US011377909B2

( 12) United States Patent ( 10) Patent No .: US 11,377,909 B2

Odell , II et al. (45 ) Date of Patent : Jul . 5 , 2022

( 54 ) EXTENDABLE CUTTING TOOLS FOR USE ( 56 ) References Cited

IN A WELLBORE
U.S. PATENT DOCUMENTS
( 71 ) Applicant: Weatherford Technology Holdings ,
LLC , Houston , TX (US ) 2,170,451 A 8/1939 Grant
2,409,811 A 10/1946 Taylor, Jr. et al .
( 72 ) Inventors: Albert C. Odell, II , Kingwood, TX
2
(Continued )
(US ) ; Wei Jake Xu , Cypress, TX (US ) FOREIGN PATENT DOCUMENTS
( 73 ) Assignee : Weatherford Technology Holdings , CA 2298298 A1 8/2000
LLC , Houston , TX (US ) EP 2304159 A2 4/2011
( * ) Notice: Subject to any disclaimer, the term of this (Continued )
patent is extended or adjusted under 35
U.S.C. 154 ( b ) by 110 days . OTHER PUBLICATIONS
( 21 ) Appl. No .: 16 /112,468 Dictionary definition of " attach ” , accessed Apr. 7 , 2021 via www .
dictionary.com . *
( 22 ) Filed : Aug. 24, 2018 ( Continued )
( 65 ) Prior Publication Data
Primary Examiner Blake Michener
US 2019/0003260 A1 Jan. 3 , 2019 (74 ) Attorney, Agent, or Firm Patterson + Sheridan,
Related U.S. Application Data LLP
( 60 ) Continuation of application No. 14/ 450,661 , filed on (57 ) ABSTRACT
Aug. 4 , 2014 , now Pat. No. 10,060,190 , which is a
( Continued ) A tool for use in a wellbore includes aa tubular body having
a bore therethrough , an opening through a wall thereof, and
( 51 ) Int. Ci . a connector at each longitudinal end thereof; and an arm .
E21B 10/32 ( 2006.01 ) The arm is pivotally connected to a first piston and rota
E21B 47/00 ( 2012.01 ) tionally coupled to the body, is disposed in the opening in a
(Continued ) retracted position , and is movable to an extended position
( 52) U.S. CI . where an outer surface of the arm extends outward past an
CPC E21B 10/322 ( 2013.01 ) ; E21B 7/28 outer surface of the body. The first piston is disposed in the
(2013.01 ) ; E21B 10/32 (2013.01 ) ; E21B 23/04 body bore, has a bore therethrough , and is operable to move
( 2013.01 ) ; the arm from the retracted position to the extended position
( Continued ) in response to fluid pressure in the piston bore exceeding
( 58 ) Field of Classification Search fluid pressure in the opening . The tool further includes a lock
CPC E21B 10/327 ; E21B 10/34; E21B 10/345 ; operable to retain the first piston in the retracted position ;
E21B 10/322; E21B 7/28 ; E21B 10/32 ; and a second piston operably coupled to the lock .
E21B 10/325
See application file for complete search history. 22 Claims , 23 Drawing Sheets
100
50a 7
55 25
100 10h 5b
14
.

A
XS
TITZ

100 12u 5s

15u

210
205
101
 US 11,377,909 B2
Page 2

Related U.S. Application Data 5,203,414 A 4/1993 Hromas et al .

5,219,027 A 6/1993 Taylor
division of application No. 13 /748,193 , filed on Jan. 5,242,201 A 9/1993 Beeman
23 , 2013 , now Pat . No. 8,794,354 , which is a division 5,332,048 A 7/1994 Underwood et al .
of application No. 12 / 616,107 , filed on Nov. 10 , 2009 , 5,507,349 A 4/1996 Wray et al.
5,558,153 A 9/1996 Holcombe et al.
now Pat . No. 8,540,035, which is a continuation -in 5,580,114 A 12/1996 Palmer
part of application No. 12 / 436,077 , filed on May 5 , 5,589,825 A 12/1996 Pomerleau
2009 , now Pat . No. 8,991,489 . 5,615,741 A 4/1997 Coronado
5,695,009 A 12/1997 Hipp
( 60 ) Provisional application No. 61 / 113,198 , filed on Nov. 5,706,896 A 1/1998 Tubel et al.
10 , 2008, provisional application No. 61 /050,511, 5,718,291 A 2/1998 Lorgen et al.
5,785,120 A 7/1998 Smalley et al .
filed on May 5 , 2008 . 5,787,982 A 8/1998 Bakke
5,797,454 A 8/1998 Hipp
(51 ) Int. Cl. 5,803,182 A 9/1998 Bakke
E21B 47/13 ( 2012.01 ) 5,845,711 A 12/1998 Connell et al .
5,984,028 A 11/1999 Wilson
E21B 7/28 ( 2006.01 ) 5,984,029 A 11/1999 Griffin et al .
E21B 47/14 (2006.01 ) 6,009,948 A 1/2000 Flanders et al .
E21B 23/04 ( 2006.01 ) 6,021,095 A 2/2000 Tubel et al.
E21B 47/12 ( 2012.01 ) 6,029,748 A 2/2000 Forsyth et al .
( 52 ) U.S. Cl . 6,041,860 A 3/2000 Nazzal et al .
6,050,341 A 4/2000 Metcalf
CPC E21B 47/00 (2013.01 ) ; E21B 47/12 6,053,262 A 4/2000 Ferguson et al .
(2013.01 ) ; E21B 47/13 (2020.05 ) ; E21B 47/14 6,055,213
6,131,953
A
A
4/2000
10/2000
Rubbo et al .
Connell et al .
(2013.01 ) 6,164,393 A 12/2000 Bakke
6,213,206 B1 4/2001 Bakke
(56 ) References Cited 6,267,185 B1 7/2001 Mougel et al.
U.S. PATENT DOCUMENTS 6,269,891 B1 8/2001 Runia
6,289,999 B1 9/2001 Dewey et al .
6,290,004 B1 9/2001 Evans
2,719,362 A 10/1955 Montgomery et al . 6,321,847 B1 11/2001 Brown
2,719,363 A 10/1955 Montgomery et al . 6,333,700 B1 12/2001 Thomeer et al .
2,726,848 A 12/1955 Montgomery et al . 6,338,504 B1 1/2002 Hilliard
2,868,506 A 1/1959 Nestle 6,343,649 B1 2/2002 Beck et al .
3,092,188 A 6/1963 Farris et al . 6,349,767 B2 2/2002 Gissler
3,222,089 A 12/1965 Otteman 6,349,772 B2 2/2002 Mullen et al .
3,223,164 A 12/1965 Otteman 6,408,945 B1 6/2002 Telfer
3,233,674 A 2/1966 Leutwyler 6,408,946 B1 6/2002 Marshall et al .
3,321,217 A 5/1967 Ahlstone 6,419,013 B1 7/2002 Milne et al.
3,344,861 A 10/1967 Claycomb 6,443,228 B1 9/2002 Aronstam et al .
3,357,489 A 12/1967 Brown 6,454,007 B1 9/2002 Bailey
3,390,898 A 7/1968 Sumida 6,457,520 B2 10/2002 Mackenzie et al .
3,516,703 A 6/1970 Templeton 6,536,524 B1 3/2003 Snider
3,559,732 A 2/1971 Tucker 6,608,565 B1 8/2003 Van Steenwyk et al .
3,669,190 A 6/1972 Sizer et al . 6,668,949 B1 12/2003 Rives
3,675,713 A 7/1972 Watkins 6,712,146 B2 3/2004 Estep et al .
3,813,656 A 5/1974 Fowler 6,736,210 B2 5/2004 Hosie et al.
3,820,389 A 6/1974 Richter, Jr. et al . 6,776,240 B2 8/2004 Kenison et al .
3,842,914 A 10/1974 Mott 6,802,373 B2 10/2004 Dillenbeck et al .
4,013,945 A 3/1977 Grosso 6,834,726 B2 12/2004 Giroux et al .
RE29,471 E 11/1977 Giroux 6,845,820 B1 1/2005 Hebert et al.
4,109,712 A 8/1978 Regan 6,877,567 B2 4/2005 Hirth
4,153,109 A 5/1979 Szescila 6,892,819 B2 5/2005 Cook et al .
4,223,920 A 9/1980 Van Bilderbeek 6,989,764 B2 1/2006 Thomeer et al .
4,224,986 A 9/1980 Rothberg 6,997,266 B2 2/2006 Jackson et al .
4,224,993 A 9/1980 Huckaby 7,011,162 B2 3/2006 Maguire
4,273,372 A 6/1981 Sheshtawy 7,044,229 B2 5/2006 Tennoy et al .
4,282,941 A 8/1981 Perkin 7,048,078 B2 5/2006 Dewey et al .
4,285,399 A 8/1981 Holland et al . 7,063,142 B2 6/2006 Cook et al .
4,349,072 A 9/1982 Escaron et al . 7,083,209 B2 8/2006 Leman et al .
4,491,345 A 1/1985 Regan 7,093,656 B2 8/2006 Maguire
4,515,225 A 5/1985 Dailey 7,100,696 B2 9/2006 Marshall
4,619,324 A 10/1986 Couch 7,100,713 B2 9/2006 Tulloch
4,691,776 A 9/1987 Pringle 7,114,573 B2 10/2006 Hirth et al .
4,705,117 A 11/1987 Warren et al . 7,134,493 B2 11/2006 Runia
4,750,560 A 6/1988 Gazda 7,140,454 B2 11/2006 Runia
4,763,258 A 8/1988 Engelder 7,152,674 B2 12/2006 Bowles
4,856,594 A 8/1989 Jennings 7,159,667 B2 1/2007 Cook et al .
4,901,804 A 2/1990 Thometz et al .
7,163,058 B2 1/2007 Bakke et al .
4,902,044 A 2/1990 Williams et al . 7,165,612 B2 1/2007 McLaughlin
4,911,243 A 3/1990 Beynet 7,172,021 B2 2/2007 Brisco et al .
4,913,229 A 4/1990 Hearn
7,174,963 B2 2/2007 Bertelsen
4,986,359 A 1/1991 Cromar et al .
3/2007 Berkheimer et al .
4,993,493 A 2/1991 Arnold 7,188,672 B2
5,163,514 A 11/1992 Jennings RE39,583 E 4/2007 Upchurch
5,170,847 A 12/1992 Mims et al . 7,198,101 B2 4/2007 McGarian et al .
5,195,586 A 3/1993 Gambertoglio 7,213,655 B2 5/2007 Parrott
 US 11,377,909 B2
Page 3

( 56 ) References Cited 2009/0194285 A1 8/2009 Redlinger et al .

2009/0223670 A1 9/2009 Snider
U.S. PATENT DOCUMENTS 2009/0230340 A1 9/2009 Purkis
2009/0266544 Al 10/2009 Redlinger et al .
7,216,699 B2 5/2007 Nelson et al . 2009/0294178 A1 * 12/2009 Radford E21B 17/1078
7,225,870 B2 6/2007 Pedersen et al . 175/57
7,225,880 B2 6/2007 Braddick 2010/0025047 A1 2/2010 Sokol et al .
7,243,731 B2 7/2007 Watson et al . 2010/0252252 A1 10/2010 Harris et al .
7,245,229 B2 7/2007 Baron et al. 2010/0252278 Al 10/2010 Harris et al .
7,252,150 B2 8/2007 Downie et al. 2011/0155368 A1 6/2011 El -Khazindar
7,252,152 B2 8/2007 LoGiudice et al . 2011/0278064 Al 11/2011 Rasheed
7,290,616 B2 11/2007 Cook et al .
7,296,637 B2 11/2007 Gudac FOREIGN PATENT DOCUMENTS
7,296,639 B2 11/2007 Millar et al .
7,322,410 B2 1/2008 Vinegar et al . GB 2294486 A 5/1996
7,337,852 B2 3/2008 Manke et al . GB 2361727 A 10/2001
7,360,594 B2 4/2008 Giroux et al . GB 2378197 A 2/2003
7,363,691 B2 4/2008 Cook et al . GB 2394740 A 5/2004
7,370,712 B2 5/2008 Stout et al . WO 9958809 A2 11/1999
7,373,974 B2 5/2008 Connell et al. WO 0024997 A1 5/2000
7,380,596 B2 6/2008 De Clute -Melancon WO 03004825 A1 1/2003
7,401,666 B2 7/2008 Fanuel et al . WO 2003102354 Al 12/2003
7,431,094 B2 10/2008 De Clute -Melancon WO 2004097163 A1 11/2004
7,438,133 B2 10/2008 Brisco WO 2005124094 Al 12/2005
7,513,318 B2 4/2009 Underwood et al . WO 200913753 A1 1/2009
7,556,092 B2 7/2009 Cook et al .
7,562,712 B2 7/2009 Cho et al.
7,588,100 B2 9/2009 Hamilton OTHER PUBLICATIONS
7,603,758 B2 10/2009 Cook et al .
7,681,642 B2 3/2010 Bell et al . Fraley et al . — “ RFID Technology for Downhole Well Applications ,"
7,703,553 B2 4/2010 Eddison et al . Exploration & Production Oil & Gas Review 2007 – OTC Edi
7,762,330 B2 7/2010 Saylor, III et al . tion , pp . 60-62 .
7,891,441 B2 2/2011 Lee
7,900,717 B2 3/2011 Radford et al . Snider et al. — “ RFID Downhole Tools and Development for the
8,006,779 B2 8/2011 Moore et al . Drilling Environment,” 2009 National AADE Technical Conference
8,028,763 B2 10/2011 Mackenzie & Exhibition , New Orleans, Louisiana, AADE 2009NTCE - 16-04 ,
8,028,767 B2 10/2011 Radford et al . pp. 1-3 .
8,881,833 B2 11/2014 Radford et al . International Search Report and Written Opinion dated Feb. 25 ,
8,991,489 B2 3/2015 Redlinger et al . 2010 , International Application No. PCT /US2009 / 063934 .
2001/0054969 Al 12/2001 Thomeer et al .
2002/0046834 A1 4/2002 Rayssiguier et al . Australian Patent Examination Report No. 1 , dated Nov. 23 , 2012 ,
2003/0070842 A1 4/2003 Bailey et al . Australian Application No. 2009313207 .
2003/0079913 Al 5/2003 Eppink et al . Canadian Office Action ; Canadian Patent Application No. 2,742,767 ;
2003/0155155 Al 8/2003 Dewey et al . dated Aug. 15 , 2012 .
2004/0040707 Al 3/2004 Dusterhoft et al. Canadian Office Action dated May 4 , 2012 , Candian Patent Appli
2004/0251027 A1 12/2004 Sonnier et al.
2004/0256113 A1 * 12/2004 LoGiudice E21B 34/066 cation No. 2,722,608 .
166/381 Gelfgat et al.— “ Retractable Drillbit Technology Drilling Without
2005/0006106 Al 1/2005 Hirth et al . Pulling Out Drillpipe, ” Advanced Drilling Solutions Lessons from
2005/0029017 A1 2/2005 Berkheimer et al . the FSU vol . II PennWell Corporation Tulsa Oklahoma 2003 pp .
2005/0045342 Al 3/2005 Luke et al. 365 430 432 and 435 .
2005/0072565 A1 4/2005 Segura et al . Canadian Office Action dated Jun. 25 , 2013 , Canadian Patent
2005/0145417 A1 * 7/2005 Radford E21B 7/00 Application No. 2,742,767 .
175/57 Canadian Office Action dated May 15 , 2014 , Canadian Patent
2005/0200498 Al 9/2005 Gleitman Application No. 2,844,909 .
2005/0205305 A1 9/2005 Stout et al . Austrailian Exam Report for Patent Application No. 2012268851 ,
2005/0236162 A1 10/2005 Badrak et al . dated May 16 , 2014 .
2005/0241856 Al 11/2005 Lassoie et al . EPO Search Report for European Application No. 13193719.5 ,
2006/0000604 A1 1/2006 Jenkins et al . dated Oct. 13 , 2014 .
2006/0065408 A1 3/2006 Green et al .
2006/0118339 A1 6/2006 Takhaundinov et al . Snider et al . , “Marathon , partners adapt RFID technology for
2006/0124295 A1 6/2006 Maguire downhole drilling, completion applications,” Drilling Contractor,
2006/0131011 A1 6/2006 Lynde et al . Mar./Apr. 2007 .
2006/0207797 A1 9/2006 Dewey et al . Fraley, Karen et al.— “ RFID Technology for Downhole Well Appli
2007/0000664 A1 1/2007 Ring et al . cations , ” Exploration and Production - Oil & Gas Review 2007
2007/0107937 A1 5/2007 Sugiura OTC Edition, pp . 60-62 .
2007/0205022 Al 9/2007 Treviranus et al . Snider, Philip M. et al. — “ RFID Downhole Tools and Development
2007/0251687 A1 11/2007 Martinez et al . for the Drilling Environment , ” American Association of Drilling
2007/0251701 A1 11/2007 Jahn et al . Engineers 2009 National Technical Conference & Exhibition, New
2007/0285275 A1 12/2007 Purkis et al .
2008/0041587 Al 2/2008 Bell et al. Orleans, Louisiana, AADE 2009NTCE - 16-04 Tech Paper, pp . 1-3 .
2008/0041597 A1 2/2008 Fisher et al . U.S. Appl. No. 12 / 184,785 , Sokol et al .
2008/0128169 A1 6/2008 Radford et al . PCT Search Report for International Application No. PCT /US2009 /
2008/0128174 Al 6/2008 Radford et al . 042918 dated Mar. 25 , 2011 .
2008/0128175 Al 6/2008 Radford et al . Webster's New Universal Unabridged Dictionary, Second Edition ,
2008/0149348 Al 6/2008 DiFoggio et al . 1983 , published by New World Dictionaries/Simon & Schuster,
2008/0202767 Al 8/2008 Sheiretov et al . New York, NY, p . 1901 .
2008/0245532 Al 10/2008 Rhinehart et al . Australian Patent Examination Report dated Mar. 19 , 2015 , for
2009/0090508 A1 4/2009 Brouse Australian Patent Application No. 2013203056 .
 US 11,377,909 B2
Page 4

( 56 ) References Cited
OTHER PUBLICATIONS
Canadian Office Action dated Oct. 29 , 2015 for Application No.
2,871,928 .
Australian Examination Report dated Mar. 16 , 2016 , for Australian
Patent Application No. 2013203056 .
Australian Patent Examination Report dated Nov. 17 , 2016 , for
Australian Patent Application No. 2015252100 .
EPO Partial European Search Report dated Feb. 27 , 2017 , for
European Patent Application No. 14193056.0 .
EPO Extended European Search Report dated Jun . 19 , 2017 , for
European Application No. 14193056.0 .
Australian Examination Report dated Nov. 8 , 2017 , for Australian
Patent Application No. 2015252100 .
EPO Office Action dated Mar. 16 , 2018 , for European Patent
Application No. 14193056.0 .
* cited by examiner
U.S. Patent Jul . 5 , 2022 Sheet 1 of 23 US 11,377,909 B2

10
121

10p
W
72
50
4 151
20

55

FIG
1B
. 50p-
14
AZBIMZ 4
101

14 1A
.
FIG
25

50a
55

5a
207 7 12u
100
5p

15u
5
210

0 0 205
U.S. Patent Jul . 5 , 2022 Sheet 2 of 23 US 11,377,909 B2

52
51a 50b
50a
-510
51g
511
55
516

25

5r

FIG . 1C
U.S. Patent Jul . 5 , 2022 Sheet 3 of 23 US 11,377,909 B2

5
10
212
0

2050
210
2105 235

205
2058
2 54
2914 227
2B
.
FIG

230
230s 2A
FIG
.
2 5s
224 225
2101 215 2 0b
222
2 0p
214 214
?? 220 215
290 2 0s
205a
200
U.S. Patent Jul . 5 , 2022 Sheet 4 of 23 US 11,377,909 B2

342

355
351
300 361360362
366365
this WWW. 367
371

372 FIG
3
.

351352341350369
370

343

345 378 Z S Vanda n 325301

347325
346
U.S. Patent Jul . 5 , 2022 Sheet 5 of 23 US 11,377,909 B2

400 408

407

431 425

406 426
404
455
4
.
FIG
409a 402a
b
,

403
475
409b

401

4012
U.S. Patent Jul . 5 , 2022 Sheet 6 of 23 US 11,377,909 B2

300
4A
.
FIG CONTRL MODULE
475
MUD PULSER
BATERY PACK 431

GENRATO 432
430
MICROPES SENOR
455
405
,
402

RADIO
PRESU SWITCH 433 CONTRL SIGNALS RECOV D SIGNAL TRNSMTR CONTRL RECIVD SIGNAL TRANSCIEV 429

434
RFSWITCH 428 NOISE FILTER SIGNAL DETCOR
426

426
RFID RECV AMPLFIER RF 427

425 TRANSMIT
U.S. Patent Jul . 5 , 2022 Sheet 7 of 23 US 11,377,909 B2

450p

TRANSMI TRANSMIT CRUITS RFPOWER GENRATO RECIVE CIRUTS RECV

4B
.
FIG

TRANSMIT TRANSMIT CRUITS TIMER PRESU SWITCH BAT ERY 450a

U.S. Patent Jul . 5 , 2022 Sheet 8 of 23 US 11,377,909 B2

409b 477 479

409a
Thr 4D
.
FIG
bruto

480 476 478

45 a 4C
.
FIG
G
45 b
VERTEL
??
,
405 404
U.S. Patent Jul . 5 , 2022 Sheet 9 of 23 US 11,377,909 B2

RPM /
FLOW
RATE ?
TIME
SURFACE
545 CONTROLLER 545

525
290 450a , p

510

542
520 528

524 . 514f 518

500 514r
519 -511 520
502
516a 517
400
550 200/300
100
5198

FIG . 5A
U.S. Patent Jul . 5 , 2022 Sheet 10 of 23 US 11,377,909 B2

FLOW
RATE
TIME

SURFACE
545 CONTROLLER

525
290 450a,p

510

542
520 528

524 5141 518

500
519
511 520
514r

502
516a
516r .
517

550 200/300
50b
50a
516p 505

FIG . 5B
U.S. Patent Jul . 5 , 2022 Sheet 11 of 23 US 11,377,909 B2

605 ZZZ
612 77

9809
ZZ T209 N
6A
.
FIG
616
604
7zz
602u
603a 621
909 w

622

009
U.S. Patent Jul . 5 , 2022 Sheet 12 of 23 US 11,377,909 B2

605 ZZZ
612 27 2

9809
ZZ 6021 N
6B
.
FIG
647 616

603a
ZZ nz09
N
621
909 w

622

089
U.S. Patent Jul . 5 , 2022 Sheet 13 of 23 US 11,377,909 B2

65 b
210s
660
210
235

g 230 6C
.
FIG
625
227
675
680677
}

655 665

650 65a78
U.S. Patent Jul . 5 , 2022 Sheet 14 of 23 US 11,377,909 B2

400 400

IC
10 1 10 1 100

PIT
7A
.
FIG w
I IG 7B
.
FIG .
FIG
7C

705 €
100
705 30 1 705 30 1

10 u
TOTD 10 u

Har
30 u 30 u 30 u
U.S. Patent Jul . 5 , 2022 Sheet 15 of 23 US 11,377,909 B2

1001

30 1 8
.
FIG
400

30 0

IN

???
U.S. Patent Jul . 5 , 2022 Sheet 16 of 23 US 11,377,909 B2

950a
955

FIG.9
U.S. Patent Jul . 5 , 2022 Sheet 17 of 23 US 11,377,909 B2

10 5

10 9b 1027
10 5108750
1022101810201010 1019a
10A
,
FIG 10B
.
FIG
10 5
1070
1030

10 5

10 0
U.S. Patent Jul . 5 , 2022 Sheet 18 of 23 US 11,377,909 B2

9910 a
1034 &
1032 1036b
1031 10 b
1035a 1034
103
1035b 1036a 103126 103 a
101
103 6 1025

1
107285 103 a 1031a 1078

1030
10 0a
FIG.10C 10D
.
FIG
U.S. Patent Jul . 5 , 2022 Sheet 19 of 23 US 11,377,909 B2
AN

SURJALLANLA L L L L
*** ***
R

105

1075 1025 1065

?

1034 777 2
???? 1072 1060
1046b 1046a6 1071
101 1025 10F
.
FIG
103 b 1031a 1025 ??? 1043
1070
1078 1041 104987
1030 426

10 0 105
104 1042
FIG
10E
. 10 0C
U.S. Patent Jul . 5 , 2022 Sheet 20 of 23 US 11,377,909 B2

1 05
1 35b
1 30
1 34
1 15 p 1 35a
1 15 1 05 11A
.
FIG 1 0b
1 15C 13b
1 10c 13a
1 0n 1 25
1 20 426
1 70
1 10
10
1 05
1 0a 1 30
11B
.
FIG
U.S. Patent Jul5, 2022 Sheet 21 of 23 US 11,377,909 B2

T
>

1205
'
2.

?
???
?????
????
E
&
???
??

1230
#PB
???
o
?
1 2 3 5 a ????
?21 7?2 ?0a ??
? ?
12 7
Z22
1250e1
gj
?
2E
??

12 0 20a
1250b ]
722

235 **
?????
??
12158 ) ??
??????
1205 1250
250p
2
?

1215
?250s

120
1205a
12A
.
FIG 3
???
)
12B
.
FIG 120 120
.
FIG
U.S. Patent Jul . 5 , 2022 Sheet 22 of 23 US 11,377,909 B2

1307a I

GE 1310s
1310 1307
1390
13075
13101 1307a
13 0u 1310s
131
1315p 132
1315
1320

14
To 5S .
u

150
5

130 .
FIG
13A 13B
.
FIG
130
U.S. Patent Jul . 5 , 2022 Sheet 23 of 23 US 11,377,909 B2

1410
1405b 22
1410
ht ZB 1405 177
1430 noCMD
14301
1415 ?? 1412 7
1435
1405a June 1420

1407
1407a 140 14B
.
FIG
140 14A
.
FIG
 US 11,377,909 B2
1 2
EXTENDABLE CUTTING TOOLS FOR USE ingly, by enlarging the borehole below the previously cased
IN A WELLBORE borehole , the bottom of the formation can be reached with
comparatively larger diameter casing / liner, thereby provid
BACKGROUND OF THE INVENTION ing more flow area for the production of oil and / or gas .
5 Underreamers also lessen the equivalent circulation density
Field of the Invention (ECD ) while drilling the borehole.
In order to accomplish drilling a wellbore larger than the
Embodiments of the present invention generally relate to bore of the casing / liner, a drill string with an underreamer
extendable cutting tools for use in a wellbore . and pilot bit may be employed. Underreamers may include
10 a plurality of arms which may move between a retracted
Description of the Related Art position and an extended position . The underreamer may be
passed through the casing/ liner, behind the pilot bit when the
A wellbore is formed to access hydrocarbon bearing arms are retracted . After passing through the casing , the
formations, e.g. crude oil and / or natural gas , by the use of arms may be extended in order to enlarge the wellbore below
drilling. Drilling is accomplished by utilizing a drill bit that 15 the casing .
is mounted on the end of a tubular string, such as a drill
string. To drill within the wellbore to a predetermined depth , SUMMARY OF THE INVENTION
the drill string is often rotated by a top drive or rotary table
on a surface platform or rig , and / or by a downhole motor Embodiments of the present invention generally relate to
mounted towards the lower end of the drill string. After 20 extendable cutting tools for use in a wellbore . In one
drilling to a predetermined depth , the drill string and drill bit embodiment, a tool for use in aa wellbore includes a tubular
are removed and a section of casing is lowered into the body having a bore therethrough, an opening through a wall
wellbore . An annulus is thus formed between the string of thereof, and a connector at each longitudinal end thereof;
casing and the formation . The casing string is temporarily and an arm . The arm is pivotally connected to a first piston
hung from the surface of the well . The casing string is 25 and rotationally coupled to the body. The arm is disposed in
cemented into the wellbore by circulating cement into the the opening in a retracted position , and is movable to an
annulus defined between the outer wall of the casing and the extended position where an outer surface of the arm extends
borehole. The combination of cement and casing strengthens outward past an outer surface of the body. The tool further
the wellbore and facilitates the isolation of certain areas of includes the first piston . The first piston is disposed in the
the formation behind the casing for the production of 30 body bore, has aa bore therethrough, and is operable to move
hydrocarbons. the arm from the retracted position to the extended position
It is common to employ more than one string of casing in in response to fluid pressure in the piston bore exceeding
a wellbore . In this respect , the well is drilled to a first fluid pressure in the opening . The tool further includes aa lock
designated depth with a drill bit on a drill string. The drill operable to retain the first piston in the retracted position ;
string is removed . A first string of casing is then run into the 35 and a second piston operably coupled to the lock .
wellbore and set in the drilled out portion of the wellbore, In another embodiment, a tool for use in a wellbore
and cement is circulated into the annulus behind the casing includes a tubular body having a bore therethrough and an
string. Next , the well is drilled to a second designated depth , opening through a wall thereof; and an arm . The arm is
and a second string of casing or liner, is run into the drilled pivotally connected to the body or a first piston, disposed in
out portion of the wellbore . If the second string is a liner 40 the opening in a retracted position, and movable to an
string, the liner is set at a depth such that the upper portion extended position where an outer surface of the arm extends
of the second string of casing overlaps the lower portion of outward past an outer surface of the body. The first piston is
the first string of casing. The liner string may then be fixed , disposed in the body bore, has a bore therethrough, and is
or " hung” off of the existing casing by the use of slips which operable to move the arm from the retracted position to the
utilize slip members and cones to frictionally affix the new 45 extended position in response to fluid pressure in the piston
string of liner in the wellbore . The second casing or liner bore exceeding fluid pressure in the opening . The tool
string is then cemented . This process is typically repeated further includes a lock operable to retain the piston in the
with additional casing or liner strings until the well has been retracted position ; and a controller operable to release the
drilled to total depth . In this manner, wells are typically lock in response to receiving an instruction signal .
formed with two or more strings of casing / liner of an 50 In one aspect of the embodiment, the tool further includes
ever -decreasing diameter. a tachometer for measuring an angular speed of the body and
As more casing/ liner strings are set in the wellbore , the in communication with the controller, wherein the controller
casing / liner strings become progressively smaller in diam- is operable to receive the instruction signal using the
eter to fit within the previous casing /liner string . In a drilling tachometer. In another aspect of the embodiment, the tool
operation , the drill bit for drilling to the next predetermined 55 further includes an antenna in communication with the
depth must thus become progressively smaller as the diam- controller, wherein the controller is operable to receive the
eter of each casing/ liner string decreases . Therefore, mul- instruction signal using the antenna. In another aspect of the
tiple drill bits of different sizes are ordinarily necessary for embodiment , the tool further includes a pressure sensor or
drilling operations. As successively smaller diameter casing / flow sensor, wherein the controller is operable to receive the
liner strings are installed, the flow area for the production of 60 instruction signal using the pressure or flow sensor. In
oil and gas is reduced . Therefore , to increase the annulus for another aspect of the embodiment, the tool further includes
the cementing operation, and to increase the production flow a mud pulser in communication with the controller, wherein
area , it is often desirable to enlarge the borehole below the the controller is operable to modulate the mud pulser to send
terminal end of the previously cased /lined borehole . By a signal to the surface . In another aspect of the embodiment,
enlarging the borehole , a larger annulus is provided for 65 the tool further includes a tachometer for measuring an
subsequently installing and cementing a larger casing/ liner angular speed of the body; and a pressure sensor or flow
string than would have been possible otherwise . Accord- sensor and in communication with the controller, wherein
 US 11,377,909 B2
3 4
the controller is operable to receive the instruction signal extending the other of the underreamers; and drilling and
using either the tachometer or the pressure or flow sensor . reaming the wellbore using the drill bit and the extended
In another aspect of the embodiment, the tool further other underreamer.
includes a sensor operable to measure a position of the first In another embodiment, a method of drilling a wellbore
piston and in communication with the controller. Each of the 5 includes running a drilling assembly into the wellbore
body and the arm may have a shoulder and the shoulders through a casing string , the drilling assembly including a
may be engaged in the extended position . Each shoulder tubular string, upper and lower underreamers, and a drill bit ;
may be radially inclined to create a radially inward compo injecting drilling fluid through the tubular string and rotating
nent of a normal reaction force between the arm and the the drill bit , wherein the underreamers remain locked in the
body. In another aspect of the embodiment, the controller is 10 retracted position ; sending an instruction signal to one of the
underreamers , thereby extending one of the underreamers ;
operable to re - engage the lock in response to receiving a drilling
second instruction signal. The controller may also be oper and reaming the wellbore the drill bit and the
able to re -engage the lock when the arm is an intermediate extended
other of
underreamer; pumping a closure member to the
the underreamers or injecting drilling fluid through
position between the retracted and extended position . In 15 the drilling assembly at a flow rate greater than or equal to
another aspect of the embodiment, the tool further includes a predetermined flow rate , thereby extending the other of the
an actuator in communication with the controller, wherein underreamers; and drilling and reaming the wellbore using
the controller is operable to move the first piston toward the the drill bit and the extended other underreamer.
retracted position using the actuator, and the actuator is In another embodiment, a method of drilling a wellbore
operable to move the first piston when fluid is being injected 20 includes: running a drilling assembly into the wellbore
through the tool . through a casing string. The drilling assembly includes a
In another aspect of the embodiment, the tool may be used tubular string, upper and lower underreamers, and aa drill bit .
in a method including running a drilling assembly into the The method further includes extending one of the under
wellbore through a casing string, the drilling assembly reamers ; drilling and reaming a first geological formation
comprising a tubular string, the tool , and a drill bit; injecting 25 using the drill bit and the extended underreamer; extending
drilling fluid through the tubular string and rotating the drill the other underreamer; and drilling and reaming a second
bit , wherein the tool remains locked in the retracted position ; geological formation using the drill bit and the extended
sending an instruction signal from the surface to the tool , other underreamer.
thereby extending the arm ; and drilling and reaming the In another embodiment, a cutter for use in a wellbore ,
wellbore using the drill bit and the extended tool . The 30 includes: a tubular body having a bore therethrough and an
drilling assembly may further include a stabilizer and the opening through a wall thereof; an arm disposed in the
instruction signal may also extend an arm of the stabilizer. opening in a retracted position and movable to an extended
The method may further include running an actuator through position where an outer surface of the arm extends outward
the tubular string to the tool using wireline or slickline ; and past an outer surface of the body ; and a piston . The piston
retracting the arm using the actuator. 35 is disposed in the body bore , has aa bore therethrough , and is
In another embodiment, a tool for use in a wellbore operable to move the arm from the retracted position to the
includes a tubular body having a bore therethrough and an extended position in response to fluid pressure in the piston
opening through a wall thereof; and an arm . The arm is bore exceeding fluid pressure in the opening. The cutter
disposed in the opening in a retracted position , and movable further includes a controller operable to : receive a position
to an extended position where an outer surface of the arm 40 signal from the surface , and move to a set position in
extends outward past an outer surface of the body. The tool response to the signal.
further includes a first piston disposed in the body bore , In another embodiment, a cutter for use in a wellbore
having a bore therethrough, and operable to move the arm includes a tubular body having a bore therethrough and an
from the retracted position to the extended position in opening through a wall thereof; an arm disposed in the
response to fluid pressure in the first piston bore exceeding 45 opening in a retracted position and movable to an extended
fluidpressure in the opening . The tool further includes aa lock position where an outer surface of the arm extends outward
operable to retain the first piston in the retracted position ; a past an outer surface of the body; and a mandrel. The
second piston operable to release the lock in response to mandrel is disposed in the body bore, having a bore there
fluid pressure ; an actuator operable to move the piston and through, and operable to move the arm from the retracted
release the lock ; and a controller operable to receive an 50 position
instruction signal and operate the actuator.
to the extended position. The cutter further includes
a controller operable to : receive a position signal from the
In another embodiment, a method of drilling a wellbore surface, and move the mandrel to a set position in response
includes running a drilling assembly into the wellbore to the position signal, thereby at least partially extending the
through a casing string. The drilling assembly includes a arm .
tubular string, upper and lower underreamers, and a drill bit . 55 In another embodiment, a method of cutting or milling a
The method further includes injecting drilling fluid through tubular cemented to a wellbore includes deploying a cutting
the tubular string and rotating the drill bit , wherein the assembly into the wellbore , the cutting assembly comprising
underreamers remain locked in the retracted position ; send- a workstring and a cutter; sending an instruction signal to the
ing an instruction signal to the underreamers via modulation cutter, thereby extending one or more arms of the cutter; and
of a rotational speed of the drilling assembly , modulation of 60 rotating the cutter, thereby milling or cutting the tubular.
a drilling fluid injection rate, or modulation of a drilling fluid
pressure , thereby extending one of the underreamers; and BRIEF DESCRIPTION OF THE DRAWINGS
drilling and reaming the wellbore the drill bit and the
extended underreamer; sending an instruction signal to the So that the manner in which the above recited features of
underreamers via modulation of aa rotational speed of the 65 the present invention can be understood in detail , a more
drilling assembly, modulation of a drilling fluid injection particular description of the invention , briefly summarized
rate , or modulation of a drilling fluid pressure , thereby above , may be had by reference to embodiments, some of
 US 11,377,909 B2
5 6
which are illustrated in the appended drawings. It is to be FIGS . 14A and 14B are cross -sections of a hydraulic
noted, however, that the appended drawings illustrate only control module in a retracted and extended position, respec
typical embodiments of this invention and are therefore not tively, according to another embodiment of the present
to be considered limiting of its scope , for the invention may invention .
admit to other equally effective embodiments. 5
FIGS . 1A and 1B are cross - sections of an underreamer in DETAILED DESCRIPTION
a retracted and extended position , respectively, according to
one embodiment of the present invention . FIG . 1C is an FIGS . 1A and 1B are cross - sections of an underreamer
isometric view of arms of the underreamer . 10
100 in a retracted and extended position, respectively,
FIGS . 2A and 2B are cross - sections of a mechanical according to one embodiment of the present invention .
control module connected to the underreamer in a retracted The underreamer 100 may include a body 5 , an adapter 7 ,
and extended position , respectively, according to another a piston 10 , one or more seal sleeves 15u , l, a mandrel 20 , and
embodiment of the present invention . one or more arms 50a, b ( see FIG . 1C for 506 ) . The body 5
FIG . 3 illustrates an electro -hydraulic control module for may be tubular and have a longitudinal bore formed there
15
use with the underreamer, according to another embodiment through . Each longitudinal end 5a , b of the body 5 may be
of the present invention . threaded for longitudinal and rotational coupling to other
FIG . 4 illustrates a telemetry sub for use with the control members, such as a control module 200 at 5a and the adapter
module, according to another embodiment of the present 7 at 5b . The body 5 may have an opening 50 formed through
invention . FIG . 4A illustrates an electronics package of the 20 a wall thereof for each arm 50a , b . The body 5 may also have
telemetry sub . FIG . 4B illustrates an active RFID tag and a a chamber formed therein at least partially defined by
passive RFID tag for use with the telemetry sub . FIG . 4C shoulder 5s for receiving a lower end of the piston 10 and the
illustrates accelerometers of the telemetry sub . FIG . 4D lower seal sleeve 151. The body 5 may include an actuation
illustrates a mud pulser of the telemetry sub . profile 5p formed in a surface thereof for each arm 50a , b
FIGS . 5A and 5B illustrate a drilling system and method 25 adjacent the opening 50. An end of the adapter 7 distal from
utilizing the underreamer, according to another embodiment the body (not shown) may be threaded for longitudinal and
of the present invention . rotational coupling to another member of a bottomhole
FIG . 6A illustrates an alternative electro -hydraulic control assembly (BHA) .
module for use with the underreamer, according to another The piston 10 may be a tubular, have a longitudinal bore
embodiment of the present invention. FIG. 6B illustrates 30 formed therethrough, and may be disposed in the body bore.
The piston 10 may have a flow port 10p formed through a
another alternative electro -hydraulic control module for use wall thereof corresponding to each arm 50a, b . A nozzle 14
with the underreamer, according to another embodiment of may be
the present invention . FIG . 6C illustrates an alternative resistantdisposed
material
in each port 10p and made from an erosion
, such as a metal , alloy, ceramic, or cermet.
electro -mechanical control module for use with the under 35 The mandrel 20 may be tubular, have a longitudinal bore
reamer, according to another embodiment of the present formed therethrough , and be longitudinally coupled to the
invention . lower seal sleeve 151 by a threaded connection . The lower
FIG . 7A illustrates a bottom hole assembly ( BHA) includ seal sleeve 151 may be longitudinally coupled to the body 5
ing dual underreamers, according to another embodiment of by being disposed between the shoulder 5s and a top of the
the present invention . FIGS . 7B and 7C illustrates an oper- 40 adapter 7. The upper seal sleeve 15u may be longitudinally
ating sequence for the dual underreamers. coupled to the body 5 by a threaded connection .
FIG . 8 illustrates an alternative dual underreamer BHA , Each arm 50a, b may be movable between an extended
according to another embodiment of the present invention . and a retracted position and may initially be disposed in the
FIG . 9 illustrates an underreamer arm configured for soft opening 50 in the retracted position . Each arm 50a , b may be
formations, according to another embodiment of the present 45 pivoted to the piston 10 by a fastener 25. Each arm 50a, b
invention . may be biased radially inward by a torsion spring ( not
shown ) disposed around the fastener 25. A surface of the
FIG . 10A is a cross section of a casing cutter in a retracted body
position , according to another embodiment of the present stop for 5 defining each opening 50 may serve as a rotational
invention . FIG . 10B is a cross section of the casing cutter in a respective blade 50a , b , thereby rotationally cou
9

an extended position . FIG . 10C is an enlargement of a retracted blade

50 pling the 50a , b to the body 5 ( in both the extended and
positions ) . Each arm 50a , b may include an actua
portion of FIG . 10A . FIG . 10D is a cross section of a portion tion profile 50p formed in an inner surface thereof corre
of an alternative casing cutter.
FIG . 10E is a cross section of a portion of an alternative along the toactuation
sponding the profile 5p . Movement of each arm 50a , b
profile 5p may force the arm radially
casing cutter. FIG . 10F is a cross section of an alternative 55 outward from the retracted position to the extended position .
casing cutter in an extended position . Each actuation profile 5p , 50p may include aa shoulder. The
FIG . 11A is a cross section of a section mill in a retracted shoulders may be inclined relative
a a
to a radial axis of the
position , according to another embodiment of the present body 5 in order to secure each arm 50a , b to the body in the
invention . FIG . 11B is an enlargement of a portion of FIG . extended position so that the arms do not chatter or vibrate
11A . 60 during reaming . The inclination of the shoulders may create
FIGS . 12A - 12C are cross - sections of a mechanical con a radial component of the normal reaction force between
trol module in a first retracted, extended , and second each arm and the body 5 , thereby holding each arm 50a , b
retracted position , respectively, according to another radially inward in the extended position. Additionally , the
embodiment of the present invention . actuation profiles 5p, 50p may each be circumferentially
FIGS . 13A and 13B are cross - sections of an underreamer 65 inclined ( not shown ) to retain the arms 50a, b against a
in an extended and second retracted position , respectively, trailing surface of the body defining the opening 50 to
according to another embodiment of the present invention . further ensure against chatter or vibration .
 US 11,377,909 B2
7 8
The underreamer 100 may be fluid operated by drilling actuator spring be unable to retract the blades . Cutters 55
fluid injected through the drill string being at a high pressure may be disposed on both a leading and trailing surface of
and drilling fluid and cuttings , collectively returns, flowing each blade for back - reaming capability. The cutters in the
to the surface via the annulus being at a lower pressure. A leading and trailing ends of each blade may be super - flush
first surface 10h of the piston 10 may be isolated from a 5 with the blade . The gage portion may be raised and the
second surface 101 of the piston 10 by a lower seal 121 gage - cutters flattened and flush with the blade, thereby
disposed between an outer surface of the piston 10 and an ensuring a concentric and full - gage hole .
inner surface of the lower seal sleeve 151. The lower seal 121 Alternatively, the cutters 55 may be omitted and the
may be a ring or stack of seals , such as chevron seals , and underreamer 100 may be used as a stabilizer instead .
made from a polymer, such as an elastomer. The high 10 FIGS . 2A and 2B are cross - sections of a mechanical
pressure may act on the first surface 10h of the piston via one control module 200 connected to the underreamer 100 in a
or more ports formed through a wall of the mandrel 20 and retracted and extended position, respectively , according to
the low pressure may act on the second surface 101 of the another embodiment of the present invention . The control
piston 10 via fluid communication with the openings 50 , module 200 may include a body 205 , a control mandrel 210 ,
thereby creating a net actuation force and moving the arms 15 a piston housing 215 , a piston 220 , a keeper 225 , a lock
50a, b from the retracted position to the extended position . mandrel 230 , and a biasing member 235. The body 205 may
An upper seal 12u may be disposed between the upper seal be tubular and have a longitudinal bore formed there
sleeve 15u and an outer surface of the piston 10 to isolate the through. Each longitudinal end 205a , b of the body 205 may
openings 50. The upper seal 12u may be a ring or stack of be threaded for longitudinal and rotational coupling to other
seals , such as chevron seals , and made from a polymer, such 20 members , such as the underreamer 100 at 205b and a drill
as an elastomer. Various other seals , such as o - rings may be string at 205a .
disposed throughout the underreamer 100 . The biasing member may be a spring 235 and may be
In the retracted position , the piston ports 10p may be disposed between a shoulder 210s of the control mandrel
closed by the mandrel 20 and straddled by seals , such as 210 and a shoulder of the lock mandrel 230. The spring 235
o -rings , to isolate the ports from the piston bore . In the 25 may bias a longitudinal end of the control mandrel or a
extended position, the flow ports 10p may be exposed to the control module adapter 212 into abutment with the under
piston bore , thereby discharging a portion of the drilling reamer piston end 10t , thereby also biasing the underreamer
fluid into the annulus to cool and lubricate the arms 50a , b piston 210 toward the retracted position . The control module
and carry cuttings to the surface. This exposure of the flow adapter 212 may be longitudinally coupled to the control
ports 10p may result in a drop in upstream pressure, thereby 30 mandrel 210 , such as by a threaded connection, and may
providing an indication at the surface that the arms 50a, b are allow the control module 200 to be used with differently
extended configured underreamers by changing the adapter 212. The
FIG . 1C is an isometric view of the arms 50a , b . An outer control mandrel 210 may be longitudinally coupled the
surface of each arm 50a, b may form one or more blades lock mandrel 230 by a latch or lock, such as a plurality of
51a, b and a stabilizer pad 52 between each of the blades . 35 dogs 227. Alternatively, the latch or lock may be a collet.
Cutters 55 may be bonded into respective recesses formed The dogs 227 may be held in place by engagement with a lip
along each blade 51a , b . The cutters 55 may be made from 2251 of the keeper 225 and engagement with a lip 2101 of the
a super -hard material, such as polycrystalline diamond com- control mandrel 210. The lock mandrel 230 may be longi
pact ( PDC ) , natural diamond , or cubic boron nitride. The tudinally coupled to the piston housing 215 by a threaded
PDC may be conventional, cellular, or thermally stable 40 connection and may abut a body shoulder 205s and the
( TSP ) . The cutters 55 may be bonded into the recesses , such piston housing 215 .
as by brazing , welding, soldering, or using an adhesive . The piston housing 215 may be longitudinally coupled to
Alternatively, the cutters 55 may be pressed or threaded into the body 205 by a threaded connection . The piston 220 may
the recesses. Inserts, such as buttons 56 , may be disposed be longitudinally coupled to the keeper 225 by one or more
along each pad 52. The inserts 56 may be made from a 45 fasteners, such as set screws 224 , and by engagement of a
wear - resistant material, such as a ceramic or cermet (e.g. , piston end 220b with a keeper shoulder 225s . The set screws
tungsten carbide ). The inserts 56 may be brazed, welded , or 224 may each be disposed through a respective slot formed
pressed into recesses formed in the pad 52 . through a wall of the piston 220 so that the piston may move
The arms 50a , b may be longitudinally aligned and cir- longitudinally relative to the keeper 225 , the movement
cumferentially spaced around the body 5 and junk slots 5r 50 limited by a length of the slot . The keeper 225 may be
may be formed in an outer surface of the body between the longitudinally movable relative to the body 205 , the move
arms. The junk slots 5r may extend the length of the ment limited by engagement of the keeper shoulder 225s
openings 50 to maximize cooling and cuttings removal (both with a piston housing shoulder 215s and engagement of a
from the drill bit and the underreamer ). The arms 50a , b may keeper longitudinal end with aa lock mandrel shoulder 230s .
be concentrically arranged about the body 5 to reduce 55 The piston 220 may be longitudinally coupled to the piston
vibration during reaming. The underreamer 100 may include housing 215 by one or more frangible fasteners, such as
a third arm (not shown ) and each arm may be spaced at shear screws 222. The piston 220 may have a seat 220s
one -hundred twenty degree intervals. The arms 50a , b may formed therein for receiving a closure element, such as a ball
be made from a high strength metal or alloy, such as steel . 290 , plug , or dart. A nozzle 214 may be disposed in aa bore
The blades 51a , b may each be arcuate , such as parabolic, 60 of the piston 220 and made from an erosion resistant
semi- elliptical, semi- oval, or semi-super - elliptical. The material, such as a metal , alloy, ceramic , or cermet .
arcuate blade shape may include a straight or substantially When deploying the underreamer 100 and control module
straight gage portion 51g and curved leading 511 and trailing 200 in the wellbore , a drilling operation ( e.g. , drilling
51t ends, thereby allowing for more cutters 55 to be disposed through a casing shoe) may be performed without operation
at the gage portion thereof and providing a curved actuation 65 of the underreamer 100. Even though force is exerted on the
surface against a previously installed casing shoe when underreamer piston 10 by drilling fluid , the shear screws 222
retrieving the underreamer 100 from the wellbore should the may prevent the underreamer piston 10 from extending the
 US 11,377,909 B2
9 10
arms 50a , b . When it is desired to operate the underreamer bodies 341 , 350. The lower end of tubular body 350 may
100 , the ball 290 is pumped or dropped from the surface and slidingly support a positioning piston 355 , the lower end of
lands in the ball seat 220s . Drilling fluid continues to be which may extend out of the body 350 and may engage
injected or is injected through the drill string. Due to the piston end 10t.
obstructed piston bore , fluid pressure acting on the ball 290 5 The interior of the piston 355 may be hollow in order to
and piston 220 increases until the shear screws 222 are receive a longitudinal position sensor 360. The position
fractured , thereby allowing the piston to move longitudi- sensor 360 may include two telescoping members 361 and
nally relative to the body 205. The piston end 220b may then 362. The lower member 362 may be connected to the piston
engage the keeper shoulder 225s and push the keeper 225 355 and be further adapted to travel within the first member
longitudinally relative to the body 205 , thereby disengaging 10 361. The amount of such travel may be electronically
the keeper lip 2251 from the dogs 227. The control mandrel measured . The position sensor 360 may be a linear poten
lip 2101 may be inclined and force exerted on the control tiometer. The upper member 361 may be attached to a
mandrel 210 by the underreamer piston 10 may push the bulkhead 365 which may be fixed within the tubular body
dogs 227 radially outward into a radial gap defined between 350 .
the lock mandrel 230 and the keeper 225 , thereby freeing the 15 The bulkhead 365 may have a solenoid operated valve
control mandrel and allowing the underreamer piston 10 to 366 and passage extending therethrough. The bulkhead 365
extend the arms 50a , b . Movement of the piston 220 may also may further include a pressure switch 367 and passage . A
expose a piston housing bore and place bypass ports 220p conduit tube ( not shown) may be attached at its lower end to
formed through a wall of the piston 220 in fluid communi- the bulkhead 365 and at its upper end to and through a
cation therewith . 20 second bulkhead 369 to provide electrical communication
Alternatively, the control mandrel 210 may be released by for the position sensor 360 , the solenoid valve 366 , and the
increasing an injection rate of the drilling fluid to or past a pressure switch 367 , to a battery pack 370 located above the
predetermined flow rate instead of using the ball 290. The second bulkhead 369. The batteries may be high temperature
casing shoe may be drilled through without operation of the lithium batteries . A compensating piston 371 may be slid
underreamer 100 by maintaining the injection rate below or 25 ingly positioned within the body 350 between the two
substantially below the predetermined flow rate . When the bulkheads 365,369 . A spring 372 may be located between
injection rate of the drilling fluid is increased to or past the the piston 371 and the second bulkhead 369 , and the
predetermined rate , the drilling fluid is choked through the chamber containing the spring may be vented to allow the
nozzle 214 , thereby exerting a longitudinal force on the entry of drilling fluid .
piston 220 downward or toward the underreamer 100. 30 A tube 301 may be disposed in the connector sub 345 and
Simultaneously, the underreamer piston 10 exerts longitu- may house an electronics package 325. The electronics
dinal force via the control mandrel 210 onto dogs 227 package 325 may include aa controller, such as microproces
upward or toward the body connector 205a , thereby pushing sor, power regulator, and transceiver. Electrical connections
the dogs 227 radially against the keeper 225 and exerting a 377 may be provided to interconnect the power regulator to
longitudinal friction force on the keeper 225 upward or 35 the battery pack 370. A data connector 378 may be provided
toward the body connector 205a . If the piston 220 and for data communication between the microprocessor 325
keeper 225 were a single integral piece , the friction force and the telemetry sub 400. The data connector may include
would counteract the piston force created by differential a short -hop electromagnetic telemetry antenna 378 .
pressure across the nozzle 214. By allowing the initial Hydraulic fluid ( not shown ), such as oil , may be disposed
longitudinal movement between piston 220 and keeper 225 , 40 in a lower chamber defined by the positioning piston 355 ,
the piston 220 may fracture the screws 222 first without the bulkhead 365 , and the body 350 and an upper chamber
having to overcome the friction force as well and then defined by the compensating piston 371 , the bulkhead 365 ,
9

engage the keeper 225 and overcome the isolated friction and the body 350. The spring 372 may bias the compensat
force . ing piston 371 to push hydraulic oil from the upper reservoir,
Alternatively, if the flow rate operation option is not 45 through the bulkhead passage and valve , thereby extending
needed , the nozzle 214 may be omitted and the keeper 225 the positioning piston into engagement with the underreamer
and piston 220 may be formed as an integral piece , thereby piston 10 and biasing the underreamer piston toward the
also omitting the fastener 224 . retracted position . Alternatively, the underreamer 100 may
FIG . 3 illustrates an electro -hydraulic control module 300 include its own return spring and the spring 372 may be used
for use with the underreamer 100 , according to another 50 maintain engagement of the positioning piston 355 with the
embodiment of the present invention . The control module underreamer piston 10. The solenoid valve 366 may be a
300 may be used instead of the control module 200. The check valve operable between a closed position where the
control module 300 may include an outer tubular body 341 . valve functions as a check valve oriented to prevent flow
The lower end of the body 341 may include a threaded from the lower chamber to the upper chamber and allow
coupling, such as pin 342 , connectable to the threaded end 55 reverse flow therethrough, thereby fluidly locking the under
5a of the underreamer 100. The upper end of the body 341 reamer 100 in the retracted position and an open position
may include a threaded coupling , such as box 343 , con- where the valve allows flow through the passage ( in either
nected to a threaded coupling, such as lower pin 346 , of the direction) . Alternatively, a solenoid operate shutoff valve
retainer 345. The retainer 345 may have threaded couplings , may be used instead of the check valve . To allow extension
such as pins 346 and 347 , formed at its ends . The upper pin 60 of the underreamer 100 , the valve 366 may be opened when
347 may connect to a threaded coupling, such as box 408b , drilling fluid is flowing. The underreamer piston 10 may
of a telemetry sub 400 . then actuate and push the positioning piston 355 toward the
The tubular body 341 may house an interior tubular body lower bulkhead 365 .
350. The inner body 350 may be concentrically supported The position sensor 360 may measure the position of the
within the tubular body 341 at its ends by support rings 351. 65 piston 355. The controller 325 may monitor the sensor 360
The support rings 351 may be ported to allow drilling fluid to verify that the piston 355 has been actuated . The differ
flow to pass into an annulus 352 formed between the two ential pressure switch 367 in the lower bulkhead 365 may
 US 11,377,909 B2
11 12
verify that the underreamer piston 10 has made contact with uplink housing 403 , a sensor housing 404 , a pressure sensor
the positioning piston 355. The force exerted on the piston 405 , a downlink mandrel 406 , a downlink housing 407 , a
355 by the underreamer piston 310 may cause a pressure lower adapter 408 , one or more data /power couplings 409a ,
increase on that side of the bulkhead. Additionally, the b , an electronics package 425 , an antenna 426 , a battery 431 ,
underreamer 100 may be modified to be variable ( see section 5 accelerometers 455 , and a mud pulser 475. The housings
mill 1100 ) and the controller 325 may close the valve 366 403 , 404 , 407 may each be modular so that any of the
before the underreamer arms 50a , b are fully extended, housings 403 , 404 , 407 may be omitted and the rest of the
thereby allowing the underreamer 100 to have one or more housings may be used together without modification thereof.
intermediate positions . Additionally, the controller may lock Alternatively, any of the sensors or electronics of the telem
and unlock the underreamer 100 repeatedly . 10 etry sub 400 may be incorporated into the control module
In operation, the control module 300 may receive an 300 and the telemetry sub 400 may be omitted .
instruction signal from the surface ( discussed below ) . The The adapters 401,408 may each be tubular and have a
instruction signal may direct the control module 300 to threaded coupling 401p , 408b formed at a longitudinal end
allow full or partial extension of the arms 50a , b . The thereof for connection with the control module 300 and the
controller 325 may open the solenoid valve 366. If drilling 15 drill string. Each housing may be longitudinally and rota
fluid is being circulated through the BHA , the underreamer tionally coupled together by one or more fasteners, such as
piston 10 may then extend the arms 50a , b . During extension , screws ( not shown ), and sealed by one or more seals , such
the controller 325 may monitor the arms using the pressure as O - rings ( not shown ).
sensor 367 and the position sensor 361. Once the arms have The sensor housing 404 may include the pressure sensor
reached the instructed position , the controller 325 may close 20 405 and a tachometer 455. The pressure sensor 405 may be
the valve 366 , thereby preventing further extension of the in fluid communication with aa bore of the sensor housing via
arms. The controller 325 may then report a successful a first port and in fluid communication with the annulus via
extension of the arms or an error if the arms are obstructed a second port. Additionally, the pressure sensor 405 may also
from the instructed extension . Once the underreamer opera- measure temperature of the drilling fluid and / or returns. The
tion has concluded, the control module 300 may receive a 25 sensors 405,455 may be in data communication with the
second instruction signal to retract the arms. If the valve 366 electronics package 425 by engagement of contacts disposed
is the check valve , the controller may open the valve or may at a top of the mandrel 406 with corresponding contacts
not have to take action as the check valve may allow for disposed at aa bottom of the sensor housing 406. The sensors
hydraulic fluid to flow from the upper chamber to the lower 405,455 may also receive electricity via the contacts . The
chamber regardless of whether the valve is open or closed . 30 sensor housing 404 may also relay data between the mud
The controller may simply monitor the position sensor and pulser 475 , the auxiliary sensors 402a , b , and the electronics
report successful retraction of the arms. If the valve 366 is package 425 via leads and radial contacts 409a , b .
a shutoff valve , the instruction signal may include a time at The auxiliary sensors 2a , b may be magnetometers
which the rig pumps are shut off or the controller 325 may which may be used with the accelerometers for determining
wait for indication from the telemetry sub that the rig pumps 35 directional information, such as azimuth , inclination , and / or
are shut off. The controller may then open the valve to allow tool face /bent sub angle.
the retraction of the arms. Since the control module may not The antenna 426 may include an inner liner, a coil , and an
force retraction of the arms 50a, b the control module may be outer sleeve disposed along an inner surface of the downlink
considered a passive control module. Advantageously, the mandrel 406. The liner may be made from a non -magnetic
passive control module may use less energy to operate than 40 and non - conductive material , such as a polymer or compos
an active control module (discussed below ) . ite , have a bore formed longitudinally therethrough, and
As shown , components of the control module 300 are have a helical groove formed in an outer surface thereof. The
disposed in a bore of the body 341 and connector 345 . coil may be wound in the helical groove and made from an
Alternatively, components of the control module may be electrically conductive material, such as a metal or alloy.
disposed in a wall of the body 341 , similar to the telemetry 45 The outer sleeve may be made from the non -magnetic and
sub 400. The center configured control module 300 may non - conductive material and may be insulate the coil from
allow for: stronger outer collar connections, a single size the downlink mandrel 406. The antenna 426 may be longi
usable for different size underreamers or other downhole tudinally and rotationally coupled to the downlink mandrel
tools , and easier change - out on the rig floor. The annular 406 and sealed from a bore of the telemetry sub 400 .
alternative arranged control module may provide a central 50 FIG . 4A illustrates the electronics package 425. FIG . 4B
bore therethrough so that tools , such as a ball , may be illustrates an active RFID tag 450a and a passive RFID tag
run - through or dropped through the drill string. 450p. The electronics package 425 may communicate with
Additionally, as illustrated in FIG . 7 of the ' 198 provi- a passive RFID tag 450p or an active RFID tag 450a . Either
sional, a latch , such as a collet , may be formed in an outer of the RFID tags 450a,p may be individually encased and
surface of the position piston 355. A corresponding profile 55 dropped or pumped through the drill string. The electronics
may be formed in an inner surface of the interior body 350 . package 425 may be in electrical communication with the
The latch may engage the profile when the position piston is antenna 426 and receive electricity from the battery 431 .
in the retracted position . The latch may transfer at least a Alternatively, the data sub 400 may include a separate
substantial portion of the underreamer piston 10 force to the transmitting antenna and a separate receiving antenna . The
interior body 350 when drilling fluid is injected through the 60 electronics package 425 may include an amplifier 427 , a
underreamer 100 , thereby substantially reducing the amount filter and detector 428 , a transceiver 429 , a microprocessor
of pressure required in the lower hydraulic chamber to 430 , an RF switch 434 , a pressure switch 433 , and an RF
restrain the underreamer piston . field generator 432 .
FIG . 4 illustrates a telemetry sub 400 for use with the The pressure switch 433 may remain open at the surface
control module 300 , according to another embodiment of the 65 to prevent the electronics package 425 from becoming an
present invention . The telemetry sub 400 may include an ignition source . Once the data sub 400 is deployed to a
upper adapter 401 , one or more auxiliary sensors 402a , b , an sufficient depth in the wellbore, the pressure switch 433 may
 US 11,377,909 B2
13 14
close . The microprocessor 430 may also detect deployment longitudinal Z accelerometer. Alternatively, magnetometers
in the wellbore using pressure sensor 405. The micropro- may be used instead of accelerometers to determine the
cessor 430 may delay activation of the transmitter for a angular speed .
predetermined period of time to conserve the battery 431 . Instead of using one of the RFID tags 450a,p to activate
When it is desired to operate the underreamer 100 , one of 5 the underreamer 100 , an instruction signal may be sent to the
the tags 450a , p may be pumped or dropped from the surface controller 430 by modulating angular speed of the drill
to the antenna 426. If a passive tag 450p is deployed, the string according to a predetermined protocol. An exemplary
microprocessor 430 may begin transmitting a signal and signal is illustrated in FIG . 10 of the ' 937 publication. The
listening for a response . Once the tag 450p is deployed into modulated angular speed may be detected by the tachometer
proximity of the antenna 426 , the passive tag 450p may 10 455. The controller 430 may then demodulate the signal and
relay the signal to the control module controller 325 , thereby
receive the signal , convert the signal to electricity, and operating the underreamer 100. The protocol may represent
transmit a response signal . The antenna 426 may receive the data by varying the angular speed on to off, a lower speed
response signal and the electronics package 425 may to a higher speed and / or a higher speed to a lower speed, or
amplify, filter, demodulate, and analyze the signal. If the 15
signal matches a predetermined instruction signal , then the
monotonically increasing from a lower speed to a higher
speed and /or a higher speed to a lower speed .
microprocessor 430 may communicate the signal to the FIG . 4D illustrates the mud pulser 475. The mud pulser
underreamer control module 300 using the antenna 426 and 475 may include a valve , such as a poppet 476 , an actuator
the transmitter circuit . The instruction signal carried by the 477 , a turbine 478 , a generator 479 , and a seat 480. The
tag 450a,p may include an address of a tool (if the BHA 20
includes multiple underreamers and / or stabilizers, discussed
poppet 476 may be longitudinally movable by the actuator
477 relative to the seat 480 between an open position
below ) and a set position ( if the underreamer / stabilizer is ( shown) and a choked position (dashed) for selectively
adjustable ). restricting flow through the pulser 475 , thereby creating
If an active tag 450a is used, then the tag 450a may pressure pulses in drilling fluid pumped through the mud
include its own battery, pressure switch , and timer so that the 25 pulser. The mud pulses may be detected at the surface,
tag 450a may perform the function of the components thereby communicating data from the microprocessor to the
432-434 . Further, either of the tags 450a ,p may include a surface . The turbine 478 may harness fluid energy from the
memory unit (not shown) so that the microprocessor 430 drilling fluid pumped therethrough and rotate the generator
may send a signal to the tag and the tag may record the 30 479 , thereby producing electricity to power the mud pulser.
signal. The signal may then be read at the surface. The signal The mud pulser may be used to send confirmation of receipt
of commands and report successful execution of commands
may be confirmation that a previous action was carried out
or errors to the surface . The confirmation may be sent during
or a measurement by one of the sensors . The data written to circulation
the RFID tag may include a date / time stamp , a set position sinusoidal mud of drilling fluid . Alternatively, a negative or
( the command ), a measured position (of control module 35 mud pulser 475.pulser The
may be used instead of the positive
microprocessor may also use the
position piston ), and a tool address. The written RFID tag turbine 478 and / or pressure sensor as a flow switch and / or
may be circulated to the surface via the annulus. flow meter.
Alternatively , the control module 300 may be hard - wired Instead of using one of the RFID tags 450a, p or angular
to the telemetry sub 400 and a single controller, such as a speed modulation to activate the underreamer 100 , a signal
microprocessor , disposed in either sub may control both 40 may be sent to the controller by modulating a flow rate ofthe
subs. The control module 300 may be hard -wired by replac- rig drilling fluid pump according to a predetermined proto
ing the data connector 378 with contact rings disposed at or col . Alternatively, a mud pulser (not shown) may be installed
near the pin 347 and adding corresponding contact rings in the rig pump outlet and operated by the surface controller
to / near the box 408b of the telemetry sub 400. Alternatively, to send pressure pulses from the surface to the telemetry sub
inductive couplings may be used instead of the contact rings . 45 controller according to a predetermined protocol. The telem
Alternatively, a wet or dry pin and socket connection may be etry sub controller may use the turbine and / or pressure
used instead of the contact rings. sensor as a flow switch and / or flow meter to detect the
FIG . 4C is a schematic cross - sectional view of the sensor sequencing of the rig pumps / pressure pulses . The flow rate
sub 404. The tachometer 455 may include two diametrically protocol may represent data by varying the flow rate on to
opposed single axis accelerometers 455a , b . The accelerom- 50 off, a lower speed to a higher speed and / or a higher speed to
eters 455a , b may be piezoelectric, magnetostrictive, servo- a lower speed, or monotonically increasing from a lower
controlled , reverse pendular, or microelectromechanical speed to a higher speed and / or a higher speed to a lower
( MEMS ) . The accelerometers 455a , b may be radially X speed . Alternatively, an orifice flow switch or meter may be
oriented to measure the centrifugal acceleration A, due to used to receive pressure pulses / flow rate signals communi
rotation ofthe telemetry sub 400 for determining the angular 55 cated through the drilling fluid from the surface instead of
speed . The second accelerometer may be used to account for the turbine and / or pressure sensor. Alternatively, the sensor
gravity G if the telemetry sub is used in a deviated or sub may detect the pressure pulses /flow rate signals using
horizontal wellbore . Detailed formulas for calculation of the the pressure sensor and accelerometers to monitor for BHA
angular speed are discussed and illustrated in U.S. Pat . App . vibration caused by the pressure pulse /flow rate signal.
Pub . No. 2007/0107937 , which is herein incorporated by 60 Alternatively, an electromagnetic ( EM ) gap sub ( not
reference in its entirety. Alternatively, as discussed in the shown ) may be used instead of the mud pulser, thereby
937 publication, the accelerometers may be tangentially Y allowing data to be transmitted to the surface using EM
oriented, dual axis, and /or asymmetrically arranged ( not waves . Alternatively, an RFID tag launcher (not shown) may
diametric and /or each accelerometer at a different radial be used instead of the mud pulser. The tag launcher may
location ). Further, as discussed in the ' 937 publication , the 65 include one or more RFID tags . The microprocessor 430
accelerometers may be used to calculate borehole inclination may then encode the tags with data and the launcher may
and gravity tool face. Further, the sensor sub may include a release the tags to the surface . Alternatively, an acoustic
 US 11,377,909 B2
15 16
transmitter may be used instead of the mud pulser. Alterna- the bit . The drilling fluid and cuttings , collectively returns
tively, and as discussed above , instead of the mud pulser, 514r , flow upward along an annulus 517 formed between the
RFID tags may be periodically pumped through the telem- drill string and the wall of the wellbore 516a /casing 519 ,
etry sub and the microprocessor may send the data to the tag . through a solids treatment system (not shown) where the
The tag may then return to the surface via an annulus formed 5 cuttings are separated. The treated drilling fluid may then be
between the workstring and the wellbore . The data from the discharged to the mud pit for recirculation .
tag may then be retrieved at the surface . Alternatively, and The drilling system may further include a launcher 520 ,
as discussed above, instruction signals may be sent to the surface controller 525 , and a pressure sensor 528. The
electronics package using mud pulses , EM waves, or acous- pressure sensor 528 may detect mud pulses sent from the
tic signals. 10 telemetry sub 400. The surface controller 525 may be in data
For deeper wells , the drill string may further include a communication with the rig pump 518 , launcher 520 , pres
signal repeater (not shown) to prevent attenuation of the sure sensor 528 , and top drive 542. The rig pump 518 and / or
transmitted mud pulse . The repeater may detect the mud top drive 542 may include a variable speed drive so that the
pulse transmitted from the mud pulser 475 and include its surface controller 525 may modulate 545 a flow rate of the
own mud pulser for repeating the signal. As many repeaters 15 rig pump 518 and / or an angular speed (RPM) of the top
may be disposed along the workstring as necessary to drive 542. The modulation 545 may be a square wave ,
transmit the data to the surface, e.g. , one repeater every five trapezoidal wave , or sinusoidal wave . Alternatively, the
thousand feet. Each repeater may also be a telemetry sub and controller 545 may modulate the rig pump and / or top drive
add its own measured data to the retransmitted data signal. by simply switching them on and off.
If the mud pulser is being used , the repeater may wait until 20 A first section of a wellbore 516a has been drilled . A
the data sub is finished transmitting before retransmitting the casing string 519 has been installed in the wellbore 516a and
signal. The repeaters may be used for any of the mud pulser cemented 511 in place . A casing shoe 519s remains in the
alternatives, discussed above . Repeating the transmission wellbore . The drilling assembly 500 may then be deployed
may increase bandwidth for the particular data transmission . into the wellbore 516a until the drill bit 505 is proximate the
Alternatively, multiple telemetry subs may be deployed in 25 casing shoe 519s . The drill bit 505 may then be rotated by
a workstring or drill string. An RFID tag including a the top drive and mud injected through the drill string by the
memory unit may be dropped /pumped through the telemetry rig pump . Weight may be exerted on the drill bit , thereby
subs and record the data from the telemetry subs until the tag causing the drill bit to drill through the casing shoe . The
reaches a bottom of the data subs. The tag may then transmit underreamer 100 may be restrained in the retracted position
the data from the upper subs to the bottom sub and then the 30 by the control module 200/300 . Once the casing shoe 519s
bottom sub may transmit all of the data to the surface . has been drilled through and the underreamer 100 is in a
Alternatively, the mud pulser may instead be located in a pilot section 516p of the wellbore , the underreamer 100 may
measurement while drilling (MWD ) and / or logging while be extended. If the control module 200 is use then the
drilling (LWD ) tool assembled in the drill string downstream surface controller 525 may instruct the launcher 520 to
of the underreamer. The MWD /LWD module may be 35 deploy the ball 290. If the control module 300 is used , then
located in the BHA to receive written RFID tags from the surface controller 525 may instruct the launcher 520 to
several upstream tools . The mud pulse module or MWD/ deploy one of the RFID tags 450a , p ; modulate angular speed
LWD module may then pulse a signal to the surface indi- of the top drive 545 ; or flow rate of the rig pump 518 ,
cating time to shut down pumps to allow passive activation . thereby conveying an instruction signal to extend the under
Alternatively, the mud pulse module or MWD /LWD module 40 reamer 100. Alternatively, the ball 290 /RFID tags 450a , p
may send a mud -pulse to annulus pressure measurement may be manually launched . The telemetry sub 400 may
module ( PWD subs) along the drill string. The PWD module receive the instruction signal; relay the instruction signal to
may then upon command, or periodically, write RFID tags the control module 300 allow the arms 50a , b to extend; and
and eject the tags into the annulus for telemetry to surface or send a confirmation signal to the surface via mud pulse . The
into the bore for telemetry to the MWD /LWD module . 45 pressure sensor 528 may receive the mud pulse and com
Alternatively , the control module may send and receive municate the mud pulse to the surface controller. The
instructions via wired drill /casing string. underreamer 100 may then ream the pilot section 516p into
FIGS . 5A and 5B illustrate a drilling system 500 and a reamed section 516r , thereby facilitating installation of a
method utilizing the underreamer 100 , according to another larger diameter casing /liner upon completion of the reamed
embodiment of the present invention . 50 section .
The drilling system 500 may include a drilling derrick Alternatively, instead of drilling through the casing shoe ,
510. The drilling system 500 may further include drawworks a sidetrack may be drilled or the casing shoe may have been
524 for supporting a top drive 542. The top drive 542 may drilled during a previous trip .
in turn support and rotate a drilling assembly 500. Alterna- Once drilling and reaming are complete, it may be desir
tively, a Kelly and rotary table (not shown) may be used to 55 able to perform a cleaning operation to clear the wellbore
rotate the drilling assembly instead of the top drive. The 516r of cuttings in preparation for cementing a second string
drilling assembly 500 may include a drill string 502 and a of casing . A second instruction signal may be sent to the
bottomhole assembly ( BHA) 550. The drill string 502 may telemetry sub 400 commanding retraction of the arms. The
include joints of threaded drill pipe connected together or rig pump may be shut down, thereby allowing the control
coiled tubing. The BHA 550 may include the telemetry sub 60 module 300 to retract the arms and lock the arms in the
400 , the control module 300 , the underreamer 100 , and a retracted position . Once the arms are retracted , the rig pump
drill bit 505. A rig pump 518 may pump drilling fluid , such may resume circulation of drilling fluid and the telemetry
as mud 514f, out of aa pit 520 , passing the mud through a sub may confirm retraction of the arms via mud pulse . Once
stand pipe and Kelly hose to a top drive 542. The mud 514f the confirmation is received at the surface, the cleaning
may continue into the drill string, through a bore of the drill 65 operation may commence . The cleaning operation may
string, through a bore of the BHA , and exit the drill bit 505 . involve rotation of the drill string at a high angular velocity
The mud 514f may lubricate the bit and carry cuttings from that may otherwise damage the arms if they are extended .
 US 11,377,909 B2
17 18
The drilling assembly may be removed from the wellbore may be made as separate pieces as shown in FIG . 3. The
during the cleaning operation . Additionally, the control control module 600 may further include upper 602u and
module 300 may be commanded to retract and lock the arms lower 6021 hydraulic chambers having hydraulic fluid dis
for other wellbore operations, such as underreaming only a posed therein and isolated by seals 603a , b . The control
selected portion of the wellbore. Alternatively, the drill 5 module 600 may further include an actuator so that the
string may remain in the wellbore during the cleaning control module 600 may actively move the underreamer
operation and then the arms may be re -extended by sending piston 10 while the rig pump 518 is injecting drilling fluid
another instruction signal and the wellbore may be back through the control module 600 and the underreamer 100 .
reamed while removing the drill string from the wellbore . The actuator may be a hydraulic pump 601 in communica
The
casingarms
shoemay then be retracted
. Alternatively again when
, the cleaning reaching
operation may the
be 10 tion with the upper 602u and lower 6021 hydraulic chambers
omitted . Alternatively or additionally, the cleaning operation via a hydraulic passage and operable to pump the hydraulic
may be occasionally or periodically performed during the fluid from the upper chamber 602u to the lower chamber
6021 while being opposed by the underreamer piston 10 .
drilling and reaming operation .
Alternatively, the drill bit may be rotated at a high speed 15 Alternatively, the pump may be a hydraulic amplifier on a
by a mud motor (not shown) of the BHA and the under lead or ball screw being turned by the electric motor.
reamer 100 may be rotated at a lower speed by the top drive . Additionally, as with the control module 300 , the control
Since the bit speed may equal the motor speed plus the top module 600 may further include a second passage (not
drive speed , the mud motor speed may be equal or substan- shown ) with a pressure sensor for detecting engagement of
tially equal to the top drive speed . 20 the underreamer piston with the position sensor .
For directional drilling operations, the telemetry sub 400 The electric motor 604 may drive the hydraulic pump 601 .
may be used as an MWD sub for meas easuring and transmitting The electric motor 604 may be reversible to cause the
orientation data to the surface. Alternatively, the BHA may hydraulic pump 601 to pump fluid from the lower chamber
include a separate MWD sub . The surface may need to send 6021 to the upper chamber 602u . The active control module
instruction signals to the separate MWD sub in addition to 25 600 may receive an instruction signal from the surface (as
the instruction signals to the telemetry sub . If modulation of discussed above via the telemetry sub 400 ) and operate the
the rig pump is the chosen communication media for both underreamer 100 without having to wait for shut down of the
MWD and underreamer instruction signals , then the proto rig pump 518. Alternatively, the underreamer piston force
col may include an address field or the signals may be may be reduced by decreasing flow rate of the drilling fluid
multiplexed ( e.g. , frequency division) . Alternatively, modu- 30 or shutting off the rig pump before or during sending of the
lation of the rig pump may be used to send MWD instruc
tions and top drive modulation may be used to send under instruction signal.
The control module 600 may further include a solenoid
reamer instructions. If dynamic steering is employed as valve , such as a check valve 616 or shutoff valve , operable
discussed in the ' 100 patent and the underreamer instruction
signal is sent by top drive modulation , then the underreamer 35 tochamber
preventin flow from the lower chamber to the upper
the closed position . Similar to the control
signal may be multiplexed with the dynamic steering signal.
Alternatively, the RFID tag protocol may include an address module 300 , the position piston 605 may prevent the under
field distinguishing the instructions . reamer piston 10 from extending the arms 50a , b while
Alternatively, the underreamer may be used in a drilling drilling fluid 514f is pumped through the control module 600
with casing/ liner operation . The drilling assembly may 40 and the underreamer 100 due to the closed check valve 616 .
include the casing /liner string instead of the drill string. The The control module 600 may further include a position
BHA may be operated by rotation of the casing /liner string sensor, such as a Hall sensor 611 and magnet 612 , which
from the surface of the wellbore or a motor as part of the may be monitored by the controller 325 to allow extension
BHA . After the casing / liner is drilled and set into the of the arms to one or more intermediate positions and / or to
wellbore , the BHA may be retrieved from the wellbore . To 45 confirm full extension of the arms. Alternatively, the posi
facilitate retrieval of the BHA , the BHA may be fastened to tion sensor may be a linear voltage differential transformer
the casing/ liner string employing a latch , such as is disclosed ( LVDT). The control module 600 may further include a
in U.S. Pat. No. 7,360,594 , which is herein incorporated by compensating piston 621 to equalize pressure between drill
reference in its entirety. Alternatively, the BHA may be ing fluid (via port 606 ) and the upper chamber 602u . The
drillable . Once the BHA is retrieved , the casing /liner string 50 control module may further include a biasing member, such
may then be cemented into the wellbore . as a spring 622 , to bias flow of hydraulic fluid from the upper
Alternatively, the underreamer may be used in an expand- 602u to the lower 6021 chamber.
able casing /liner operation . The casing /liner may be In operation , when the controller 325 receives a signal
expanded after it is run - into the wellbore . instructing extension of the arms 50a, b , the controller 325
Additionally, a single or multiple underreamers may be 55 may open the solenoid check valve 616 so oil may flow
used without the pilot bit to ream a casing or liner into a through the hydraulic passage from the lower chamber to the
pre -drilled wellbore. upper chamber. Depending on whether the rig pump is
FIG . 6A illustrates a portion of an alternative electro- operating, the controller 325 may then supply electricity to
hydraulic control module 600 for use with the underreamer the motor 604 , thereby driving the pump 601. If the rig pump
100 , according to another embodiment of the present inven- 60 is operating, the underreamer piston 10 may force hydraulic
tion . The rest of the control module 600 may be similar to fluid through the pump 601 , thereby obviating the need to
the control module 300. The control module 600 may be operate the motor and the pump. The hydraulic pump 601
used instead of the control module 300 . may then transfer oil from the lower reservoir to the upper
The control module 600 may include an inner body and reservoir to retract the position piston 605. If the rig pump
bulkhead 615. For ease of depiction , the bulkhead and inner 65 is shut down , the underreamer piston may not follow the
body are shown as an integral piece 615. To facilitate position piston until the rig pump is operated . Once the
manufacture and assembly, the inner body and bulkhead controller 325 detects that the position piston 605 is in the
 US 11,377,909 B2
19 20
instructed position via the position sensor 611 , 612 , the chamber and bias the arms 50a , b toward the retracted
controller may shut off the motor and pump and close the position . Alternatively , the motor 604 and pump 601 may be
solenoid check valve . installed in the first passage instead of or in addition to the
In operation , when the controller 325 may receive a signal shutoff valve 647 .
instructing retraction of the arms 50a , b , the controller 325 5 In operation, when the controller 325 receives a signal
may open the solenoid check valve 616 so oil may flow instructing extension of the arms 50a, b , the controller 325
through the hydraulic passage from the upper chamber to the may open the shutoff valve 647 so oil may flow through the
lower chamber or operation of the pump may open the valve . first hydraulic passage from the lower chamber to the upper
The controller 325 may then supply electricity to the motor chamber and hold the shutoff valve open while the under
604 , thereby driving the pump 601. The hydraulic pump 601 10 reamer is in use to ensure firm engagement of the blades
may then transfer oil from the upper reservoir to the lower 50a , b with the body 5. The holding and opening currents
reservoir to extend the position piston 605. Once the con- may be different. The controller 325 may occasionally
troller 325 detects that the position piston 605 is in the reapply the opening current to ensure that shock or vibration
instructed position via the position sensor 611 , 612 , the has not caused closure of the shutoff valve 647. Alterna
controller may shut off the motor and pump and close the 15 tively, as discussed below, if the control module 630 is
solenoid check valve . If the controller 325 does not detect deployed with an adjustable underreamer or adjustable sta
that the position piston has moved to the instructed position bilizer, the controller may close the shutoff valve 647 once
after a predetermined period of time , the controller 325 may the controller detects that the piston 605 is in the instructed
shut off the motor and close the valve and send an error position .
message to the surface (via the telemetry sub ) . Alternatively, 20 In operation, when the controller 325 receives a signal
the controller 325 may periodically retry to move the instructing retraction of the arms 50a, b , the controller 325
position piston or wait for shut - down of the rig pump and may open the shutoff valve 647 so oil may flow through the
then re -try. hydraulic passage from the upper chamber to the lower
FIG . 6B illustrates a portion of an alternative electro- chamber ( once the rig pump is shut off). The controller may
hydraulic control module 630 for use with the underreamer 25 then close the shutoff valve after a predetermined period of
100 , according to another embodiment of the present inven time or upon detection ofmovement of the piston 605 to the
tion . The rest of the control module 630 may be similar to retracted position . If the arms 50a , b are not fully retracted
the control module 300. The control module 630 may be when the shutoff valve is closed , the check valve 646 may
used instead of the control module 300 . allow the spring 622 to complete retraction of the arms.
The control module 630 may include an inner body and 30 FIG . 6C illustrates an alternative electro -mechanical con
bulkhead 645. For ease of depiction , the bulkhead and inner trol module 650 for use with the underreamer 100 , according
body are shown as an integral piece 645. To facilitate to another embodiment of the present invention .
manufacture and assembly , the inner body and bulkhead [ moo ] The control module 650 may include a body 655 ,
may be made as separate pieces as shown in FIG . 3. The the control mandrel 210 , an actuator housing 665 , a keeper
control module 630 may further include upper 602u and 35 675 , the lock mandrel 230 , an electronics package 625 , the
lower 6021 hydraulic chambers having hydraulic fluid dis- biasing member 235 , a battery 670 , and a linear actuator
2

posed therein and isolated by seals 603a , b . The control 680. The body 655 may be tubular and have a longitudinal
module 630 may further include an actuator, such as a bore formed therethrough . Each longitudinal end 655a , b of
solenoid operated shutoff valve 647 , in communication with the body 655 may be threaded for longitudinal and rotational
the upper 602u and lower 602 hydraulic chambers via aa first 40 coupling to other members, such as the underreamer 100 at
hydraulic passage . A check valve 646 may be disposed in a 655b and the telemetry sub 400 at 655a . The electronics
second hydraulic passage in communication with the package 625 may include a controller, such as a micropro
hydraulic chambers 602u, l . The check valve 646 may be cessor, a power regulator, and a modem . A data connector,
oriented to allow fluid flow from the lower chamber 6021 to such as an inductive coupling 678 , may be disposed at or
the upper chamber 602u and prevent fluid flow from the 45 near upper end 655a for interfacing with an inductive
upper chamber to the lower chamber. The shutoff valve 647 coupling disposed at or near a lower end of the telemetry sub
may normally be in aa closed position until operated by the 400 , thereby providing data communication between the
controller 325. Additionally, as with the control module 300 , controller 430 and the controller 625. Alternatively, the data
the control module 600 may further include a third passage connector may be hard -wire or short -hop antenna . The
( not shown ) with a pressure sensor for detecting engagement 50 controller 625 may be in electrical communication with the
of the underreamer piston with the position sensor. inductive coupling 678 , position sensor 660 , and power
Similar to the control module 300 , the position piston 605 coupling 677 via leads . The power coupling 677 may be in
may prevent the underreamer piston 10 from extending the electrical communication with the linear actuator 680 via
arms 50a , b while drilling fluid 514f is pumped through the leads . The linear actuator 680 may be a linear motor or a
control module 630 and the underreamer 100 due to the 55 rotary motor and a lead screw or a ball screw . The linear
closed check valve 616. The control module 630 may further actuator 680 may also include a position sensor for moni
include a position sensor, such as a Hall sensor 611 and toring the position of the keeper 675 and may communicate
magnet 612 , which may be monitored by the controller 325 with the controller 625 via the power coupling 677 or a
to allow extension of the arms to one or more intermediate separate data coupling (not shown ) .
positions and/ or to confirm full extension of the arms. 60 In operation, the control module 650 may operate similar
Alternatively, the position sensor may be a linear voltage to the control module 200 except that instead of dropping the
differential transformer (LVDT). The control module 630 ball 290 to operate the piston 220 , the controller 625 may
may further include a compensating piston 621 to equalize operate the linear actuator 680 to move the keeper 675 ,
pressure between drilling fluid ( via port 606 ) and the upper thereby releasing the dogs 227. The controller 625 may
chamber 602u . The control module may further include a 65 receive the instruction signal from the telemetry sub 400 via
biasing member, such as a spring 622 , to bias flow of the inductive coupling 678. The controller 625 may also
hydraulic fluid from the upper 602u to the lower 6021 monitor a position of the control mandrel shoulder 210s
 US 11,377,909 B2
21 22
using position sensor 660 in order to report successful In operation, the BHA 700 is deployed into the wellbore
deployment of the arms 50a , b . After completion of the and , if necessary, the casing shoe is drilled with both
drilling / reaming operation, the controller 625 may receive a underreamers 100u, l locked in the retracted position . Once
signal instructing retraction of the arms 50a, b from the the shoe is drilled through and the BHA is in the pilot section
telemetry sub 400. The controller 625 may wait for detection 5 clear of the casing, an instruction signal may be sent to the
of movement of the control mandrel to the retracted position telemetry sub 400 commanding extension of the upper
by the spring 235. The controller 625 may then reverse the underreamer 100u . The telemetry sub 400 may then relay the
linear actuator 680 , thereby re - locking the dogs 227 against signal to the upper control module 300u . The upper control
the control mandrel. The controller 625 may then report module 300u may then release the upper underreamer as
successful retraction and re - locking of the arms to the 10 discussed above. The wellbore may then be drilled and
surface or an error message if either retraction or re - locking reamed until the upper underreamer becomes dull . An
instruction signal may then be sent to the telemetry sub 400
is not successful
Alternatively, the dogs 227 may be replaced by a collet extension of theretraction
commanding
lower
of the upper underreamer 100u and
underreamer without tripping the drill
fingers (not shown) formed on an end of the lock mandrel 15 string from the wellbore . The wellbore may then be drilled
230 and a corresponding profile may be formed in the end and reamed until the section is finished . As discussed above ,
of the control mandrel 210. The keeper 675 may then engage the wellbore may then be cleaned and / or back reamed and
the collet fingers and prevent the fingers from expanding the drilling assembly removed from the wellbore .
until moved by the linear actuator 680. Alternatively, lock- Additionally, a third underreamer and control module
ing pins may be used instead of the dogs and an electro- 20 may be added if necessary. The third underreamer may be
magnet may be used instead of the linear actuator. placed adjacent the bit . The third underreamer may be
Alternatively, instead of replacing the piston 220 with the activated at total depth (TD ) to eliminate the rat hole .
linear actuator, the actuator may instead be arranged to move Additionally, the BHA may include four or more underream
the piston 220 without obstructing the ball seat 220s so that ers and control modules.
the piston may be moved using either the actuator or the ball 25 Alternatively, the operating sequence may be reversed .
290 , thereby providing redundancy. Alternatively, both underreamers may be opened together.
Alternatively, instead of modifying the mechanical con- When the lower underreamer becomes dull, the lower under
trol module 200 , an electromechanical adapter (not shown ) reamer may be closed and drilling may continue with only
may be connected to the mechanical control module 200 by the upper underreamer. Alternatively the lower underreamer
a threaded connection . The adapter may include the elec- 30 arms may have a smaller outer diameter in the extended
tronics package and an actuator for engaging the ball seat position and the upper underreamer may have a greater
and breaking the shear screws 222. The actuator may include diameter in the extended position and both underreamers
a plunger which may engage or abut the ball seat. Alterna- may be opened together, thereby creating a two -stage
tively the adapter may break or remove the shear screw . reamer . The two - stage reaming may lessen the wear on both
Alternatively, the actuator 680 , electronics package 680 , 35 underreamers .
and battery 670 may be omitted and the keeper 675 may be Alternatively, the mechanical control module 200 may be
modified to have a latch profile ( not shown) formed in an used instead of the upper electro -hydraulic control module
inner surface thereof and a detent disposed in an outer 300u . Both underreamers may be locked in the retracted
surface thereof. The actuator housing 665 may be modified position upon deployment through the casing and drill
to have detent profiles formed on an inner surface thereof 40 through of the casing shoe . The ball 290 may then be
corresponding to positions where the keeper is engaged with launched and the upper underreamer extended . Once the
the dogs 227 and disengaged from the dogs 227 , respec- upper underreamer arms become dull, an instruction signal
tively. An actuator having a latch may then be deployed from may be sent to the telemetry sub and relayed to the lower
the surface using wireline to engage the latch profile. The control module, thereby extending the lower underreamer
keeper 675 may then be moved from one of the engaged and 45 arms. Drilling and reaming may then re - commence . The
disengaged positions to the other position using the actuator. drill string may be raised before extension of the lower
The latch may then be released by sending a signal to the underreamer so that the lower underreamer is in the section
actuator via the wireline . The wireline and actuator may be reamed by the upper underreamer, thereby maintaining hole
retrieved to the surface and re -deployed when it is desired to size . The upper underreamer nozzles may include a screen ,
move the keeper 675. Alternatively, the actuator may be 50 such as a sand screen , for preventing the RFID tag from
deployed using slickline by including a battery and a con- being discharged therethrough. The upper underreamer may
troller. Additionally if the arms 50a, b are jammed in the be left in the extended position and used as a stabilizer.
extended position, the actuator may engage the control Alternatively, the operating sequence may be reversed .
mandrel 210 and weight of the actuator may be set on the Extending the lower underreamer arms first may negate the
control mandrel to push the blades toward the retracted 55 need for a screen since the upper nozzles would be closed by
position. the mandrel 20. Further, reversing the order negates the need
FIG . 7A illustrates an alternate BHA 700 including dual for lifting the drill string before re -commencing drilling.
underreamers 100u , l, according to another embodiment of Further, reversing the order and activating the lower under
the present invention . FIGS . 7B and 7C illustrates an oper- reamer first reduces or eliminates the risk that the lower
ating sequence for the dual underreamers 100u,l. The BHA 60 electro -hydraulic control module will become damaged dur
700 may be used instead of the BHA 550. The BHA 700 may ing drilling prior to the desired actuation of the lower
include an upper control module 300u , an upper under- underreamer.
reamer 100u , one or more stabilizers 705 , a lower control Alternatively, the mechanical control module 200 may be
module 3001 , a lower underreamer 3001 , and the telemetry used instead of the lower electro -hydraulic control module
sub 400 , and aa drill bit (not shown , see 505 ) . Alternatively, 65 3001 and the electro -mechanical control module 650 may be
the control module 600 or control module 650 may replace used instead of the upper electro -hydraulic control module
the control modules 300u, l. 300u . Both underreamers may be locked in the retracted
 US 11,377,909 B2
23 24
position upon deployment through the casing and drill- underreamer 100u and control module 300u may be flipped
through of the casing shoe . An instruction signal may be sent upside down so that the control modules and the telemetry
to the telemetry sub and relayed to the upper control module, sub may be placed adjacent one another. This arrangement
thereby extending the upper underreamer arms. Drilling and may facilitate hard -wiring or inductive couplings to be used
reaming may then commence. Once the upper underreamer 5 to transfer data between the control modules and the telem
becomes dull, the ball may then be launched and the lower etry sub .
underreamer arms extended . The upper underreamer may be Alternatively, this arrangement may facilitate integration
left in the extended position and used as a stabilizer or it may of the control module and telemetry sub electronics and even
be retracted . structural integration so that one sub having one battery and
Alternatively, each of the control modules 300u, l may be 10 one controller may perform the function of the control
replaced by the mechanical control module 200 and the modules and the telemetry sub .
telemetry sub 400 may be omitted . The wellbore may then FIG.9 illustrates an underreamer arm 950a configured for
be drilled with the upper underreamer first. The upper soft formations, according to another embodiment of the
control module may be modified with a hinged expandable present invention . Instead of super -hard cutters, the arm 955
or frangible ball seat set at a pressure greater than the shear 15 may have teeth formed on one or more blades thereof, such
screws 222. When the upper underreamer becomes dull, as by casting, milling, or machining. Alternatively, cutters
then the pressure may be increased to fracture the hinged made from a hard or superhard material may be disposed
ball seat , thereby dropping the ball to the lower control along each of the blades , as discussed above . The cutters
module ball seat . The lower control module may then be may be substantially larger than the cutters 55 and spaced
activated . The upper control module may remain extended 20 substantially further apart than the cutters 55. Alternatively,
and serve as a stabilizer. Alternatively, the upper control the teeth may be hard - faced . The arms 50a, b of either of the
module may have a larger ball seat than the lower control underreamers 100u, l may be replaced by the arm 950a so
module . The lower control module may be activated first that one of the underreamers is configured to ream a hard
with aa smaller ball which may pass through the larger upper formation , such as limestone, and the other is configured to
seat . A larger ball may then be dropped to activate the upper 25 ream a soft formation , such as shale . The soft - arm under
control module . reamer may then be extended for reaming the soft formation
Alternatively, the cutters 55 may be omitted from the while the hard - arm underreamer is retracted and the hard
upper underreamer 100u and the upper underreamer 100u arm underreamer may be extended for reaming a hard
may be extended simultaneously with or shortly after the formation while the soft - arm underreamer is retracted . Alter
lower underreamer 1001 and used as a stabilizer. Alterna- 30 natively, one of the upper underreamer and lower under
tively, a third underreamer without cutters and a third control reamer may have arms configured to forward ream and the
module may be added to the BHA 700 above the upper other of the upper and lower underreamer may have arms
control module 300u and used as a stabilizer. Alternatively, configured back ream and the forward arm underreamer
the section mill 1100 without cutters may replace the upper may be extended while forward reaming while the back
underreamer and control module and be extended and used 35 ream underreamer is retracted and vice versa . Alternatively,
as an adjustable stabilizer or added to the BHA 700 above the BHA may include an underreamer and a casing cutter or
the upper control module 300u . In the adjustable stabilizer section mill ( discussed below ) .
alternatives, the instruction signal may include an extension
9 Alternatively, the arms of a first of the underreamers
setting for the adjustable stabilizer. The adjustable stabilizer 100u, l may be configured to ream a first geological forma
arms may be extended to a diameter substantially equal to 40 tion and the arms of a second of the underreamers 100u ,l
the extended lower underreamer arms. may be configured to ream a second geological formation . In
Alternatively, the adjustable stabilizer may be used to operation , the arms of the first underreamer may be extended
steer the drill bit in a directional drilling operation . In a and the first formation drilled and reamed until the second
directional drilling operation, the lower underreamer 1001 formation is encountered. The arms of the second under
may act as a fulcrum or pivot point for the bit due to the 45 reamer may then be extended and the arms of the first
weight of the drill collars behind the lower underreamer 1001 underreamer may be optionally retracted . The second for
forcing the lower underreamer 1001 to push against the mation may then be drilled and reamed . Optionally, the arms
lower side of the borehole. Accordingly, the drill bit tends to of the first underreamer may then be extended if a new
be lifted upwardly at an angle , e.g. build angle. Selective geological formation is encountered .
extension of the adjustable stabilizer may control this effect. 50 FIG . 10A is a cross section of a casing cutter 1000 in a
Namely , as the drill bit builds angle due to the fulcrum effect retracted position , according to another embodiment of the
created by the lower underreamer 1001, the adjustable sta- present invention . FIG . 10B is a cross section of the casing
bilizer engages the lower side of the borehole, thereby cutter 1000 in an extended position . FIG . 10C is an enlarge
causing the longitudinal axis of the bit to pivot downwardly ment of a portion of FIG . 10A . The casing cutter 1000 may
so as to drop angle . A radial change of the adjustable 55 include a housing 1005 , a plurality of arms 1015 , a piston
stabilizer arms may control the pivoting of the bit on the 1010 , a seal 1012 , a piston spring 1020 , a follower 1022 , a
lower underreamer 1001, thereby providing a two -dimen- follower spring 1027 , and a control module 1030. The
sional, gravity based steerable system to control the build or control module 1030 may include an electronics package
drop angle of the drilled borehole as desired. 1025 , a solenoid valve 1031 , a stop spring 1032 , a flow
FIG . 8 illustrates an alternative dual underreamer BHA 60 passage 1033 , a position sensor 1034 , chambers 1035a , b ,
800 , according to another embodiment of the present inven- and a sleeve 1036 , a battery 1170 , and an antenna 1178. The
tion . The BHA 800 may include an upper control module electronics package 1025 may include a controller, such as
300u , an upper underreamer 100u , one or more stabilizers microprocessor, power regulator, and transceiver.
705 , a lower control module 3001, a lower underreamer 3001 , The housing 1005 may be tubular and may have a
and the telemetry sub 400 , and a drill bit (not shown, see 65 threaded coupling formed at a longitudinal end thereof for
505 ) . Alternatively, the control module 600 or control mod- connection to a workstring (not shown) deployed in a
ule 650 may replace the control modules 300u , l. The upper wellbore for an abandonment operation. The workstring
 US 11,377,909 B2
25 26
may be drill pipe or coiled tubing. To facilitate manufacture through, thereby fluidly stopping downward movement of
and assembly, the housing 1005 may include a plurality of the sleeve 1036. The sleeve 1036 may further include a
longitudinal sections , each section longitudinally and rota- second shoulder 1036b and the piston may include a stop
tionally coupled , such as by threaded connections, and shoulder 1010b . Engagement of the stop shoulder 1010b
sealed (above the piston 1010 ) , such as by o -rings . Each arm 5 with the second shoulder 1036b may also stop downward
1015 may be pivoted 1018 to the housing for rotation movement of the piston , thereby limiting extension of the
relative to the housing between a retracted position and an arms 1015 .
extended position . A coating 1017 of hard material, such as In operation, when it is desired to activate the cutter 1000 ,
tungsten carbide ceramic or cermet, may be bonded to an an instruction signal may be sent to the telemetry sub 400
outer surface and a bottom of each arm 1016. The hard 10 and relayed to the controller 1025 via the antenna 1078 ,
material 1017 may be coated as grit. An upper surface of thereby conveying an arm setting command . Drilling fluid
each arm 1015 may form a cam 1019a and an inner surface may then be circulated through the workstring from the
of each arm may form a taper 10196. The housing 1005 may surface to extend the arms 1015. The microprocessor 1025
have an opening 10050 formed therethrough for each arm may monitor the position of the sleeve 1036 until the sleeve
1015. Each arm 1015 may extend through a respective 15 reaches a position corresponding to the set position of the
opening 10050 in the extended position . arms 1015. The microprocessor 1025 may then supply
The piston 1010 may be tubular, disposed in aa bore of the electricity from the battery 1070 to the solenoid valve 1031 ,
housing 1005 , and include a main shoulder 1010a . The thereby closing the solenoid valve and halting downward
piston spring 1020 may be disposed between the main movement of the sleeve 1036 and extension of the arms
shoulder
the 1010a
housing and alongitudinally
, thereby shoulder formedbiasing
in an the
innerpiston
surface1010of 20 a1015.
wall The
of a workstring
casing stringmayto then be rotatedfrom
be removed , cutting through.
the wellbore
away from the arms 1015. A nozzle 1011 may be longitu- Once the casing string has been cut , the casing cutter 1000
dinally coupled to the piston 1010 , such as by a threaded may be redeployed in the same trip to cut a second casing
connection , and made from an erosion resistant material, string having a different diameter by sending a second
such as a metal, alloy, or cermet . To extend the arms 1015 , 25 instruction signal .
drilling fluid may be pumped through the workstring to the Additionally, the control module may lock the arms in the
housing bore . The drilling fluid may then continue through retracted position to prevent premature actuation of the
the nozzle 1011. Flow restriction through the nozzle 1011 arms. Alternatively, the first arm setting may be prepro
may cause pressure loss so that a greater pressure is exerted grammed at the surface .
on a top of the piston 1010 than on the main shoulder 1010a , 9 30 FIG . 10D is a cross section of a portion of an alternative
thereby longitudinally moving the piston downward toward casing cutter 1000a including an alternative control module
the arms and against the piston spring 1020. As the piston 1030a in a retracted position . Instead of the solenoid valve ,
1010 moves downward, a bottom of the piston 1010 may the alternative control module may include a pump 1031a in
engage the cam surface 1019a of each arm 1015 , thereby communication with each of the chambers 1035a , b via
rotating the arms 1015 about the pivot 1018 to the extended 35 passages 1033a , b . The sleeve may be moved to the set
position . position by supplying electricity to the pump and then
The housing 1005 may have a stem 1005s extending shutting the pump off when the sleeve is in the set position
between the arms 1015. The follower 1022 may extend into as detected by the position sensor 1034 .
a bore of the stem 1005s . The follower spring 1027 may be FIG . 10E is a cross section of a portion of an alternative
disposed between a bottom of the follower and aa shoulder of 40 casing cutter 1000b including an alternative control module
the stem 1005s . The follower 1022 may include a profiled 1030b . The control module 1030b may further include a
top mating with each arm taper 1019b so that longitudinal body 1041 , a nozzle 1042 , a flange 1043 , and a sleeve 1046 .
movement of the follower toward the arms 1015 radially The body 1041 may include a nose formed at a bottom
moves the arms toward the retracted position and vice versa. thereof for seating against the nozzle 1011. The nozzle 1042
The follower spring 1027 may longitudinally bias the fol- 45 may be longitudinally coupled to the body 1041 via a
lower 1022 toward the arms 1015 , thereby also biasing the threaded cap 1044. The flange 1043 may be biased toward
arms toward the retracted position . When flow through the a shoulder formed in an outer surface of the body 1041 a
housing 1005 is halted , the piston spring 1020 may move the spring 1048. The spring 1048 may be disposed between the
piston 1010 upward away from the arms 1015 and the body 1041 and one or more threaded nuts 1047 engaging a
follower spring 1027 may push the follower 1022 along the 50 threaded outer surface of the body. The flange 1043 may be
taper 1019b , thereby retracting the arms. longitudinally coupled to the sleeve 1046 by abutment with
The chambers 1035a , b may be filled with a hydraulic a shoulder 1046b of the sleeve and abutment with aa fastener,
fluid , such as oil . The first chamber 1035a may be formed such as a snap ring . The flange 1043 may have one or ports
radially between an inner surface of the housing 1005 and an formed therethrough . The body 1041 may be longitudinally
outer surface of the sleeve 1036 and longitudinally between 55 movable downward toward the nozzle 1011 relative to the
a bottom of a first shoulder 1036a of the sleeve and a top of flange 1043 by a predetermined amount adjustable at the
one of the housing sections . The second chamber 1035b may surface by the nuts 1047 .
be formed radially between an inner surface of the housing During normal operation in the extended position , the
1005 and an outer surface of the sleeve 1036 and longitu- body nose may be maintained against the nozzle 1011 .
dinally between a top of the first shoulder 1036a and a 60 Drilling fluid may be pumped through both nozzles 1042 ,
shoulder of the housing. The position sensor 1034 may 1011 , thereby extending the arms . As the piston 1010 moves
measure a position of the first shoulder 1036a and commu- downward toward the arms 1015 , fluid pressure exerted on
nicate the position to the controller 1025. The solenoid the body 1041 by restriction through the nozzle 1042 may
operated valve 1031 may be a check valve operable between push the body 1041 longitudinally toward the piston 1010 ,
a closed position where the valve functions as a check valve 65 thereby maintaining engagement of the body nose and the
oriented to prevent flow from the first chamber to the second nozzle 1011. If the arms 1015 extend past a desired cutting
chamber (downward flow ) and allow reverse flow there- diameter, the nuts 1047 may abut the stop 1049 , thereby
 US 11,377,909 B2
27 28
preventing the body nose from following the nozzle 1011 . follower 1022 may retract the arms. The casing cutter 10000
Separation of the blade nose from the nozzle 1011 may allow may be redeployed in the same trip to cut a second casing
fluid flow to bypass the nozzle 1042 via the flange ports, string having a different diameter by sending another
thereby creating a pressure differential detectable at the instruction signal including a second arm setting.
surface. To initialize or change the setting of the sleeve 5 FIG . 11A is a cross section of a section mill 1100 in a
1046 , an instruction signal may be sent to the telemetry sub retracted position , according to another embodiment of the
400 and relayed to the controller 1025. The controller 1025 present invention . FIG . 11B is an enlargement of a portion
may move the sleeve 1046 to the setting using the pump of FIG . 11A . The section mill 1100 may include a housing
1031a , thereby also moving the body 1041 . 1105 , a piston 1110 , a plurality of arms 1115 , a piston spring
FIG . 10F is a cross section of an alternative casing cutter 10 1120 , and a control module 1130. The control module 1130
9

1000c in an extended position . The casing cutter 1000c may may include an electronics package 1125 , an electric pump
include aa housing 1055 , a plurality of arms 1075 , a follower 1131 , flow passages 1133a, b , chambers 1135a , b , a second
1022 , a follower spring 1027 , and aa control module 1030c .
2 piston shoulder 1110b , a position sensor 1134 , a battery
The housing 1055 may be tubular and may have a threaded 1170 , and an antenna 1178. The electronics package 1125
coupling formed at a longitudinal end thereof for connection 15 may include a controller, such as microprocessor, power
to a workstring ( not shown ) deployed in a wellbore for an regulator, and transceiver.
abandonment operation. The workstring may be drill pipe or The housing 1105 may be tubular and may have a
coiled tubing. To facilitate manufacture and assembly, the threaded couplings formed at longitudinal ends thereof for
housing 1055 may include a plurality of longitudinal sec- connection to a workstring (not shown) deployed in a
tions , each section longitudinally and rotationally coupled, 20 wellbore for a milling operation. The workstring may be
such as by threaded connections, and sealed ( above the arms drill pipe or coiled tubing. To facilitate manufacture and
1075 ) , such as by O - rings . Although shown schematically, assembly, each of the housing 1105 and the piston 1110 may
the arms 1075 may be similar to the arms 1015 and may be include a plurality of longitudinal sections , each section
returned to the retracted position by the follower 1022 and longitudinally and rotationally coupled , such as by threaded
the follower spring 1027 . 25 connections . Each arm 1115 may be pivoted 1115p to the
The control module 1030c may include the electronics housing 1105 for rotation relative to the housing between a
package 1025 , a cam 1060 , a shaft 1065 , a battery 1070 , an retracted position and an extended position . Each arm 1115
electric motor 1071 , a position sensor 1072 , and an antenna may include a coating (not shown ) of hard material, such as
1078. The shaft 1065 may be longitudinally and rotationally tungsten carbide ceramic or cermet, bonded to an outer
coupled to the motor 1071. The shaft 1065 may include a 30 surface and a bottom thereof. The hard material may be
threaded outer surface . The cam 1060 may be disposed coated as grit. An inner surface of each arm may be cammed
along the shaft 1065 and include a threaded inner surface 1115c . The housing may have an opening 11050 formed
( not shown) . The cam 1060 may be moved longitudinally therethrough for each arm 1115. Each arm 1115 may extend
along the shaft by rotation of the shaft 1065 by the motor through a respective opening 11050 in the extended position .
1071. As discussed above , the controller 1025 may measure 35 The piston 1110 may be tubular, disposed in a bore of the
the longitudinal position of the cam 1065 and the position of housing 1105 , and include one or more shoulders 1110a , b .
the arms 1075 using the position sensor 1072. The motor The piston spring 1120 may be disposed between the first
1070 may further include a lock to hold the arms in the set shoulder 1110a and a shoulder formed by a top of one of the
position . Although shown schematically, as the cam 1060 housing sections , thereby longitudinally biasing the piston
moves downward, a bottom of the cam may engage a cam 40 1110 away from the arms 1115. The piston 1110 may have
surface of each arm 1075 , thereby rotating the arms about a nozzle 1110n . To extend the arms, drilling fluid may be
the pivot to the extended position . The control module 10300 pumped through the workstring to the housing bore . The
may further include a load cell ( not shown ) operable to drilling fluid may then continue through the nozzle 1110n .
measure a cutting force exerted on the arms 1075 and the Flow restriction through the nozzle may cause pressure loss
controller 1025 may be programmed to control the blade 45 so that a greater pressure is exerted on the nozzle 1110n than
position to maintain a constant predetermined cutting force . on a cammed surface 1110c of the piston 1110c , thereby
The control module 1030c may communicate with the longitudinally moving the piston downward toward the arms
telemetry sub 400 to send a signal to the surface when the and against the piston spring . As the piston 1110 moves
cut is finished or if the cutting forces exceed a predetermined downward , the cammed surface 1110c engages the cam
maximum . 50 surface 1115c of each arm 1115 , thereby rotating the arms
In operation, when it is desired to activate the cutter about the pivot 1115p to the extended position .
1000c , an instruction signal may be sent to the telemetry sub The chambers 1135a , b may be filled with a hydraulic
400 and relayed to the controller 1025 via the antenna 1078 , fluid , such as oil . The first chamber 1135a may be formed
thereby conveying an arm setting command. The controller radially between an inner surface of the housing 1105 and an
1025 may supply electricity to the motor 1071 and monitor 55 outer surface of the piston 1110 and longitudinally between
the position of the arms 1075 until the set position is a bottom of the shoulder 1110b and a top of one of the
reached . The microprocessor 1025 may shut off the motor housing sections . The second chamber 1135b may be formed
(which may also set the lock) . Drilling fluid may then be radially between an inner surface of the housing and an outer
circulated through the workstring from the surface and the surface of the sleeve and longitudinally between a top of the
workstring may then be rotated , thereby cutting through a 60 shoulder 1110b and a shoulder of the housing . The pump
wall of a casing string to be removed from the wellbore . 1131 may be in fluid communication with each of the
Once the casing string has been cut, a second instruction chambers 1135a, b via a respective passage 1133a , b.
signal may be sent commanding retraction of the arms. In operation, when it is desired to activate the mill 1100 ,
Alternatively, the arms may automatically retract when the an instruction signal may be sent to the telemetry sub 400
cut is finished . The controller 1025 may supply reversed 65 and relayed to the controller 1125 via the antenna 1178 ,
polarity electricity to the motor 1070 , thereby unsetting the thereby conveying an extension command. The controller
lock and moving the cam away from the arms so that the 1125 may supply electricity to the pump 1131 , thereby
 US 11,377,909 B2
29 30
pumping fluid from the chamber 1135b to the chamber one or more frangible fasteners , such as shear pin 1222b .
1135a and allowing the piston 1110 to move longitudinally The retraction piston 1250 may be longitudinally movable
downward and extending the arms 1115. As with the casing relative to the body 1205 , the movement limited by engage
cutter, the signal may include a position setting command so ment of the slotted end 1250e with the lip 12201. The
that the controller may actuate the piston to the instructed set 5 extension piston 1250 may have a seat 1250s formed therein
position which may be fully extended , partially extended , or for receiving a closure element, such as a ball 1290b , plug ,
substantially extended depending on the diameter of the or dart. The seat 1250s may have a larger diameter than the
casing/ liner section to be milled . As discussed above, the seat 1220s ,> thereby allowing passage of the dissolvable ball
controller may monitor the position of the piston shoulder 1290a therethrough . The ball 1290b may be dissolvable or
1110b using the position sensor 1134. Drilling fluid may then 10 non - dissolvable .
be circulated and the workstring may then be rotated and When deploying the underreamer 100 and control module
raised / lowered until a desired section of casing or liner has 1200 in the wellbore , a drilling operation (e.g. , drilling
been removed . Once the casing / liner has been milled , the through a casing shoe) may be performed without operation
mill may be retracted by sending another instruction signal, of the underreamer 100. Even though force is exerted on the
thereby conveying retraction command . The controller may 15 underreamer piston 10 by drilling fluid , the shear screws
then reverse operation of the pump. Alternatively, the con- 1222a may prevent the underreamer piston 10 from extend
trol module may include a motor instead of a pump in which ing the arms 50a , b . When it is desired to operate the
case the piston may be aa mandrel. underreamer 100 , the ball 1290a is pumped or dropped from
FIGS . 12A - 12C are cross - sections of a mechanical con- the surface and lands in the ball seat 1220s . Drilling fluid
trol module 1200 in a first retracted , extended, and second 20 continues to be injected or is injected through the drill string.
retracted position , respectively, according to another Due to the obstructed piston bore , fluid pressure acting on
embodiment of the present invention . The control module the ball 1290a and piston 1220 increases until the shear pin
1200 may include a body 1205 , a control mandrel 1210 , a 1222a is fractured, thereby allowing the extension piston
piston housing 1215 , an extension piston 1220 , a lock 1220 to move longitudinally relative to the body 1205 and
mandrel 1230 , one or more biasing members 1235a, b , and 25 disengaging the lip 12201 from the dogs 1227. The control
a retraction piston 1250. The body 1205 may be tubular and mandrel lip may be inclined and force exerted on the control
have a longitudinal bore formed therethrough. Each longi- mandrel 1210 by the underreamer piston 10 may push the
tudinal end 1205a, b of the body 205 may be threaded for dogs 1227 radially outward into a radial gap defined
longitudinal and rotational coupling to other members, such between the lock mandrel 230 and the extension piston
as the underreamer 100 at 1205b and a drill string at 1205a . 30 1220 , thereby freeing the control mandrel and allowing the
The biasing members may each be springs 1235a, b . A underreamer piston 10 to extend the arms 50a , b . Movement
return spring 1235a may be disposed between a shoulder of the extension piston 1220 may also open bypass ports
1210s of the control mandrel 1210 and aa shoulder of the lock 1220p formed through a wall of the extension piston 1220 .
mandrel 1230. The return spring 1235a may bias a longi- The ball 1290a may then gradually dissolve as drilling
tudinal end of the control mandrel or a control module 35 continues.
adapter 1212 into abutment with the underreamer piston end When or if it is desired to re -lock the arms 50a , b in the
10t, thereby also biasing the underreamer piston 210 toward retracted position , the second ball 1290b is pumped or
the retracted position . The control module adapter 1212 may dropped from the surface and lands in the ball seat 1250s .
be longitudinally coupled to the control mandrel 1210 , such Drilling fluid continues to be injected or is injected through
as by a threaded connection , and may allow the control 40 the drill string. Due to the obstructed piston bore , fluid
module 1200 to be used with differently configured under- pressure acting on the ball 1290b and piston 1250 increases
reamers by changing the adapter 1212. The control mandrel until the shear pin 1222b is fractured, If the ball 1290b was
1210 may be longitudinally coupled to the lock mandrel dropped, the retraction piston 1250 may move longitudinally
1230 by a latch or lock , such as a plurality of dogs 1227 . relative to the body 1205 and engage the end 1250e with the
Alternatively, the latch or lock may be a collet . The dogs 45 dogs 1227 , push the dogs 1227 into engagement with the
1227 may be held in place by engagement with a lip 12201 control mandrel lip , and continue until engaging the exten
of the extension piston 1220 and engagement with a lip of sion piston lip 12201. If the ball 1290b was pumped, the
the control mandrel 1210. The lock mandrel 1230 may be retraction piston 1250 may move longitudinally relative to
longitudinally coupled to the piston housing 1215 by a the body 1205 and engage the end 1250e with the dogs 1227
threaded connection and may abut a body shoulder and the 50 and stop due to interference with an outer surface of the
piston housing 1215 . control mandrel 1210. Injection of drilling fluid may then be
The piston housing 1215 may be longitudinally coupled to halted allowing the return spring 1235a to push the control
the body 1205 by a threaded connection . The extension mandrel 1210 and underreamer piston 10 to the retracted
piston 1220 may include recesses for receiving a slotted end position . The piston spring 1235b may then push the retrac
1250e of the retraction piston 1250. The extension piston 55 tion piston 1250 to engage the dogs 1227 with the control
1220 may be longitudinally movable relative toa the body mandrel lip . Movement of the retraction piston 1250 by the
1205 , the movement limited by engagement of a shoulder piston spring 1235b may continue until the end 1250e
1220b with an upper end of the lock mandrel 1230. The engages the extension piston lip 12201. Movement of the
extension piston 1220 may be longitudinally coupled to the retraction piston 1250 may also open bypass ports 1250p
piston housing 1215 by one or more frangible fasteners, such 60 formed through a wall thereof.
as shear pin 1222a . The extension piston 1220 may have a Alternatively, instead of a dissolvable ball 1290a , the
seat 220s formed therein for receiving a dissolvable closure extension piston 1220 may be modified so that the ball seat
element, such as a ball 1290a , plug , or dart . 1220s is radially movable between a contracted position and
A piston spring 1235b may be disposed between a shoul- an extended position . The modified ball seat 1220s may
der formed in the piston housing 1215 and a shoulder 1250b 65 receive the ( non - dissolvable ) ball in the contracted position
formed in the retraction piston 1250. The retraction piston and move to the extended position as the extension piston
1250 may be longitudinally coupled to the piston housing by 1220 moves longitudinally. To allow radial movement, the
 US 11,377,909 B2
31 32
ball seat may be split into fingers biased toward the extended pressure acting on the ball 1390 and retraction piston 1310
position . In the extended position, the ball seat may allow increases until the shear pins 1322 are fractured . The retrac
passage of the ball therethrough. The ball may then be tion piston 1310 may move longitudinally relative to the
caught by a receptacle (not shown ) located in the under- body 1305 until the shoulder 1310s engages the shoulder
reamer adapter. Alternatively, instead of aa dissolvable ball 5 1307a , thereby opening lower ports 13101 and closing upper
1290a , the ball 1290a may be deformable. The ball 1290a ports 1310u . Closing of the upper ports 1310u may isolate
may be received by the seat 1220s until a predetermined the control chamber 1311 except for the check valve 1317
deformation pressure is applied . The pressure necessary to allowing retraction of the extension piston 10 via bypass
shear the pins 1222b may be less or substantially less than 1307b . The lower ports 1310 provide fluid communication
the deformation pressure . Once the deformation pressure 10 between around the closed ball seat . The ball 1390 may or
exerted on the deformable ball is exceeded, the ball may may not gradually dissolve to reopen the seat 1310s . Injec
elastically or plastically deform and pass through the seat tion of drilling fluid may then be halted, thereby allowing the
1220s and be received by the receptacle , discussed above . control module spring to retract the arms 50a, b . Once the
FIGS . 13A and 13B are cross - sections of an underreamer arms are retracted , isolation of the piston surface 10h
1300 in an extended and second retracted position , respec- 15 prevents further extension of the arms 50a , b when drilling
tively, according to another embodiment of the present fluid is injected through the underreamer 1300 .
invention. The underreamer 1300 may include a body 5 , an Alternatively, a similar effect may be achieved by adding
adapter 1307 , an extension piston 10 , a retraction piston a circulation sub (not shown) to a BHA including the
1310 , one or more seal sleeves 15u , 1315 , a mandrel 1320 , underreamer 100 and the control module 200. The circula
a retraction piston and one or more arms 50a, b ( see FIG . 1C 20 tion sub may include a body having a bore therethrough and
for 506) . Relative to the underreamer 100 , reference numer- one or more ports formed through a wall thereof. A piston
als for unchanged parts have been kept and the discussion may be disposed in the body and seal the port in a closed
thereof is not repeated . position . The piston may have a seat for receiving a closure
An end 1307a of the adapter 1307 distal from the body member, such as a ball . The piston may be longitudinally
may be threaded for longitudinal and rotational coupling to 25 coupled to the body by one or more frangible fasteners , such
another member of a bottomhole assembly ( BHA) . The as shear pins . The piston may be longitudinally movable
mandrel 1320 may be tubular, have a longitudinal bore relative to the body to an open position where the ports are
formed therethrough , and be longitudinally coupled to the in fluid communication with the body bore . In operation ,
lower seal sleeve 1315 by a threaded connection . The lower after the underreaming operation is complete, the ball may
seal sleeve 1315 may be longitudinally coupled to the body 30 be pumped or dropped down to the seat. The circulation seat
5 by being disposed between the shoulder 5s and a top of the may be larger than the control module seat to allow passage
adapter 1307. The lower seal sleeve 1315 may have one or of the ball 290. The circulation ball may land in the
more longitudinal ports 1315p formed through a cap thereof. circulation seat and pressure may increase or be increased
The ports 1315p may provide fluid communication between fracture the shear pins and move the piston to the open
the piston surface 10h and a control chamber 1311 formed 35 position . The ball and piston may seal or at least substan
between the adapter 1307 and the retraction piston 1310 . tially obstruct the body bore below the ports, thereby pre
The retraction piston 1310 may include one or more upper venting fluid pressure from operating the underreamer piston
ports 1310u and one or more lower ports 13101 formed and allowing the cleaning operation, discussed above to be
through a wall thereof. The upper ports 1310u may provide performed without extending the underreamer arms.
fluid communication between a bore of the retraction piston 40 FIGS . 14A and 14B are cross - sections of a hydraulic
and the control chamber 1311 . control module 1400 in a retracted and extended position ,
The retraction piston 1310 may be received by a seat respectively, according to another embodiment of the pres
1307s formed in the adapter 1307. A bypass 1307b may be ent invention . The control module 1400 may include a body
formed through the seat 1307s and a check valve 1317 may 1405 , an adapter 1407 , a control mandrel 1410 , a piston
be disposed in the bypass and oriented to allow fluid flow 45 1415 , a piston mandrel 1420 , a valve mandrel 1425 , a valve
from a bore of the adapter to the control chamber but to head 1430i , a valve seat 14300 , and a biasing member 1435 .
prevent flow of fluid from the control chamber to the adapter The body 1405 may be tubular and have aa longitudinal bore
bore . The retraction piston may be longitudinally coupled to formed therethrough . Each longitudinal end 1405a ,b of the
the mandrel 1320 by one or more frangible fasteners, such body 1405 may be threaded for longitudinal and rotational
as shear pins 1322. The lower ports 13101 may be closed . 50 coupling to other members, such as the underreamer 100 at
The retraction piston 1310 may have a seat 1310s formed 1405b and the adapter at 1405a . The adapter 1407 may be
therein receiving a closure element, such as a ball 1390 , tubular and have a longitudinal bore formed therethrough .
plug , or dart. The ball 1390 may be dissolvable or non- Each longitudinal end 1407a of the adapter 1407 may be
dissolvable . The retraction piston 1310 may have a shoulder threaded for longitudinal and rotational coupling to other
1310s engageable with a shoulder 1307a formed in the 55 members, such as the drill string at 1407a .
adapter 1307 . The biasing member may be aa spring , such as a Belleville
The underreamer 1300 may be deployed with the control spring 1435 , and may be disposed between a bottom of the
module 200 in a similar fashion as the underreamer 100 with adapter 1407 and a top of the piston 1415. The spring 1435
the exception that the underreamer 1300 may be re - locked in may bias a longitudinal end of the control mandrel 1410 or
the retracted position . The ball 290 may be removed as 60 a control module adapter (not shown ) into abutment with the
discussed above for removing the ball 1290a (e.g. , by underreamer piston end , thereby also biasing the under
deforming, dissolving, or modifying the ball seat to be reamer piston toward the retracted position . Advanta
extendable ). When or if it is desired to re - lock the arms geously, a preload of the Belleville spring 1435 may be
50a, b in the retracted position , the ball 1390 is pumped or easily adjusted for various underreamer configurations. The
dropped from the surface and lands in the ball seat 1310s . 65 control mandrel 1410 may be longitudinally coupled to the
Drilling fluid continues to be injected or is injected through piston 1415 , such as with a threaded connection . The piston
the drill string. Due to the obstructed piston bore , fluid mandrel 1420 may be longitudinally coupled to the piston
 US 11,377,909 B2
33 34
1415 , such as with a threaded connection . A vent (not mill 1100. Alternatively, the section mill may be used in an
shown ) may be formed through a wall of the body 1405 and underreaming operation or vice versa . Alternatively, any of
provide fluid communication between a spring chamber the sensors or electronics of the telemetry sub 400 may be
formed radially between the spring mandrel and the body incorporated into any of the control modules 300 , 600 , 630 ,
and an exterior of the control module 1400 . 5 650 , 1030 , 1030a - c , 1130 and the telemetry sub 400 may be
The valve head 1430i and seat 14300 may each be rings omitted .
made from an erosion resistant material, such as a metal , Additionally, as with the underreamer, two section mills
alloy, ceramic, or cermet. The valve head 1430i may be may be connected . The primary section mill may be
longitudinally coupled to the valve mandrel 1425 , such as by extended to mill a section of casing/ liner. Once the arms of
being disposed between a shoulder formed in the valve 10 the primary mill become worn , the backup mill may be
mandrel 1425 and a fastener ( not easily seen due to scale) . extended by sending an instruction signal , thereby com
The valve mandrel 1425 may be longitudinally coupled to manding retraction of the primary mill and extension of the
the piston 1415 , such as with a threaded connection . The backup mill . The milling operation may then continue
valve seat 14300 may be longitudinally coupled to the body without having to remove the primary mill to the surface for
1405 , such as by being disposed between a shoulder 1405s 15 repair. Alternatively, two casing cutters 1000 may be
formed in the body 14205 and a fastener (not easily seen due deployed in a similar fashion . Alternatively, also as with the
to scale ) . One or more seals , such as O - rings 1412 , may be underreamer, a stabilizer or adjustable stabilizer may be
disposed between the piston 1415 and the body 1405 and used with the casing cutter or section mill or with two casing
may isolate the spring chamber from a piston chamber cutters or section mills .
formed radially between the piston 1415 /valve mandrel and 20 In another alternative ( not shown) , any of the electric
the body 1405. Various other seals , such as o -rings may be control modules 300 , 600 , 630 , 650 , 1030 , 1030a - c , 1130
disposed throughout the control module 1400 . may include an override connection in the event that the
The valve 1430i, oo may be operable between an open and telemetry sub 400 and / or controllers of the control modules
closed position . In the closed position , the valve 14301,0 fail . An actuator may then be deployed from the surface to
may at least substantially isolate the piston chamber from a 25 the control module through the drill string using wireline or
valve chamber formed radially between the control mandrel slickline . The actuator may include a mating coupling. The
1410 and the body 1405. One or more ports 1410p formed actuator may further include a battery and controller if
through wall of the control mandrel 1410 may provide deployed using slickline . The override connection may be a
fluid communication between the valve chamber and a bore contact or hard -wire connection, such as a wet -connection,
of the control mandrel. A predetermined radial clearance 30 or a wireless connection , such as an inductive coupling. The
(not easily seen due to scale ) may be formed between the override connection may be in direct communication with
valve head 1430i and seat 14300 to at least restrict, sub- the control module actuator, e.g. , the solenoid valve , so that
stantially restrict, or severely restrict fluid flow between the transfer of electricity via the override connection will oper
valve chamber and the piston chamber. The predetermined ate the control module actuator.
radial clearance may be less than or equal to 0.005 inch , 35 In another alternative (not shown) , any of the electric
0.004 inch , 0.003 inch , or 0.002 inch . Alternatively, the control modules 300 , 600 , 630 , 650 , 1030 , 1030a - c , 1130
2

valve head and seat may each be tapered so that the head may be deployed without the electronics package and with
contacts the seat in the closed position , thereby forming a out the telemetry sub and include the override connection,
seal . discussed above . The wireline or slickline actuator may then
When deploying the underreamer 100 and control module 40 be deployed each time it is desired to operate the control
1400 in the wellbore , a drilling operation (e.g. , drilling module .
through a casing shoe) may be performed without extension Additionally, the telemetry sub 400 or any of the sensors
of the underreamer 100. Even though force is exerted on the or electronics thereof may be used with the motor actuator,
underreamer piston 10 by drilling fluid , the spring 1435 the jar actuator, the vibrating jar actuator, the overshot
preload may prevent the underreamer piston 10 from extend- 45 actuator, or the disconnect actuator disclosed and illustrated
ing the arms 50a, b at least for a predetermined duration of in the ' 077 application .
time sufficient to drill through the casing shoe . When it is While the foregoing is directed to embodiments of the
desired to operate the underreamer 100 , an injection rate of present invention , other and further embodiments of the
the drilling fluid is substantially increased from the normal invention may be devised without departing from the basic
drilling flow rate . Fluid pressure acting on the underreamer 50 scope thereof, and the scope thereof is determined by the
piston 10 ( and an end of the valve mandrel and an end of the claims that follow .
valve head) increases until the spring preload is overcome ,
thereby moving the piston 1415 and mandrels 1420 , 1425 The invention claimed is :
longitudinally relative to the body, opening the valve 1430i, 1. A bottomhole assembly ( BHA ) , comprising:
0 , and compressing the spring 1435. With the valve open , 55 a first underreamer including:
drilling fluid pressure may act on the control module piston a first underreamer piston ;
1415 and the underreamer piston 10 so that the drilling fluid a plurality of first underreamer arms; and
rate may be reduced to normal while retaining the valve in a connector for each respective underreamer arm to
the open position and the underreamer in the extended attach each respective underreamer arm to the first
position . Further, injection of the drilling fluid may be halted 60 underreamer piston ;
and the valve may be re - closed to allow aa further operation wherein the first underreamer piston and each connec
to be performed while injecting drilling fluid with the tor are operable to move the plurality of first under
underreamer retracted , such as a cleanout operation , dis reamer arms from a retracted position to an extended
cussed above . position , wherein the plurality of first underreamer
Alternatively, any of the control modules 200 , 300 , 600 , 65 arms move axially with the first underreamer piston
630 , 650 , 1030 , 1030a - c , 1130 , 1200 , 1400 may be used with and laterally outward relative to the first underreamer
any of the underreamer 100 , casing cutter 1000 , or section piston to the extended position ;
 US 11,377,909 B2
35 36
a second underreamer including a second underreamer able to move the plurality of second underreamer
piston operable to move a plurality of second under- blades from a retracted to an extended position ;
reamer arms from a retracted position to an extended a first lock operable to retain the plurality of first under
position , wherein the plurality of second underreamer reamer blades in the retracted position ;
arms are attached to the second underreamer piston ; 5 a second lock operable to retain the plurality of second
a first control module including a first controller and aa first underreamer blades in the retracted position ; and
lock, wherein the first control module is configured to an electronic package configured to release at least one of
retain the first underreamer arms in the retracted posi the first and second lock in response to an instruction
tion when the first lock is engaged , and wherein the first signal to allow the extension of the respective first and
controller is configured to release the first lock in 10 second plurality of underreamer blades .
response to a first instruction signal; and 11. The BHA of claim 10 , further comprising at least one
a second control module including a second controller and of a measuring while drilling ( MWD ) or a logging while
a second lock , wherein the second control module is
drilling ( LWD ) tool .
12. The BHA of claim 10 , wherein the electronics package
configured to retain the second underreamer arms in the 15 is configured to receive the instruction signal from a radio
retracted positon when the second lock is engaged, and frequency identification (RFID ) tag .
wherein the second controller is configured to release 13. The BHA of claim 10 , wherein the first and second
the second lock in response to a second instruction locks are a hydraulic lock .
signal. 14. The BHA of claim 10 , further comprising at least one
2. The BHA of claim 1 , wherein the first and second 20 adjustable stabilizer.
controllers are configured to receive the first and second 15. The BHA of claim 10 , wherein the electronics package
instruction signals from a radio - frequency identification is configured to release the first lock in response to the
(RFID ) tag. instruction signal, and wherein the electronics package is
3. The BHA of claim 1 , wherein the first lock and second configured to reengage the first lock after the plurality of first
lock comprise a solenoid valve . 25 underreamer blades move to the extended position .
4. The BHA of claim 1 , wherein the first and second 16. A method of actuating a first underreamer and a
control modules further comprises an actuator configured to second underreamer of a bottom hole assembly (BHA) ,
extend the respective first and second underreamer pistons in comprising:
response to the respective first and second instruction signal positioning the BHA in a wellbore , the BHA further
after the respective first and second lock is released . 30 comprising:
5. The BHA of claim 1 , further comprising at least one of a first lock operable to retain a plurality of blades of the
a measuring while drilling ( MWD ) or a logging while first underreamer in a retracted position when locked
drilling (LWD ) tool . and to allow extension of the blades to an extended
6. The BHA of claim 1 , further comprising at least one position when unlocked , wherein each blade of the
adjustable stabilizer. 35 first underreamer is attached to a piston of the first
7. The BHA of claim 1 , wherein at least one of the first underreamer by a respective connector of a plurality
controller and second controller is configured to reengage of connectors ;
their respective first and second lock in response to a third a second lock operable to retain a plurality of blades of
instruction signal , and wherein the first and second control the second underreamer in a retracted position when
module is configured to again retain their respective first and 40 locked and to allow extension of the blades to an
second underreamer arms in the retracted position when extended position when unlocked ;
their respective first and second lock is reengaged. unlocking the first lock to allow the extension of the
8. The BHA of claim 1 , further comprising a telemetry sub plurality of blades of the first underreamer, wherein the
in communication with the first and second controllers , plurality of blades move axially with the piston and
wherein the telemetry sub is between the first and second 45 laterally outward relative to the piston ;
underreamers, and wherein the telemetry sub is configured reaming the wellbore with the plurality of blades of the
to receive the first and second instruction signals . first underreamer;
9. The BHA of claim 1 , further comprising a telemetry sub unlocking the second lock to allow the extension of the
in communication with the first and second controllers , plurality of blades of the second underreamer; and
wherein the telemetry sub is below the first and second 50 reaming the wellbore with the plurality of blades of the
underreamers, and wherein the telemetry sub is configured second underreamer.
to receive the first and second instruction signals . 17. The method of claim 16 , wherein the plurality of
10. A bottomhole assembly (BHA) , comprising: blades of the first and second underreamers are extended at
a first underreamer including a plurality of first under- the same time .
reamer blades and a first underreamer piston, wherein 55 18. The method of claim 16 , wherein the BHA further
each of the first underreamer blades is attached to the comprises at least one of a measuring while drilling (MWD )
first underreamer piston by a respective connector of a or a logging while drilling (LWD ) tool .
plurality of connectors, wherein the first underreamer 19. The method of claim 18 , further comprising relocking
piston and the plurality of connectors are operable to the first lock to retain the plurality of blades of the first
move the plurality of first underreamer blades from a 60 underreamer in the retracted position .
retracted to an extended position , wherein the plurality 20. The method of claim 16 , wherein the first and second
of first underreamer blades move axially with the first locks lock and unlock in response to detecting a radio
underreamer piston and laterally outward relative to the frequency identification (RFID ) tag .
first underreamer piston to the extended position ; 21. A bottomhole assembly (BHA) , comprising:
a second underreamer including a plurality of second 65 a first underreamer including:
underreamer blades attached to a second underreamer a first underreamer piston ;
piston , wherein the second underreamer piston is oper- a plurality of first underreamer arms; and
 US 11,377,909 B2
37 38
a connector for each respective underreamer arm to
attach each respective underreamer arm to the first
underreamer piston;
wherein the first underreamer piston and each connec
tor are operable to move the plurality of first under- 5
reamer arms from a retracted position to an extended
position ;
a second underreamer including a second underreamer
piston operable to move a plurality of second under
reamer arms from a retracted position to an extended 10
position , wherein the plurality of second underreamer
arms are attached to the second underreamer piston ;
a first control module including a first controller and aa first
lock, wherein the first control module is configured to
retain the first underreamer arms in the retracted posi- 15
tion when the first lock is engaged , and wherein the first
controller is configured to release the first lock in
response to a first instruction signal ; and
a second control module including a second controller and
a second lock , wherein the second control module is 20
configured to retain the second underreamer arms in the
retracted positon when the second lock is engaged, and
wherein the second controller is configured to release
the second lock in response to a second instruction
signal, wherein the first and second control modules are 25
between the first and second underreamers .
22. The BHA of claim 21 , further comprising a telemetry
sub in communication with the first and second controllers,
wherein the telemetry sub is between the first and second
control modules , and wherein the telemetry sub is config- 30
ured to receive the first and second instruction signals .
* * * *