Wellbore Milling Tool for Unexpanded Shoe Removal
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Solution Overview
Problem
Conventional methods for removing an unexpanded shoe assembly and adjacent tubular from an expanded wellbore require multiple trips and complex tools, which are prone to malfunction.
Innovation Solution
A tool comprising a latch assembly and a mill body is used to engage and mill the unexpanded portion of the tubular, allowing the shoe assembly to be uncoupled and removed through the expanded portion, with optional protective sleeves to prevent damage during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to remove the unexpanded tubular and shoe assembly, then the removal can be accomplished, but multiple trips into the wellbore are required and complex tools are needed which are prone to malfunction
Solution Approach 1:
The patent combines the milling function and the shoe assembly engagement function into a single integrated tool. The mill body with cutting elements is integrated with the latch assembly that engages the shoe assembly, allowing both functions to be performed simultaneously in one trip into the wellbore, eliminating the need for multiple trips and complex sequential operations
Solution Approach 2:
The tool is designed with multi-functionality, serving both to mill the unexpanded tubular portion and to engage and retrieve the shoe assembly. The latch assembly can engage different shoe assembly configurations, and the mill body can handle various tubular materials, making the tool universally applicable to different wellbore scenarios
2Productivity
If conventional methods are used to remove the unexpanded tubular and shoe assembly, then the removal can be accomplished, but multiple trips into the wellbore are required which increases time and operational cost
Solution Approach 1:
The tool performs continuous useful action by simultaneously milling the unexpanded tubular while engaging the shoe assembly in a single continuous operation. The mill body rotates continuously to cut through the tubular material while the latch assembly maintains continuous engagement with the shoe assembly, eliminating interruptions and multiple trips that would otherwise be required
Solution Approach 2:
The latch assembly is designed to engage the shoe assembly before the milling operation begins. This preliminary engagement ensures that the shoe assembly is securely attached to the tool before the mill body starts cutting the unexpanded tubular, allowing for immediate retrieval after milling completes without requiring additional positioning trips
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and reliable removal of the unexpanded shoe assembly and tubular from the wellbore in a single operation, reducing the need for complex tools and multiple trips, thereby enhancing drilling efficiency.
Implementation Method 1
The mill body is rotated relative to the latch assembly so as to mill the unexpanded portion of the tubular
Data Source
Figure 1A~1C
Figure 1D~1E
Figure 2A~2C
AI summary
A method of removing an unexpanded shoe comprises disposing a tool in a wellbore. The tool includes a latch assembly and a mill body. The latch assembly is engaged with a shoe assembly that is coupled to the wellbore by a tubular having an expanded portion and an unexpanded portion. The mill body is rotated relative to the latch assembly so as to mill the unexpanded portion of the tubular until the shoe assembly is uncoupled from the wellbore. The tool and the shoe assembly are then pulled through the expanded portion and out of the wellbore.