Multi-cycle Downhole Cutter with Nested Knife Sets
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Solution Overview
Problem
In oil and gas exploration, the existing methods for removing casing from wellbores are inefficient, often requiring multiple trips and cuts to successfully sever and extract casing sections, leading to increased time and costs due to difficulties in adequately severing the casing at initial locations.
Innovation Solution
A multi-cycle downhole cutting tool with a piston assembly and multiple cutter knife sets, allowing for multiple cuts in a single trip by deploying and retracting expandable cutting arms and knife sets to efficiently sever casing sections, including the use of an underreamer and casing mill for comprehensive cutting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single cutting device is used to sever casing, then the cutting operation can be performed, but multiple trips into the wellbore are required which increases time and costs
Solution Approach 1:
The cutting tool is divided into multiple independent cutter knife sets (first, second, third cutter knife sets) that can be selectively deployed. Each cutter knife set includes multiple individual cutter knives that can be independently activated to cut casing at different locations, allowing multiple cuts to be made during a single trip into the wellbore.
Solution Approach 2:
The cutting tool is designed with multi-functionality to perform multiple cutting operations at different casing locations using different cutter knife sets. The tool can selectively engage first, second, and third cutter knife sets to cut inner casing, outer casing, and intermediate casing respectively, making the tool versatile for various cutting scenarios in a single trip.
2Adaptability or versatility
If multiple cutter knife sets with different diameters are used, then cutting operations at different locations can be performed, but the device complexity increases
Solution Approach 1:
The cutter knives within each cutter knife set are arranged in a nested configuration where they can be stacked or folded against each other when not in use. This nesting arrangement allows multiple cutter knives to be contained within a compact space, reducing the overall device complexity while maintaining the capability to perform multiple cutting operations.
Solution Approach 2:
Each cutter knife is designed with dynamic deployment capability, allowing individual cutter knives to be extended or retracted as needed. The cutter knives can be selectively deployed from a retracted position to an extended cutting position, enabling the tool to adapt to different cutting requirements without permanently increasing device complexity.
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 cost-effective multiple cuts in a single trip, reducing overall time and costs associated with casing extraction and allowing for simultaneous cutting, underreaming, and milling operations in a single downhole trip.
Implementation Method 1
a piston assembly disposed in a central bore thereof, the piston assembly configured to translate longitudinally along the central axis of the tool body
Data Source
AI summary
A downhole cutting tool includes a tool body and a plurality of cutter knife sets, each of the plurality of cutter knife sets configured to extend outwardly to separately perform a pipe cutting operation. A first cutter knife set has a diameter in an extended position larger than a diameter in an extended position of a second cutter knife set. A method includes running the downhole cutting tool into a wellbore, deploying the first set of expandable cutting arms to an extended position and engaging the extended expandable cutting arms with a first work piece, rotating the downhole cutting tool and cutting the first work piece, deploying the second set of expandable cutting arms during a single trip into the wellbore to an extended position and engaging the extended expandable cutting arms with a second work piece, and rotating the downhole cutting tool and cutting the second work piece.