosive wellbore fluids, including sour gas, brines, or acids, may also degrade the casing over time, leading to thinning, cracking, or loss of structural integrity. Additionally, casing damage may occur during cutting, milling, or other remedial operations, leaving burrs, splits, or irregularities at the casing end. When such damage occurs in an uphole portion of the casing, the damaged uphole portion may be cut and removed from the borehole. Thereafter, a casing patch may be introduced into the borehole and installed over the remaining downhole portion (or “stump”) of the casing to restore structural strength and pressure integrity.SUMMARY

[0004] Some embodiments disclosed here are directed to a casing patch that includes a receptacle and one or more seals positioned in the receptaclePATENTAttorney Docket No.: WBRE / 0017PCthat are configured to engage with a radially outer surface of a casing stump in a subterranean borehole. In addition, the casing patch includes a gripping mechanism positioned in the receptacle that is configured to grip onto the radially outer surface of the casing stump. Further, the casing patch includes a dressing assembly positioned in the receptacle that is configured to dress the radially outer surface of the casing stump as the casing stump is received into the receptacle.

[0005] Some embodiments disclosed herein are directed to a dressing assembly for dressing a casing stump in a subterranean borehole. The dressing assembly includes a tubular body that defines a receptacle to receive the casing stump. In addition, the dressing assembly includes one or more blades positioned in the receptacle that are configured to cut a bevel onto the casing stump. Further, the dressing assembly includes one or more polishing pads positioned in the receptacle that are configured to remove surface anomalies from a radially outer surface of the casing stump.

[0006] Some embodiments disclosed herein are directed to a method of installing a casing patch on a casing stump in a subterranean borehole. The method includes (a) introducing the casing patch into the subterranean borehole, and (b) advancing an uphole end of the stump into a receptacle of the casing patch after (a). In addition, the method includes (c) rotating the casing patch during (b), and (d) dressing a portion of an outer surface of the casing stump with a dressing assembly defined in the receptacle during (b) and (c). Further, the method includes (e) engaging the portion of the outer surface of the casing stump with a seal positioned in the receptacle after (d).BRIEF DESCRIPTION OF THE DRAWINGS

[0007] For a detailed description of various exemplary embodiments, reference will now be made to the accompanying drawings in which:

[0008] FIGs. 1A-1D are schematic diagrams a casing patch and a method of installing the casing patch on a casing stump in a subterranean borehole according to one or more embodiments, which may be combined with other embodiments;PATENTAttorney Docket No.: WBRE / 0017PC

[0009] FIG. 2 is a perspective, cross-sectional view of a casing patch according to one or more embodiments disclosed herein, which may be combined with other embodiments;

[0010] FIG. 3 is a perspective, cross-sectional view of a dressing assembly of the casing patch of FIG. 2 according to one or more embodiments, which may be combined with other embodiments;

[0011] FIG. 4 is a perspective, cross-sectional view of a patch assembly of the casing patch of FIG. 2 according to one or more embodiments, which may be combined with other embodiments; and

[0012] FIG. 5 is an enlarged side cross-sectional view of a portion of the casing patch of FIG. 2 according to one or more embodiments, which may be combined with other embodiments.DETAILED DESCRIPTION

[0013] A casing patch may be introduced into a subterranean borehole to replace a damaged uphole portion of a casing that was previously cut and removed. Such casing patches may engage with and seal against a remaining stump of the original casing. For so-called “external casing patches” the casing patch may sealingly engage with an outer surface of the stump. Thus, before an external casing patch may be engaged with the stump, the external surface of the stump must “dressed” to remove burrs or other surface anomalies. Dressing the stump is conventionally performed using various mills and scrapers that are separately introduced into the borehole prior to introducing the casing patch. As a result, conventional dressing operations entail making several trips into and out of the borehole prior to introducing the casing patch. However, the curtailment, or omission, of such dressing operations for the stump risks compromising the positioning of the casing patch on the stump, and also risks compromising the seal integrity between the casing patch and the stump.

[0014] Accordingly, embodiments disclosed include casing patches, such as external casing patches, that are configured to dress a stump of the original casing as the casing patch is being installed thereon. For instance, in one or more embodiments, which may be combined with other embodiments, a casingPATENTAttorney Docket No.: WBRE / 0017PCpatch may include a dressing assembly. The dressing assembly may include one or more cutting or dressing assemblies that are configured to engaged with and dress, such as de-burr, polish, cut, mill, etc., an outer surface of the stump as the casing patch is lowered downhole. Accordingly, through use of the embodiments disclosed, a casing patch may be installed onto a casing stump in fewer trips into the borehole without compromising the engagement, positioning, or seal integrity of the casing patch.

[0015] FIGs. 1A-1D schematically illustrate a casing patch 100 and a method of installing the casing patch 100 on a casing stump 20 (or “stump 20”) in a subterranean borehole 10 according to one or more embodiments, which may be combined with other embodiments. The casing stump 20 is part of a casing that is installed in at least a portion of the borehole 10. The casing stump 20 was previously connected to an uphole section of casing (not shown) that was cut and removed from the borehole 10 in a previous operation. Thus, the casing stump 20 includes an uphole end 20a that is positioned within the borehole 10.

[0016] The casing stump 20 may also include a central or longitudinal axis 25 (or “axis 25”), a throughbore 22 that extends axially downhole from the uphole end 20a along the axis 25, and a radially outer surface 24 that also extends axially downhole from the uphole end 20a along the axis 25. The radially outer surface 24 may generally comprise a cylindrical surface that extends circumferentially about the axis 25.

[0017] The casing patch 100 may be connected to (or defined on) a downhole end of a new section of replacement casing 30. As is described in more detail, the casing patch 100 may be introduced into the borehole 10 on the replacement casing 30 and installed over the uphole end 20a of the stump 20 to establish a mechanical and fluid connection between the replacement casing 30 and stump 20 (FIGs. 1B and 1C). Thus, the casing patch 100 may be an external casing patch. Together, the connected replacement casing 30 and stump 20 may define a casing string (or casing) within the borehole 10.

[0018] In one or more embodiments, which may be combined with other embodiments, the casing patch 100 is indirectly coupled to the replacementPATENTAttorney Docket No.: WBRE / 0017PCcasing 30 via any suitable connector, such as an extension joint, a slip joint, a pup joint, or (as illustrated) a crossover 32. In one or more embodiments, which may be combined with other embodiments, the casing patch 100 is directly coupled to the replacement casing 30, and the illustrated crossover 32 may be omitted.

[0019] Referring specifically to FIG. 1A, the casing patch 100 includes a central or longitudinal axis 105 (or “axis 105”), a first or uphole end 100a, and a second or downhole end 100a opposite the uphole end 100a along the axis 105. The axis 105 may also be, or may be aligned with, a central or longitudinal axis of the replacement casing 30. The uphole end 100a may be coupled to the replacement casing 30, such as via crossover 32 as illustrated and previously described. The downhole end 100b may be projected downhole along the axis 105.

[0020] In addition, the casing patch 100 may include a receptacle 102 that is aligned and in communication with a throughbore 34 of the replacement casing 30. The receptacle 102 may include an opening 104 at the downhole end 100b. During operations, the uphole end 20a of the stump 20 may be introduced into the receptacle 102 along the axis 105 via the opening 104. Specifically, as is described in more detail, the casing patch 100 is lowered axially downhole within the borehole 10 over the stump 20 and is simultaneously rotated about the axis 105.

[0021] Further, the casing patch 100 includes a patch assembly 110 and a dressing assembly 130 coupled to one another along the axis 105. The patch assembly 110 and the dressing assembly 130 may be at least partially positioned in the receptacle 102. In addition, the dressing assembly 130 may be at least partially positioned below or downhole of the patch assembly 110 along the axis 105, within the receptacle 102. Specifically, in one or more embodiments, which may be combined with other embodiments, the patch assembly 110 may be positioned at or proximate to the uphole end 100a and the dressing assembly 130 may be positioned at or proximate to the downhole end 100b. Thus, the patch assembly 110 may be positioned axially between the uphole end 100a and the dressing assembly 130, and the dressingPATENTAttorney Docket No.: WBRE / 0017PCassembly 130 may be positioned axially between the downhole end 100b (and opening 104) and the patch assembly 110.

[0022] The casing patch 100 may comprise one or more tubular bodies that are coupled, such a threaded, to one another. For instance, the patch assembly 110 may be at least partially defined or included in a first or uphole tubular body 112, and the dressing assembly 130 may be at least partially defined or included in a second or downhole tubular body 132. The uphole tubular body 112 may be coupled, such as threaded, to the downhole tubular body 132, either directly or through other tubular bodies of the casing patch 100. In one or more embodiments, which may be combined with other embodiments, the uphole tubular body 112 may define the uphole end 100a, and the downhole tubular body 132 may define the downhole end 100b and opening 104. However, in one or more embodiments, which may be combined with other embodiments, the uphole end 100a or downhole end 100b may be defined on other tubular bodies of the casing patch 100. Also, the uphole tubular body 112 and downhole tubular body 132 may at least partially define the receptacle 102.

[0023] Each of the uphole tubular body 112 and downhole tubular body 132 may, themselves, comprise multiple tubular bodies that are coupled, such as threaded, to one another. Thus, the use of the term “tubular body” is not meant to foreclose the possibility that such as a body is actually made up of multiple tubular members.

[0024] The casing patch 100, and particularly the uphole tubular body 112, the downhole tubular body 132 and any tubular bodies coupled therebetween, may have a minimum inner diameter Dwo that is sized to fit around the stump 20. Thus, the minimum inner diameter Dwo may be greater than an outer diameter of the radially outer surface 24 of stump 20.

[0025] The patch assembly 110 may include a gripping mechanism 114 and one or more seals 116. The gripping mechanism 114 may include any suitable device(s) or assembly(ies) that is configured to engage with and grip the radially outer surface 24 of the stump 20. For instance, in one or more embodiments, which may be combined with other embodiments, the gripping mechanism 114 may include one or more slips, collets, grapples, drag blocks, or the like. In onePATENTAttorney Docket No.: WBRE / 0017PCor more embodiments, which may be combined with other embodiments, the griping mechanism 114 may comprise a grapple, such as a basket grapple, that is configured to grip onto the radially outer surface 24 of stump 20 based on a tension that is placed on the casing patch 100. Such tension may be placed on the casing patch 100 via the replacement casing 30.

[0026] The seal(s) 116 may comprise any suitable radial seal that are configured to sealingly engage with the radially outer surface 24 of the stump 20. The seal(s) 116 may include one or more metallic or elastomeric seals. In one or more embodiments, the seal(s) 116 may include, without limitation, O-rings, T-seals, labyrinth seals, lip seals, chevron seals, cup seals, seal rings, wiper seals, or combinations thereof. As shown in FIG. 1 A, at least one of the seal(s) 116 may be located uphole of the gripping mechanism 114. However, it should be appreciated that at least one of the seal(s) 116 may also (or alternatively) be located downhole of the gripping mechanism 114. In one or more embodiments, which may be combined with other embodiments, the seal(s) 116 may be positioned or defined in the uphole tubular body 112, or may be positioned in other tubular bodies of the casing patch 100. In one or more embodiments, which may be combined with other embodiments, the casing patch 100 may include a plurality of seals 116 that are axially spaced along the axis 105 to provide redundant sealing engagement with the radially outer surface 24 of the stump 20 during operations.

[0027] The dressing assembly 130 may include a guide 134 at and proximate to the downhole end 100b of the casing patch 100. The guide 134 may include a tapered or frustoconical inner surface 136 that is configured to guide the uphole end 20a of the stump 20 into the casing patch 100 during operations. Thus, the guide 134 may define a funnel on the downhole end 100b of casing patch 100. In one or more embodiments, which may be combined with other embodiments, the guide 134 is configured as a cut-lip guide that is configured to guide the uphole end 20a into the receptacle 102 while lowering and rotating the casing patch 100 along and about, respectively, the axis 105.

[0028] In addition, in one or more embodiments, which may be combined with other embodiments, the downhole end 100b or the inner surface 136 mayPATENTAttorney Docket No.: WBRE / 0017PCinclude hardfacing that is configured to dress the uphole end 20a and radially outer surface 24 of the stump 20 as the casing patch 100 is lowered thereon and rotated about the axis 105. Specifically, the hardfacing may remove burrs, splits, or feathering on the stump 20 as the stump 20 is inserted into the receptacle 102 via the guide 134.

[0029] The hardfacing on the downhole end 100b or inner surface 136 may comprise any suitable hardened materials or inserts, such as crushed carbide, tungsten carbide (TCI) inserts, an overlay material, such as an overlay material that is welded onto the downhole end 100b or inner surface 136. In one or more embodiments, which may be combined with other embodiments, the hardfacing may be applied in a uniform coating over the entire or substantially the entire downhole end 100b, the inner surface 136, or both. In one or more embodiments, which may be combined with other embodiments, the hardfacing is applied in one or more selected regions or portions of the downhole end 100b, the inner surface 136, or both, as part of a pattern or arrangement.

[0030] In one or more embodiments, which may be combined with other embodiments, the inner surface 136 may include one or more flutes, such as axially oriented or helically oriented flutes, that may be at least partially coated with hardfacing as previously described. Thus, as the casing patch 100 is lowered onto the stump 20 and rotated about the axis 105, the flutes defined on the inner surface 136 may cut or dress the uphole end 20a and the radially outer surface 24.

[0031] The dressing assembly 130 may also include one or more centralizers 138 that are configured to engage with the radially outer surface 24 of stump 20 to substantially centralize the stump 20, or at least the uphole end 20a, within the dressing assembly 130. The centralizer(s) 138 may comprise fins, ridges, projections, or combinations thereof. In one or more embodiments, the centralizer(s) 138 may comprise an axial section or portion of the receptacle 102 that has a reduced inner diameter. The centralizer(s) 138 may be configured to substantially coaxially align the axis 105 of the casing patch 100 with the axis 25 of the stump 20 as the uphole end 20a of the stump 20 is introduced therein.PATENTAttorney Docket No.: WBRE / 0017PC

[0032] The dressing assembly 130 also includes one or more, including a plurality of, blades 140 that are configured to engage with and cut or mill the stump 20 during operations. The blades 140 may sometimes be referred to as “knives.” The blades 140 may each include a first or proximal end 140a and a second or distal end 140b. The proximal end 140a may be pivotably coupled to the downhole tubular body 132 via a pin 142. Thus, each blade 140 may be configured to pivot about a rotational axis 145 via the pin 142 to selectively project the distal end 140b radially inward within the receptacle 102. The rotational axis 145 of each pin 142 may extend perpendicularly (or orthogonally) to radius (or radial direction) of the axis 105. In one or more embodiments, which may be combined with other embodiments, each blade 140 may be rotationally biased so that the distal end 140b is rotationally biased away from the axis 105 about the corresponding rotational axis 145 and pin 142. Each blade 140 may include hardfacing that is configured to cut, mill, or otherwise machine a surface, such as the radially outer surface 24 or uphole end 20a, of the stump 20 as the receptacle 102 is axially advanced over the stump 20. The hardfacing on the blades 140 may be similar to the hardfacing that may be included on the downhole end 100b and inner surface 136 of guide 134 as previously described.

[0033] In one or more embodiments, which may be combined with other embodiments, a rotational range of each blade 140 may be initially limited by a corresponding frangible member 144 when the casing patch 100 is introduced into the borehole 10 and lowered onto the stump 20. The frangible members 144 may comprise shear pins, shear bolts, shear rings, or the like. The frangible members 144 may engage with the blades 140 and the downhole tubular body 132 so that the distal end 140b of each blade 140 is projected into the receptacle 102.

[0034] Referring still to FIG. 1A, the dressing assembly 130 may also include one or more polishing pads 146 that extend radially inward from the uphole tubular body 112. The polishing pads 146 may be configured to engage with and remove scale or debris from the radially outer surface 24 of the stump 20 as the casing patch 100 is lowered over the stump 20 and rotated about thePATENTAttorney Docket No.: WBRE / 0017PCaxis 105. In one or more embodiments, which may be combined with other embodiments, the polishing pads 146 may include or may be coupled to suitable biasing members, such as leaf springs, coiled spring, or like. Thus, the polishing pads 146 may be biased radially inward toward the axis 105 during operations. In one or more embodiments, which may be combined with other embodiments, the polishing pad(s) 146 may be integrally formed with the uphole tubular body 112. In one or more embodiments, which may be combined with other embodiments, the polishing pad(s) 146 may be separate components that are coupled to the downhole tubular body 132.

[0035] Referring now to FIGs. 1A and 1B, during operations, the casing patch 100 may be lowered downhole within the borehole 10 so that the uphole end 20a of stump 20 is received into the receptacle 102 via the opening 104. The casing patch 100 may be rotated about the axis 105 as it is lowered downhole over the stump 20 as previously described.

[0036] As the uphole end 20a is inserted through the opening 104, the guide 134, and particularly the inner surface 136 may slidingly engage with the uphole end 20a and radially outer surface 24 to guide the stump 20 into the receptacle 102. As previously described, the downhole end 100b or inner surface 136 may include hardfacing or other cutting features that may at least partially dress the stump 20 as the uphole end 20a is inserted through the opening 104.

[0037] As the casing patch 100 continues to be lowered downhole and rotated about the axis 105, the uphole end 20a of stump 20 may be advanced past the centralizer(s) 138 and toward the blades 140. The centralizers 138 may slidingly engage with the radially outer surface 24 of the stump 20 to centralize (or substantially centralize) the stump 20 within the receptacle 102 as previously described.

[0038] As shown in FIG. 1 B, engagement of the blades 140 with the uphole end 20a while the casing patch 100 is rotated about the axis 105 may allow the blades 140 to cut or mill a bevel or chamfer 26 on the radially outer surface 24 at the uphole end 20a of the stump 20. The initial rotational position of the blades 140 that is fixed by the frangible members 144 may determine the angle of the bevel 26 on the stump 20. Without being limited to this or any otherPATENTAttorney Docket No.: WBRE / 0017PCtheory, the bevel 26 may reduce the risk that the uphole end 20a may damage the seal(s) 116 in the patch assembly 110 as the stump 20 is axially advanced therethrough.

[0039] As shown in sequence from FIG. 1B to 1 C, once the blades 140 cut the bevel 26 on the stump 20, additional pressure may be placed on the casing patch 100 via the replacement casing 30 such that the blades 140 shear the frangible members 144. Once the frangible members 144 have sheared or have otherwise failed, the sliding contact between the stump 20 and the rotational bias applied to the blades 140 may cause the blades 140 to rotate about the pins 142 and rotational axes 145 to pivot the distal ends 140b away from the axis 105 and allow the stump 20 to continue to axially advance into the receptacle 102.

[0040] As is also shown in FIG. 1 C, after the uphole end 20a of stump 20 is advanced past the blades 140, the radially outer surface 24 may be engaged by the polishing pads 146, while the casing patch 100 continues to rotate about the axis 105. As previously described, the polishing pads 146 may engage with the radially outer surface 24 of stump 20 to remove debris, scale, or other surface anomalies on the radially outer surface 24. Without being limited to this or any other theory, the removal of such surface anomalies on the radially outer surface 24 may prepare the radially outer surface for sealing engagement with the seal(s) 116. In one or more embodiments, which may be combined with other embodiments, the casing patch 100 may be axially reciprocated, that is reciprocally moved uphole and downhole, and rotated about axis 105 while engaging the polishing pads 146 with the radially outer surface 24 to enhance contact therebetween.

[0041] As shown in the sequence from FIG. 1C to 1 D, as the casing patch 100 is further lowered downhole over the stump 20, the uphole end 20a may be axially advanced past both the gripping mechanism 114 and the seal(s) 116. The gripping mechanism 114 may allow insertion of the stump 20 into the receptacle 102, but may prevent or at least resist an axial withdrawal of the stump 20 from the receptacle 102. As previously described, in one or more embodiments, which may be combined with other embodiments, the grippingPATENTAttorney Docket No.: WBRE / 0017PCmechanism 114 may comprise a grapple. However, other types of systems, devices, and assemblies are contemplated for the gripping mechanism 114. For instance, in one or more embodiments, which may be combined with other embodiments, the gripping mechanism 114 may include one or more actuatable features that may be selectively actuated to engage with and grip the radially outer surface 24.

[0042] In addition, the engagement between the radially outer surface 24 and the seal(s) 116 may form a fluid-tight seal between the stump 20 and the receptacle 102. As previously described, the bevel 26 that is cut into the stump 20 may prevent snagging or other damage to the seal(s) 116 as the uphole end 20a is advanced axially therethrough.

[0043] Accordingly, the dressing assembly 130 of the casing patch 100 may dress the stump 20 during installation of the patch assembly 110 onto the stump 20. As a result, additional trips into the borehole to dress the stump 20 in preparation of installing the casing patch 100 may be reduced or entirely avoided. Thus, use of the dressing assembly 130 may allow an operator to avoid an intervening trip between dressing the radially outer surface 24 and sealingly engaging the radially outer surface with the seal(s) 116. However, one of skill in the art will appreciate that, according to one or more embodiments, which may be combined with other embodiments, the dressing assembly 130 may be separately lowered downhole during a first trip into the borehole 10 to dress the stump 20 in the manner previously described. Thereafter, the dressing assembly 130 may be raised to the surface, and the patch assembly 110 may be separately lowered in a second trip into the borehole 10 to install the patch assembly 110 onto the stump as previously described. Even in these embodiments, dressing the stump 20 may be accomplished in a single trip into the borehole 10, which may be provide an increase in operational efficiency over conventional practices.

[0044] Referring now to FIG. 2, a casing patch 200 that may be utilized in the operation of FIGs. 1A-1D as the casing patch 100 is shown according to one or more embodiments, which may be combined with other embodiments. The casing patch 200 is an elongate tubular member that includes a central orPATENTAttorney Docket No.: WBRE / 0017PClongitudinal axis 205 (or “axis 205”), a first or uphole end 200a, and a second or downhole end 200b opposite the uphole end 200a.

[0045] In addition, the casing patch 200 may comprise a plurality of tubular bodies that are coupled, such as threaded, to one another. In particular, the casing patch 200 includes a catch assembly 210 that is at least partially defined in a first or uphole tubular body 212, and a dressing assembly 230 that is at least partially defined in a second or downhole tubular body 232. As will be described in more detail, the catch assembly 210 and dressing assembly 230 may be substantially similar to the catch assembly 110 and dressing assembly 130, respectively, of the casing patch 100 shown in FIGs. 1A-1D and previously described.

[0046] In addition, a tubular spacer 220 is engaged, such as threadably engaged to and axially between the uphole tubular body 212 and the downhole tubular body 232. Further, a pair of tubular connectors 224, 222 are coupled to an uphole end of the uphole tubular body 212. The tubular connectors 224, 222 may define the uphole end 200a of the casing patch 200 and may facilitate connection of the casing patch 200 to a string of replacement casing, such as replacement casing 30 shown in FIGs. 1A-1D and previously described. Specifically, in one or more embodiments, which may be combined with other embodiments, a first tubular connector222 may be coupled to the uphole end of the uphole tubular body 212, and a second tubular connector 224 may be coupled to an uphole end of the first tubular connector 222. Thus, the second tubular connector 224 may define the uphole end 200a of the casing patch 200.

[0047] In one or more embodiments, which may be combined with other embodiments, the pair of tubular connectors 222, 224 may be replaced with a single tubular connector or more than two tubular connectors. In one or more embodiments, which may be combined with other embodiments, the pair of tubular connectors 222, 224 may be omitted and the uphole end of the uphole tubular body 212 may define the uphole end 200a of the casing patch 200 that is connected to a string of replacement casing.

[0048] Referring now to FIG. 3, the dressing assembly 230 of the casing patch 200 of FIG. 2 is shown according to one or more embodiments, whichPATENTAttorney Docket No.: WBRE / 0017PCmay be combined with other embodiments. The dressing assembly 230 may include the guide 134 as previously described. However, the guide 134 may be defined in a separate tubular body 231 that is coupled to a downhole end of the downhole tubular body 232 via a pair of threaded connectors 238, 236. Specifically, the downhole tubular body 232 may include a female or box threaded connector 238 that is threadably engaged with a male or pin threaded connector 236 on the tubular body 231 ; however, alternative arrangements and configurations and connections are contemplated. Thus, the tubular body 231 may define the downhole end 200b of the casing patch 200 (FIG. 2) when connected to the downhole tubular body 232.

[0049] In addition, as shown in FIG. 3, the blades 140 and polishing pads 146 of the dressing assembly 230 may each be at least partially inserted within a corresponding pocket or recess 240, 242, respectively, defined within the downhole tubular body 232. Specifically, each of the blades 140 may be at least partially inserted into a corresponding recess 240 defined in the tubular body 232. The recesses 240 may extend partially or fully through the wall of the downhole tubular body 232 in a radial direction relative to the axis 205. Thus, the distal ends 140b of the blades 140 may be pivoted into and out of the recesses 240 via the pins 142. As previously described, the blades 140 may be rotationally biased away from the axis 205 about the pins 142. Thus, the blades 140 may be radially biased into the recesses 240 about the pins 142. As is also previously described, each of the blades 140 may be initially prevented from rotating into the recesses 240 via the frangible members 144.

[0050] Referring still to FIG. 3, each of the polishing pads 146 may be at least partially inserted into a corresponding recess 242 defined in the tubular body 232. The recesses 242 may extend partially or fully through the wall of the downhole tubular body 232 in a radial direction relative to the axis 205. Each of the polishing pads 146 may comprise leaf springs that are radially biased inward, toward the axis 205.

[0051] The dressing assembly 230 may include the plurality of blades 140 and a plurality of polishing pads 146 that are circumferentially spaced evenly about the axis 205 within the downhole tubular body 232. In one or morePATENTAttorney Docket No.: WBRE / 0017PCembodiments, which may be combined with other embodiments, the dressing assembly 230 may include a total of six (6) blades 140 and six (6) polishing pads 146 that are evenly circumferentially spaced about the axis 205 (such as every 60° about axis 205). In one or more embodiments, which may be combined with other embodiments, each of the blades 140 may be circumferentially aligned with a corresponding one of the polishing pads 146.

[0052] However, other numbers, arrangements, and spacings of the blades 140 and polishing pads 146 are contemplated. For example, there may be more or fewer than six (6) blades 140 or polishing pads 146. As another example, at least some of the blades 140 may be circumferentially mis-aligned with the polishing pads 146.

[0053] Referring still to FIG. 3, the dressing assembly 230 may lack the centralizers 138 (FIGs. 1A-1D). For instance, the inner diameter of the casing patch 200 (FIG. 2) and particularly the downhole tubular body 232 may be sized to centralize the stump 20 (FIGs. 1A-1D) along the axis 205 during operations.

[0054] In addition, as shown in FIG. 3, an uphole end of the downhole tubular body 232 may include a threaded connector 234 that is configured to engage with a corresponding threaded connector on the tubular spacer 220. For instance, the threaded connector 234 may comprise a male or pin threaded connector that is configured to engage with a female or box threaded connector (not shown) defined on the downhole end of the tubular spacer 220.

[0055] Referring now to FIG. 4, the patch assembly 210 of the casing patch 200 of FIG. 2 is shown according to one or more embodiments, which may be combined with other embodiments. The patch assembly 210 may include the gripping mechanism 114 as previously described. In addition, the uphole tubular body 212 may include a pair of threaded connectors 214, 216 for connecting the uphole tubular body 212 to the tubular spacer 220 and the tubular connectors 224, 222. Specifically, in one or more embodiments, which may be combined with other embodiments, the uphole tubular body 212 may include a male or pin threaded connector 214 that is configured to threadably engage with a threaded connector (not shown, but see threaded connector 225 in FIG. 5) on one of the first tubular connector 222, and a female or boxPATENTAttorney Docket No.: WBRE / 0017PCthreaded connector 216 that is configured to threadably engage with a threaded connector on the tubular spacer 220 (not shown).

[0056] The gripping mechanism 114 of the patch assembly 210 may comprise a basket grapple that includes a basket 260 defined on an inner surface of the uphole tubular body 232 and a grapple 250 inserted within the basket 260.

[0057] The basket 260 may include a helical groove 264 that includes an angled wall that tapers radially inward when moving axially downhole within the uphole tubular body 212. A helical groove 252 may also be defined on a radially outer surface of the grapple 250. The helical groove 252 on the grapple 250 may correspond with the helical groove 264 of the basket 260. Thus, the helical groove 252 on the grapple 250 may include an angled wall that also tapers radially inward when moving axially downhole within the uphole tubular body 212. The grapple 250 may be threaded or wound into the basket 260 via rotation of the grapple 250 about the axis 205 relative to the basket 260 and sliding engagement of the helical grooves 252, 264.

[0058] A grapple control collar 270 is secured within the uphole tubular body 212, axially downhole of the grapple 250. The grapple control collar 270 includes an axially extending projection 272 that is introduced into a corresponding notch 266 on a downhole end of the grapple 250 to prevent the grapple 250 from unthreading or unwinding from the basket 260.

[0059] The grapple 250 may include a plurality of teeth 268 on a radially inner surface thereof. The teeth 268 may be configured to engage with the radially outer surface 24 of the stump 20 (FIGs. 1A-1D), when the stump 20 is introduced through the uphole tubular body 212. The teeth 268 may be configured slide against the radially outer surface 24 as the uphole tubular body 212 is axially advanced in a downhole direction 29 along the stump 20 (FIGs.1 A-1 D). However, the teeth 268 may be configured to bite into the radially outer surface 24 to prevent a withdrawal of the stump 20 from the uphole tubular body 212, such as via a movement of the uphole tubular body 212 in an uphole direction 27. In addition, the grapple 250 may include a plurality of axiallyPATENTAttorney Docket No.: WBRE / 0017PCextending grooves 251 that separate the grapple 250 into a plurality of circumferentially adjacent, axially extending fingers or collets 254.

[0060] In one or more embodiments, which may be combined with other embodiments, the teeth 268 may extend helically about the axis 205. Without being limited to this or any other theory, the helical orientation of the teeth 268 may allow the grapple 250 to be rotated, such as via a rotation of the tubular body 212, to selectively unwind the grapple 250 from the stump 20. Thus, the grapple 250 may be referred to as a releasable grapple according to one or more embodiments, which may be combined with other embodiments.

[0061] During operations, once the stump 20 is inserted into uphole tubular body 212 such that the uphole end 20a is advanced past the gripping mechanism 114, a tension (or pull) may be placed on the casing patch 200 of FIG. 2. The tension may pull the uphole tubular body 212 in an axially uphole direction 27 relative to the stump 20 so that the teeth 268 bite into the radially outer surface 24. The engagement of the teeth 268 into the radially outer surface 24 may prevent an axial movement of the grapple 250 relative to the stump 20 so that the tension placed on the casing patch 200 may cause the uphole tubular body 212 to move in the axially uphole direction 27 relative to the grapple 250. The uphole movement of the uphole tubular body 212 may cause the helical groove 264 of the basket 260 to slide uphole relative to the helical groove 252 on the grapple 250. In turn, the sliding engagement of the tapered walls of the helical grooves 252, 264 may cause the fingers 254 of the grapple 250 to deflect radially inward toward the axis 205 (and thus the radially outer surface 24 of stump 20). Accordingly, the tension placed on the casing patch 200 may cause the grapple 250 to engage with and grip onto the stump 20, and the gripping force applied to the stump 20 may be directly proportional to the tension that is placed on the casing patch 200.

[0062] Referring now to FIG. 5, as previously described, the first tubular connector 222 may be coupled to an uphole end of the uphole tubular body 212, and the second tubular connector 224 may be coupled to an uphole end of the first tubular connector 222. In particular, the first tubular connector 222 may include a female or box threaded connector 225 that is threadably engagedPATENTAttorney Docket No.: WBRE / 0017PCwith the male threaded connector 214 of the uphole tubular body 212. In addition, the first tubular connector 222 includes a female or box threaded connector 223 that is threadably engaged with a female or box threaded connector 227 defined on a downhole end of the second tubular connector 224.

[0063] In addition, the casing patch 200 may include a pair of axially spaced seals 286, 288 that are positioned uphole of the gripping mechanism 114, such as axially between the uphole end 200a and the gripping mechanism 114. Specifically, the casing patch 200 may include a first or downhole seal 286 and a second or uphole seal 288. The downhole seal 286 may be positioned axially between the uphole end 200a and the gripping mechanism 114, and the uphole seal 288 may be positioned axially between the downhole seal 286 and the uphole end 200a. The seals 286, 288 may comprise any one or more of the example seals previously described above for the seal(s) 116 shown in FIGs.1A-1D.

[0064] The downhole seal 286 may be positioned in a recess 280 that is defined between the uphole tubular body 212 and the first tubular connector 222, and the uphole seal 288 may be positioned in a recess 282 that is defined between the second tubular connector 224 and the first tubular connector 222. Specifically, the recess 280 may be defined between an axially uphole end of the uphole tubular body 212 and an internal shoulder defined in the first tubular connector 222, and the recess 282 may be defined between an uphole end of the first tubular connector 222 and an internal shoulder defined within the second tubular connector 224.

[0065] During operations, the uphole end 20a of the stump 20 shown in FIGs. 1 A-1 D) may be advanced axially past both of the seals 286, 288 so that the seals 286, 288 are sealingly engaged with the radially outer surface. In addition, as previously described, the portion of the radially outer surface 24 of the stump 20 that is engaged with seals 286, 288 may have previously passed through the dressing assembly 230 shown in FIG. 3. As a result, the portion of the radially outer surface 24 that is engaged with the seals 286, 288 may be properly dressed (that is de-burred, polished, milled, etc.) to enhance a sealing engagement therebetween.PATENTAttorney Docket No.: WBRE / 0017PC

[0066] In addition, an internal shoulder 229 may be defined in the second tubular connector 224 that is configured to engage or abut the uphole end 20a of the stump 20 so as to limit an axial advance of the stump 20 into the casing patch 200. The internal shoulder 229 may be positioned axially uphole of the seals 286, 288, such as axially between the uphole end 200a and the uphole seal 288, within the second tubular connector 224.

[0067] As explained above and reiterated below, the present disclosure includes, without limitation, the following Examples.

[0068] Example 1: A casing patch comprising: a receptacle; one or more seals positioned in the receptacle that are configured to engage with a radially outer surface of a casing stump in a subterranean borehole; a gripping mechanism positioned in the receptacle that is configured to grip onto the radially outer surface of the casing stump; and a dressing assembly positioned in the receptacle that is configured to dress the radially outer surface of the casing stump as the casing stump is received into the receptacle.

[0069] Example 2: The casing patch of any of the Examples, wherein the dressing assembly comprises one or more blades that are configured to mill a bevel onto the casing stump.

[0070] Example s: The casing patch of any of the Examples, wherein each of the one or more blades are radially biased away from a central axis of the receptacle.

[0071] Example 4: The casing patch of any of the Examples, wherein a rotational range of each of the one or more blades is limited by a frangible member.

[0072] Example 5: The casing patch of any of the Examples, wherein the dressing assembly further comprises one or more polishing pads that are configured to remove surface anomalies from the radially outer surface of the casing stump.

[0073] Example 6: The casing patch of any of the Examples, wherein each of the one or more polishing pads is biased radially inward toward a central axis of the receptacle.PATENTAttorney Docket No.: WBRE / 0017PC

[0074] Example 7: The casing patch of any of the Examples, wherein the gripping mechanism comprises a grapple.

[0075] Example 8: The casing patch of any of the Examples, further comprising a first tubular body and a second tubular body that is coupled to the first tubular body, wherein the one or more seals and the gripping mechanism are positioned in the first tubular body, and wherein the dressing assembly is positioned in the second tubular body.

[0076] Example 9: The casing patch of any of the Examples, further comprising a guide including a funnel defined on a downhole end of the casing patch.

[0077] Example 10: A dressing assembly for dressing a casing stump in a subterranean borehole, the dressing assembly comprising: a tubular body that defines a receptacle to receive the casing stump; one or more blades positioned in the receptacle that are configured to cut a bevel onto the casing stump; and one or more polishing pads positioned in the receptacle that are configured to remove surface anomalies from a radially outer surface of the casing stump.

[0078] Example 11: The dressing assembly of any of the Examples, wherein the one or more blades and the one or more polishing pads are positioned in a tubular body that is configured to be coupled to a casing patch.

[0079] Example 12: The dressing assembly of any of the Examples, wherein each of the one or more blades are radially biased away from a central axis of the receptacle.

[0080] Example 13: The dressing assembly of any of the Examples, wherein a rotational range of each of the one or more blades is limited by a frangible member.

[0081] Example 14: The dressing assembly of any of the Examples, wherein each of the one or more polishing pads is biased radially inward toward a central axis of the receptacle.

[0082] Example 15: A method of installing a casing patch on a casing stump in a subterranean borehole, the method comprising: (a) introducing the casing patch into the subterranean borehole; (b) advancing an uphole end of the stump into a receptacle of the casing patch after (a); (c) rotating the casing patchPATENTAttorney Docket No.: WBRE / 0017PCduring (b); (d) dressing a portion of an outer surface of the casing stump with a dressing assembly defined in the receptacle during (b) and (c); and (e) engaging the portion of the outer surface of the casing stump with a seal positioned in the receptacle after (d).

[0083] Example 16: The method of any of the Examples, wherein (d) and (e) are performed during a single trip within the subterranean borehole.

[0084] Example 17: The method of any of the Examples, wherein (d) further comprises cutting a bevel on the casing stump with one or more blades of the dressing assembly.

[0085] Example 18: The method of any of the Examples, further comprising shearing one or more frangible members to allow the one or more blades to rotate out of the receptacle.

[0086] Example 19: The method of any of the Examples, wherein (d) further comprises removing surface anomalies from the portion of the outer surface with one or more polishing pads of the dressing assembly.

[0087] Example 20: The method of any of the Examples, further comprising engaging a centralizer of the dressing assembly with the portion of the outer surface before cutting the bevel and removing the surface anomalies.

[0088] Embodiments disclosed include casing patches, such as external casing patches, that are configured to dress a stump of the original casing as the casing patch is being installed thereon. For instance, in one or more embodiments, which may be combined with other embodiments, a casing patch may include a dressing assembly. The dressing assembly may include one or more cutting or dressing assemblies that are configured to engaged with and dress, such as de-burr, polish, cut, mill, etc., an outer surface of the stump as the casing patch is lowered downhole. Accordingly, through use of the embodiments disclosed, a casing patch may be installed onto a casing stump in fewer trips into the borehole without compromising the engagement, positioning, or seal integrity of the casing patch.

[0089] The preceding discussion is directed to various embodiments. However, one of ordinary skill in the art will understand that the examples disclosed have broad application, and that the discussion of any embodimentPATENTAttorney Docket No.: WBRE / 0017PCis meant only to be exemplary of that embodiment and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.

[0090] The drawing figures are not necessarily to scale. Certain features and components may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

[0091] In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection of the two devices, or through an indirect connection that is established via other devices, components, nodes, and connections. In addition, as used , the terms “axial” and “axially” generally mean along or parallel to a given axis (for example, central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the given axis. For instance, an axial distance refers to a distance measured along or parallel to the axis, and a radial distance means a distance measured perpendicular to the axis. Further, when used (including in the claims), the words “about,” “generally,” “substantially,” “approximately,” and the like, when used to refer to a stated value, mean within a range of ±10% of the stated value.

[0092] While one or more embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings . The embodiments described are examples and are not limiting to the full scope of the disclosed concept. Many variations and modifications of the systems, apparatus, and processes described are possible and are within the scope of the disclosure. Accordingly, the scope of protection is not limited to the embodiments described but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the operations in a method claim may be performed in any order. The recitation of identifiers such as (a),PATENTAttorney Docket No.: WBRE / 0017PC(b), (c) or (1), (2), (3) before operations in a method claim are not intended to and do not specify a particular order to the operations but rather are used to simplify subsequent reference to such operations.

Claims

PATENTAttorney Docket No.: WBRE / 0017PCWhat is claimed is:

1. A casing patch comprising:a receptacle;one or more seals positioned in the receptacle that are configured to engage with a radially outer surface of a casing stump in a subterranean borehole;a gripping mechanism positioned in the receptacle that is configured to grip onto the radially outer surface of the casing stump; anda dressing assembly positioned in the receptacle that is configured to dress the radially outer surface of the casing stump as the casing stump is received into the receptacle.

2. The casing patch of claim 1 , wherein the dressing assembly comprises one or more blades that are configured to mill a bevel onto the casing stump.

3. The casing patch of claim 2, wherein each of the one or more blades are radially biased away from a central axis of the receptacle.

4. The casing patch of claim 3, wherein a rotational range of each of the one or more blades is limited by a frangible member.

5. The casing patch of claim 2, wherein the dressing assembly further comprises one or more polishing pads that are configured to remove surface anomalies from the radially outer surface of the casing stump.

6. The casing patch of claim 5, wherein each of the one or more polishing pads is biased radially inward toward a central axis of the receptacle.

7. The casing patch of claim 5, wherein the gripping mechanism comprises a grapple.PATENTAttorney Docket No.: WBRE / 0017PC8. The casing patch of claim 7, further comprising a first tubular body and a second tubular body that is coupled to the first tubular body, wherein the one or more seals and the gripping mechanism are positioned in the first tubular body, and wherein the dressing assembly is positioned in the second tubular body.

9. The casing patch of claim 7, further comprising a guide including a funnel defined on a downhole end of the casing patch.

10. A dressing assembly for dressing a casing stump in a subterranean borehole, the dressing assembly comprising:a tubular body that defines a receptacle to receive the casing stump;one or more blades positioned in the receptacle that are configured to cut a bevel onto the casing stump; andone or more polishing pads positioned in the receptacle that are configured to remove surface anomalies from a radially outer surface of the casing stump.

11. The dressing assembly of claim 10, wherein the one or more blades and the one or more polishing pads are positioned in a tubular body that is configured to be coupled to a casing patch.

12. The dressing assembly of claim 10, wherein each of the one or more blades are radially biased away from a central axis of the receptacle.

13. The dressing assembly of claim 12, wherein a rotational range of each of the one or more blades is limited by a frangible member.

14. The dressing assembly of claim 12, wherein each of the one or more polishing pads is biased radially inward toward a central axis of the receptacle.PATENTAttorney Docket No.: WBRE / 0017PC15. A method of installing a casing patch on a casing stump in a subterranean borehole, the method comprising:(a) introducing the casing patch into the subterranean borehole;(b) advancing an uphole end of the stump into a receptacle of the casing patch after (a);(c) rotating the casing patch during (b);(d) dressing a portion of an outer surface of the casing stump with a dressing assembly defined in the receptacle during (b) and (c); and (e) engaging the portion of the outer surface of the casing stump with a seal positioned in the receptacle after (d).

16. The method of claim 15, wherein (d) and (e) are performed during a single trip within the subterranean borehole.

17. The method of claim 15, wherein (d) further comprises cutting a bevel on the casing stump with one or more blades of the dressing assembly.

18. The method of claim 17, further comprising shearing one or more frangible members to allow the one or more blades to rotate out of the receptacle.

19. The method of claim 17, wherein (d) further comprises removing surface anomalies from the portion of the outer surface with one or more polishing pads of the dressing assembly.

20. The method of claim 19, further comprising engaging a centralizer of the dressing assembly with the portion of the outer surface before cutting the bevel and removing the surface anomalies.

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