US20080236829A1 - Casing profiling and recovery system - Google Patents

Abstract

A casing cutting and recovery tool having a cutting assembly, an expansion assembly having one or more deforming members, and a recovery assembly is used to cut a window in wellbore casing, secure a removable segment of wellbore casing that was previously disposed within the window, and recover the removable segment of wellbore casing with the tool. One or more cutting assemblies provides one or more cuts in the wellbore casing. The deforming members of the expansion assembly then expand outwardly at least two portions of the wellbore casing shaped by the cut or cuts. The recovery assembly secures the removable segment of the wellbore casing to the tool so that the tool and the removable segment of wellbore casing can be recovered together from the wellbore.

Description

BACKGROUND
• 1. Field of Invention
• The invention is directed to a casing profiling, or cutting, and recovery systems for use in oil and gas wellbores and, in particular, to a downhole tool for cutting a section of wellbore casing and recovering the section from the wellbore.
• 2. Description of Art
• In general, cutting “windows” or openings in oil and gas wellbore casing so that “offshoot,” “lateral,” or “branch” wellbores are well known in the art. Previously, the windows were cut using a whipstock or whipstock-packer assembly and a cutting or milling tool disposed on the end of a drill string. Cutting the windows using these milling tools usually results in jagged edged and irregularly shaped openings. As a result, if it is desired to close the window, sealing the irregularly shaped opening is extremely difficult, if not impossible.
• Additionally, cutting the windows using these prior milling tools resulted in various sized debris falling into or remain in the wellbore after being cut by the milling tools. As a result, these pieces had to be recovered using wellbore fluid or fishing tools, both of which requires the wellbore to be “off-line” or “down” during the recovery efforts.
• Accordingly, prior to the development of the present invention, there has been no downhole tool for cutting and recovering a section or segment of wellbore casing or method for forming an opening in casing in a well that: permits cutting the casing segment and removing the segment of wellbore casing from the wellbore in a single downhole trip; permits cutting a segment of wellbore casing with relatively smooth edges, thereby increasing the possibility that the window can be re-sealed; and decreases the amount of debris within the wellbore as a result of cutting the window. Therefore, the art has sought a downhole tool for cutting and recovering a section or segment of wellbore casing and a method for forming an opening in casing in a well that: permits cutting the casing segment and removing the segment of wellbore casing from the wellbore in a single downhole trip; permits cutting a segment of wellbore casing with relatively smooth edges, thereby increasing the possibility that the window can be re-sealed; and decreases the amount of debris within the wellbore as a result of cutting the window.
SUMMARY OF INVENTION
• Broadly, the disclosure is directed to a casing cutting and recovery tool having a cutting assembly, an expansion assembly having one or more deforming members, and a recovery assembly that preferably includes a magnet. The casing cutting and recovery tool is used to cut a window in wellbore casing, secure a removable section of wellbore casing that was previously disposed within the window, and recover the removable section of wellbore casing with the tool. One or more cutting assemblies provide primary cuts and secondary cuts in the wellbore casing. The expansion assembly expands outwardly two portions of the wellbore casing shaped by the primary cuts. The magnet secures the removable section of wellbore casing to the tool so that the tool and the removable section of wellbore casing can be recovered together from the wellbore.
• In one specific embodiment, the casing cutting and recovery tool comprises a housing having a housing bore. The housing bore has a piston chamber and piston operatively associated therein. The piston is operatively associated with the expansion assembly and the expansion assembly has at least two expansion members operatively associated therewith. The recovery assembly includes an actuating member, such as a motor or solenoid and a recovery assembly housing. The magnet is disposed on the outer wall surface of the recovery assembly. The recovery assembly housing is moveable radially outward and inward relative to the housing by the actuating member.
• The downhole tools for cutting and recovering a section or segment of wellbore casing and methods for forming an opening in casing in a well have the advantages of: permitting cutting the casing segment and removing the segment of wellbore casing from the wellbore in a single downhole trip; permitting cutting a segment of wellbore casing with relatively smooth edges, thereby increasing the possibility that the window can be re-sealed; and decreasing the amount of debris within the wellbore as a result of cutting the window.
• In one aspect, one or more of the foregoing advantages is achieved by an apparatus for forming an opening in casing in a well in which the apparatus comprises a cutting assembly for lowering into a casing of a well, the cutting assembly having at least one cutting member for Cutting at least one slot in the casing to define a segment for removal; a deforming member carried with the cutting assembly, the deforming member being selectively actuated from a surface of the well for deforming outward at least two portions of the casing adjacent the slot; and a recovery assembly carried with the cutting assembly for engaging and removing the segment from the casing.
• A further feature of the apparatus is that the cutting assembly may be disposed above the deforming member. Another feature of the apparatus is that the deforming member may be disposed above the recovery assembly. An additional feature of the apparatus is that the deforming member may comprise at least two rollers. Still another feature of the apparatus is that the apparatus may further comprise a secondary cutting assembly, wherein the cutting assembly and the secondary cutting assembly each include at least two linear charges. A further feature of the apparatus is that the recovery assembly may include a magnet and an actuating member for moving the magnet radially outward to engage and remove the segment from the casing. Another feature of the apparatus is that the deforming member may be operatively associated with a piston disposed within a piston chamber, a lower portion of the piston being operatively associated with a conically shaped deforming member housing. An additional feature of the apparatus is that the lower portion of the piston may include a conically shaped drive wedge, the drive wedge being slidingly engaged with the conically shaped deforming member housing. Still another feature of the apparatus is that the piston and drive wedge may include a bore, the bore having disposed therein a ball seat, a ball, and a ball release. A further feature of the apparatus is that the piston chamber may include hydraulic fluid. Another feature of the apparatus is that the piston chamber may further include a vent port.
• In another aspect, one or more of the foregoing advantages is achieved by an apparatus for forming an opening in casing in a well in which the apparatus comprises a cutting assembly for lowering into a casing of a well, the cutting assembly having at least one linear shaped charge for cutting at least one slot in the casing to define a segment for removal; a piston movable by high pressure against a wedge member to radially expand a deforming member carried with the cutting assembly, the deforming member being selectively actuated by the piston for deforming outward at least two portions of the casing adjacent the slot; and a recovery assembly carried with the cutting assembly for engaging and removing the segment from the casing, the recovery assembly having a radially moveable magnet.
• A further feature of the apparatus is that the piston and wedge member each may include a bore, the bore having disposed therein a ball seat, a ball, and a ball release. Another feature of the apparatus is that the piston may be disposed within a piston chamber having an upwardly biased spring and hydraulic fluid. An additional feature of the apparatus is that the piston chamber may further include a vent port.
• In an additional aspect, one or more of the foregoing advantages is achieved by a method of cutting and removing a segment of casing disposed in a well to form an opening in the casing in which the method comprises the steps of: (a) lowering a casing cutting tool into a bore of a casing; (b) cutting at least one slot in the casing with the casing cutting tool to define a segment of casing to be removed; (c) with the casing cutting tool, forcing outward at least two portions of the casing adjacent the slot, thereby freeing the segment from the casing; then (d) removing the segment, thereby leaving an opening in the casing.
• A further feature of the method is that the method may further comprise the step of: (e) raising the casing cutting tool with the segment of the casing from the bore of the casing. Another feature of the method is that step (c) may be performed by applying downward pressure on a piston disposed within casing cutting tool causing the piston to move downward, the downward movement of the piston causing at least two expansion members to move radially outward to engage each of the at least two portions of the casing adjacent the slots to force outward each of the at least two portions of the casing against the slot. An additional feature of the method is that the downward pressure may be created by fluid pumped into a bore within casing cutting tool, the bore being in fluid communication with the piston. Still another feature of the method is that step (d) may be performed by actuating an actuating member to move a magnet radially outward to engage the segment o the casing and withdraw the segment of casing into the bore of the casing.
BRIEF DESCRIPTION OF DRAWINGS
• FIG. 1 is a partial cross-sectional view of one specific embodiment of a casing cutting and recovery tool, or system, of the present invention shown in its run-in position.
• FIG. 2 is an elevational perspective view of the exterior of wellbore casing showing primary longitudinal and primary latitudinal cuts made in the wellbore casing by the casing cutting and recovery tool shown inFIG. 1.
• FIG. 3 is a cross-sectional view of the wellbore casing shown inFIG. 2 taken along line3-3.
• FIG. 4 is an elevational view of the exterior of the wellbore casing ofFIGS. 2-3 showing the expanded casing portions formed by the casing cutting and recovery tool shown inFIG. 1.
• FIG. 5 is a cross-sectional view of the wellbore casing shown inFIG. 4 taken along line5-5.
• FIG. 6 is an elevational view of the exterior of the wellbore casing ofFIGS. 2-5 showing secondary cuts made in the wellbore casing by the casing cutting and recovery tool shown inFIG. 1.
• FIG. 7 is a cross-sectional view of the wellbore casing shown inFIG. 6, taken along line7-7.
• FIG. 8 is cross-sectional view of the casing cutting and recovery tool shown inFIG. 1 disposed within the wellbore casing shown inFIGS. 2-7 showing the expanded casing portions formed by the casing cutting and recovery tool shown inFIG. 1 and showing the section of the wellbore casing to be engaged by the recovery assembly of the casing cutting and recovery tool shown inFIG. 1.
• FIG. 9 is cross-sectional view of the casing cutting and recovery tool shown inFIG. 1 disposed within the wellbore casing shown inFIGS. 2-7 showing the section of the wellbore casing engaged by the recovery assembly of the casing cutting and recovery tool shown inFIG. 1.
• FIG. 10 is cross-sectional view of the casing cutting and recovery tool shown inFIG. 1 disposed within the wellbore casing shown inFIGS. 2-7 showing the section of the wellbore casing engaged and withdrawn into the bore of the wellbore casing by the recovery assembly of the casing cutting and recovery tool shown inFIG. 1.
• FIG. 11 is an elevational view of the exterior of the wellbore casing shown inFIGS. 2-7 showing the window made in the wellbore casing by the casing cutting and recovery tool shown inFIG. 1.
• FIG. 12 is a cross-sectional view of the wellbore casing shown inFIG. 11 taken along line11-11.
• While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
• Referring now toFIGS. 1-12, casing cutting andrecovery tool10, ortool10 ordownhlole tool10, comprisesupper end12,lower end14 andhousing16.Upper end12 andlower end14 both includethreads18 for securingtool10 to a casing, drill pipe, tubing string, or wireline (not shown) or other downhole tools (not shown).Housing16 includes housing bore20 longitudinally disposed at least partially throughhousing16 andouter wall surface22.
• Tool10 includes at least one cuttingassembly21. In the embodiment shown inFIG. 1, Cuttingassembly21 includeslinear charges24,26,28,30,32,34 disposed along a radial arc ofouter wall surface22. Linear charges are known in the art and may be obtained from Accurate Arms Company, Inc. located in McEwen, Tenn. Briefly,linear charges24,26,28,30,32,34 are shaped explosive devices having a substantially V or U cross-section. When detonated, the explosive force is expelled out of an opening along the top of the V or U cross-section so that the explosive force is directed in a desired direction. As shown inFIG. 1,linear charges24,26,28,30,32,34 are arranged in such a way that there is a left upper horizontallinear charge24, a left verticallinear charge26, a left lower horizontallinear charge28, a right upper horizontallinear charge30, a right verticallinear charge32, and a right lower horizontallinear charge34. It is to be understood, however, that a single linear charge may be shaped to have the same arrangement as shown inFIG. 1. Preferably, eachlinear charge24,26,28,30,32,34 is disposed alongouter wall surface22 such that the tops of eachlinear charge24,26,28,30,32,34 are flush withouter wall surface22. In other embodiments (not shown), cuttingassembly21 include devices for abrasive jetting, milling, electronic discharge machining, chemical jetting or erosion, flame cutting, broaching, scarring, wheel cutting, perforating, slotting, or other device, or using any method, known to persons skilled in the art. Further,linear charges24,26,28,30,32,34 do not have to provide straight cuts or parallel cuts. Instead,linear charges24,26,28,30,32,34 can be arranged to cut one or more arcuate shaped cuts, including circular shaped cuts.
• Housing16 also includespiston chamber36 disposed withinhousing16. In the embodiment shown inFIG. 1,piston chamber36 is disposed belowlinear charges24,26,28,30,32,34.Piston chamber36 includes vent port38 andpiston40 slidingly engaged withinpiston chamber36. In a preferred embodiment, hydraulic fluid is disposed withinpiston chamber36 and vent port38 includes a plug (not shown) for maintaining the hydraulic fluid withinpiston chamber36 during run. The plug is easily dislodged from vent port38 during operation of piston40 (discussed in greater detail below).Piston40 includes piston seals42,piston rod43, and piston bore44 extending throughpiston rod43 andpiston40. Vent port38 is always below piston seals42.Spring46 acts to forcepiston40 in the upward direction (arrow47). In other words,piston40 is upwardly biased.Piston rod43 can also includefastener hole48 through its side wall for receiving a fastener (not shown) such as a screw (not shown).
• The lower end ofpiston rod43 is secured by a fastener (not shown) to drivewedge50 by inserting the lower end ofpiston rod43 intoupper bore portion52 of wedge bore54 ofdrive wedge50. Alternatively, drivewedge50 andpiston rod43 can be a single component. Wedge bore54 includeslower bore portion56 that has a smaller inner diameter compared to the inner diameter ofupper bore portion52.
• Drivewedge50 has a conical shape with the narrow end at the bottom ofdrive wedge50. The outer surface ofdrive wedge50 is in sliding engagement with expansion assembly60. As illustrated inFIG. 1, expansion assembly60 includesexpansion assembly housing62. In one specific embodiment, the outer surface ofdrive wedge50 has lands and grooves (not shown) andexpansion assembly housing62 has reciprocal lands and grooves (not shown) so that upward and downward movement ofwedge driver50 pushes or pullsexpansion assembly housing62 through the connecting lands and grooves.
• Expansion assembly housing62 includes expansionassembly housing chamber64 for receivingdrive wedge50. Expansion assembly60 also includes at least two expansion members shown inFIG. 1 asexpansion rollers66. In this arrangement, asdrive wedge50 moves downward, in the direction ofarrow51,expansion assembly housing62 is forced outward radially, in the direction ofarrows68,69, so thatexpansion rollers66 engage the wellbore casing to bend or force “open” the wellbore casing as discussed in greater detail below.Ball seat70 is disposed within wedgeupper bore portion52.Ball seat70 includesball72 that initially blocks the downward flow of fluid through piston bore44. As discussed in greater detail below, afterpiston40 has been forced downward (arrow51) to radially expandexpansion rollers66,ball release74 having stem75 andhead76 engagesball72 andforces ball72 off ofball seat70 so that fluid is permitted to flow downward through piston bore44 and into expansionassembly housing chamber64. As a result, drivewedge50 can be forced upward, in the direction of arrow47, so that eachexpansion rollers66 can be retracted intohousing16 of tool10 (discussed in greater detail below). In a preferred embodiment,head76 is disposed withinchamber78 ofhousing16 such thathead76 can move slightly withinchamber78.
• Disposed below expansion assembly60 isrecovery assembly80.Recovery assembly80 includeshousing82 that is operatively associated with a source of movement, i.e., an actuating member of device such as a motor or a solenoid85 (FIGS. 8-10). The outer surface ofhousing82 includesmagnet84. In this specific embodiment, outer surface ofhousing82 also includes a second cutting assembly made up of upper horizontallinear charge86 and lower horizontallinear charge88.Housing82 is radially moveable relative tohousing16 bysolenoid85. Althoughhousing82 is shown as being flush withouter wall surface22 ofhousing16, it is to be understood thathousing82 may be slightly recessed withinhousing16 during the period of time thatrecovery assembly80 is not in use, i.e., during run-in of thetool10 or during operation ofCutting assembly21 or expansion assembly60.
• Referring now toFIGS. 2-12, in operation,tool10 is lowered throughwellbore casing90 by a work string (not shown) to the desired location where a window is to be cut inwellbore casing90. Wellbore casing has casing bore91 defined by innercasing wall surface92 and casingouter wall surface93. Once properly located withinwellbore casing90,linear charges24,26,28,30,32,34 are initiated using known devices and techniques, such as detonator and prima cord activated electronically from the surface of the well. In the embodiment shown inFIGS. 2-12, the explosive force fromlinear charges24,26,28,30,32,34 creates primarylongitudinal cuts95,98 and primaryhorizontal cuts94,96,97,99 in wellbore casing90 (FIGS. 2-3).
• Thereafter,tool100 is raised up inwellbore casing90 untilrollers66 of expansion assembly60 are disposed on theinner wall surface92 ofwellbore casing90 parallel to primarylongitudinal cuts95,98 and in between primaryhorizontal cuts94,96,97,99. Referring toFIG. 1, fluid (not shown), such as wellbore fluid or hydraulic fluid, is then pumped down the work string and into housing bore20 to actuatepiston40. Once actuated,piston40 is forced downward in the direction ofarrow51 causingdrive wedge50 to radially expandexpansion assembly housing62 and, thus,expansion rollers66 outwards in the direction ofarrows68,69. In so doing, the plug is forced out of vent port38 causingpiston chamber36 to be in fluid communication with the wellbore. Thus, the hydraulic fluid withinpiston chamber36 is forced out ofpiston chamber36 allowingpiston40 to move downward. Further, the pressure withinpiston chamber36 is hydrostatic pressure.
• Piston40 is forced downward untilball release74 engagesball72 and removesball72 fromball seat70. As a result, fluid being pumped down work string and housing bore20 is permitted to flow through piston bore44 and wedge bore54 alongsideball release74 and into expansionassembly housing chamber64. Fluid is continued to be pumped resulting in pressure equilibrium being established above and belowpiston40, i.e., within housing bore20,piston chamber36, and expansionassembly housing chamber64. Due to the equilibrium established in these spaces,expansion rollers66 remain extended to contactinner wall surface92 ofwellbore casing90 and force outward two portions ofwellbore casing90, referred to herein as expandedcasing portions100,102 (FIG. 5).Tool10 is then either raised or lowered as appropriate so thatexpansion rollers66 move along the entire longitudinal length of primarylongitudinal cuts95,98 in between primaryhorizontal cuts94,96,97,99. As a result,longitudinal openings101,103 are formed in wellbore casing90 (FIGS. 4-5).
• Afterlongitudinal openings101,103 are formed,expansion rollers66 are retracted intohousing16 by decreasing or eliminating the pumping of fluid down housing bore20 (FIG. 1). The reduced or elimination of pumping pressure down housing bore20 allowsspring46 to forcepiston40 upward in the direction of arrow47. Aspiston40 moves upwards in the direction of arrow47, fluid withinexpansion assembly chamber64 flows upwardspast ball seat70, through piston bore44, and through housing bore20. Also, wellbore fluid (not shown) flows intopiston chamber36 through vent port38. The flow of fluid flows upwardspast ball seat70, through piston bore44, and through housing bore20 and/or through vent port38 can also assist in the movement ofpiston40 upward. Aspiston40 moves upwards (arrow47),drive wedge50 also moves upwardly causingexpansion assembly housing62 and, thus,expansion rollers66 to retract intohousing16.
• Tool10 is then raised further upwellbore casing90 untilmagnet assembly80 is disposed between primarylongitudinal cuts95,98 and in between primaryhorizontal cuts94,96,97,99. A top cross-sectional view of the location oftool10 at this stage of operation is shown inFIG. 8.Tool10 may include verification tools to ensure thattool10 is properly located and expandedcasing portions100,102 are properly formed. The verification tools can include one or more video, acoustic, ultrasonic, or tactile system known in the art that can easily be adapted for these functions. If expandedcasing portions100,102 are not in their correct position,tool10 can be repositioned so that expansion assembly60 can be re-engaged to expand expandedcasing portions100,102.
• The second cutting assembly,linear charges86,88 inFIG. 1, is initiated using known devices and techniques, such as prima cord activated electronically from the surface of the well. The explosive force fromlinear charges86,88 creates secondaryhorizontal cuts112,114 in wellbore casing90 (FIG. 6). In a preferred embodiment, motor orsolenoid85 radially movesmagnet housing82 outward in the direction ofarrow130 untilmagnet84 andlinear charges86,88 contact casing inner wall surface92 (FIG. 9). It is to be understood, however, thatlinear charges86,88 do not have to be in contact withinner wall surface92. It is also to be understood thatmagnet84 does not have to be in contact withinner wall surface92 at the timelinear charges86,88 or activated.
• It is also to be understood that a second cutting assembly such aslinear charges86,88 is not required. For example, in embodiments in which cuttingassembly21 is capable of abrasive jetting, milling, electronic discharge machining, chemical jetting or erosion, flame cutting, or wheel cutting, second cutting assembly is not needed because cuttingassembly21 can be used to make secondaryhorizontal cuts112,114. Therefore, in these embodiments, asingle cutting assembly21 can be part oftool10.
• After secondaryhorizontal cuts112,114,wellbore casing section110 is now removable from the remainder ofwellbore casing90. Ifmagnet84 is not already in contact withwellbore casing section110,magnet84 is moved into contact withwellbore casing section110 by motor/solenoid85. Motor/solenoid85 may be activated through any device or method known in the art such as through electronic activation from the surface.
• Wellbore casing section110, secured bymagnet84 is then moved into wellbore casing bore91 by moving motor/solenoid85 in the direction ofarrow132.Tool10 andwellbore casing section110 can then be raised up wellbore casing bore91 by the work string, thereby leavingwellbore casing90 with window120 (FIGS. 11-12).
• Tool10 provides the advantages of creating a smoothwalled window120 inwellbore casing90. Thus, potential damage to other downhole tools, components and strings is lessened becausewindow120 includes few, if any, jagged cuts and sharp edges. Additionally, the possibility of being able to resealwindow120 is raised because there are less irregularly shaped spaces that need to be filled or covered. Further,tool10 lessens the amount of debris that may be left in the wellbore or that needs to be recovered using recovery fluids or recovery tools. Moreover,tool10permits window120 to be cut and removed using a single tool making a single downhole run. Thus, cost savings are achieved usingtool10.
• Further, additional components, such as a measurement while drilling component, flow sub, J & shear joint, bottom trip anchor, and/or whipstock may be secured tolower end14 to facilitate placement or operation oftool10 or to allow additional components, such as a whipstock, to be placed within wellbore as part of the operation oftool10 during its single trip downhole.
• It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. For example,piston40 may be actuated using any method or device known to persons of ordinary skill in the art. Additionally, one or morelinear charges24,26,28,30,32,34 may be disposed alongouter wall surface22 ofhousing16 such that the outer surfaces oflinear charges24,26,28,30,32,34 are either recessed intohousing16 or protrude outside ofouter wall surface22. Further, upper horizontallinear charge86 and lower horizontallinear charge88 are not required to be disposed on outer surface ofmagnet housing82. In other words, upper horizontallinear charge86 and lower horizontallinear charge88 are not required to be moveable radially. Instead, upper horizontallinear charge86 and lower horizontallinear charge88 may be disposed onouter wall surface22 ofhousing16. Moreover, the primary and secondary cuts may be formed using abrasive jetting, milling, electronic discharge machining, chemical jetting or erosion, flame cutting, perforating, slotting, broaching, scarring, wheel cutting, or using any other device or method known to persons skilled in the art. Further, a single cutting assembly may be included as part oftool10 to provide all of the primary and secondary cuts. Additionally, the expansion members may be inflatable components shaped to correspond to expandedcasing portions100,102 that can be inflated to force expandedcasing portions100,102 outwardly. Alternatively, the expansion member may be swage having a ramp profile. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.

Claims (20)

1. An apparatus for forming an opening in casing in a well, the apparatus comprising:

a cutting assembly for lowering into a casing of a well, the cutting assembly having at least one cutting member for cutting at least one slot in the casing to define a segment for removal;

a deforming member carried with the cutting assembly, the deforming member being selectively actuated from a surface of the well for deforming outward at least two portions of the casing adjacent the slot; and

a recovery assembly carried with the cutting assembly for engaging and removing the segment from the casing.

2. The apparatus ofclaim 1, wherein the cutting assembly is disposed above the deforming member.

3. The apparatus ofclaim 2, wherein the deforming member is disposed above the recovery assembly.

4. The apparatus ofclaim 1, wherein the deforming member comprises at least two rollers.

5. The apparatus ofclaim 1, further comprising a secondary cutting assembly, wherein the cutting assembly and the secondary cutting assembly each include at least two linear charges.

6. The apparatus ofclaim 1, wherein the recovery assembly includes a magnet and an actuating member for moving the magnet radially outward to engage and remove the segment from the casing.

7. The apparatus ofclaim 1, wherein the deforming member is operatively associated with a piston disposed within a piston chamber, a lower portion of the piston being operatively associated with a conically shaped deforming member housing.

8. The apparatus ofclaim 7, wherein the lower portion of the piston includes a conically shaped drive wedge, the drive wedge being slidingly engaged with the conically shaped deforming member housing.

9. The apparatus ofclaim 8, wherein the piston and drive wedge include a bore, the bore having disposed therein a ball seat, a ball, and a ball release.

10. The apparatus ofclaim 9, wherein the piston chamber includes hydraulic fluid.

11. The apparatus ofclaim 10, wherein the piston chamber further includes a vent port.

12. An apparatus for forming an opening in casing in a well, the apparatus comprising:

a cutting assembly for lowering into a casing of a well, the cutting assembly having at least one linear shaped charge for cutting at least one slot in the casing to define a segment for removal;

a piston movable by high pressure against a wedge member to radially expand a deforming member carried with the cutting assembly, the deforming member being selectively actuated by the piston for deforming outward at least two portions of the casing adjacent the slot; and

a recovery assembly carried with the cutting assembly for engaging and removing the segment from the casing, the recovery assembly having a radially moveable magnet.

13. The apparatus ofclaim 12, wherein the piston and wedge member each include a bore, the bore having disposed therein a ball seat, a ball, and a ball release.

14. The apparatus ofclaim 13, wherein the piston is disposed within a piston chamber having an upwardly biased spring and hydraulic fluid.

15. The apparatus ofclaim 14, wherein the piston chamber further includes a vent port.

16. A method of cutting and removing a segment of casing disposed in a well to form an opening in the casing, the method comprising the steps of:

(a) lowering a casing cutting tool into a bore of a casing;

(b) cutting at least one slot in the casing with the casing cutting tool to define a segment of casing to be removed;

(c) with the casing cutting tool, forcing outward at least two portions of the casing adjacent the slot, thereby freeing the segment from the casing; then

(d) removing the segment, thereby leaving an opening in the casing.

17. The method ofclaim 16, further comprising the step of:

(e) raising the casing cutting tool with the segment of the casing from the bore of the casing.

18. The method ofclaim 16, wherein step (c) is performed by applying downward pressure on a piston disposed within casing cutting tool causing the piston to move downward, the downward movement of the piston causing at least two expansion members to move radially outward to engage each of the at least two portions of the casing adjacent the slots to force outward each of the at least two portions of the casing against the slot.

19. The method ofclaim 18, wherein the downward pressure is created by fluid pumped into a bore within casing cutting tool, the bore being in fluid communication with the piston.

20. The method ofclaim 20, wherein step (d) is performed by actuating an actuating member to move a magnet radially outward to engage the segment o the casing and withdraw the segment of casing into the bore of the casing.

Images