FIELD OF INVENTION

The present invention relates to a method for manufacturing a downhole system, such as downhole catching apparatus, and to an apparatus for carrying out said method.

BACKGROUND TO INVENTION

In the oil and gas industry many downhole operations rely on objects dropped from surface to be caught at some point along a downhole system to perform a desired function, such as mechanical actuation, flow diversion or the like. For example, International Applications Publication Nos. WO 2011/117601 and WO 2011/117602 each disclose downhole apparatus which catch objects for use in actuation of a downhole tool and flow diversion within the tool, for example for use in fracturing operations.

To catch an object, a catching apparatus typically defines a restriction along the associated flow path. However, it is undesirable to permanently create a restriction, as this restriction in the flowpath may cause detrimental effects to the operation of the wellbore. As such, a significant challenge in the industry has been to develop a catching apparatus which can establish the necessary restriction on a temporary basis.

A collet-type catching apparatus is known which includes a number of collet fingers each carrying a collet or seat member. The collet fingers are capable of being deflected radially to move the collet members between radially extended (outwards) and retracted (inwards) configurations. When radially retracted the collet members create a restriction and permit an object to be caught.

The catching apparatus may be installed in the downhole system with its collet members in a radially extended (outwards) configuration. In use, when actuation of a tool is required, the catching apparatus is actuated, e.g. by longitudinal movement relative to a sleeve, such that the collet members move into a retracted (inwards) configuration.

To provide the catching apparatus having collet members in a radially extended (outwards) configuration, the collet members are typically provided in a plastically deformed state. That is, during manufacture of the catching apparatus, the collets are plastically deformed outwardly to force them in the extended configuration, ready to be deployed in a downhole system.

In use, depending on the position of each catching device in a series of catching devices along the wellbore, many of the catching devices may be subjected to the passage of a large number of actuating objects, e.g. balls, before being deployed into their retracted (catching) configuration. The actuating objects typically travel at high velocity, carrying high momentum and energy. As they travel down the wellbore, the actuating objects will cause high impact collisions with the various parts of the downhole system. Therefore, the passage of each actuating object may cause high energy impacts or shocks on the extended collet members of the catching apparatus.

It has been observed that repeated shocks caused by the actuating objects on the collet members tend to cause the collet members to progressively move inwards, e.g. towards their retracted pre-deformed configuration. This is undesirable for several reasons. Firstly, if the collet members move inwards into the flow path of a fluid pumped into the wellbore, the collet members are directly exposed to the fluid flow path, and are therefore more likely to suffer from premature erosion. This is particularly true when the injected fluid is an abrasive fluid, for example a fracturing fluid comprising solid proppant particles. This may cause the collet members to lose their required sealing ability when actuated into their retracted configuration.

Secondly, as the collet members move inwards into the flow path, the passage of each actuating object causes an increasingly higher impact on the collet fingers, thus exacerbating this adverse effect. Frictional collision of the collet members with the actuating objects may also cause further undesirable erosion, both of the collet members and of the actuating object.

SUMMARY OF INVENTION

According to a first aspect of the present invention there is provided a method for or of manufacturing a metal structure for use in a downhole assembly, the method comprising:

deforming at least a portion of the metal structure; and

heating at least the deformed portion of the metal structure to a temperature below its critical and/or transformation temperature.

The metal structure may comprise a downhole apparatus.

The metal structure may comprise a catching apparatus. The catching apparatus may be configured to catch an object, e.g. an actuating object, such as a ball, dart, plug, tool or the like.

The catching apparatus may be for use in catching an object passing along any flow path, such as in a pipeline environment, downhole environment or the like.

The catching apparatus may be configured to catch an object travelling in a downhole environment, for example travelling through a tubular structure positioned within a wellbore, such as a tubing string, completion string, tool string, production string, injection string, fracturing string or the like. The catching apparatus may be configured to be located within a tubular structure. For example, the catching apparatus may be configured to be mounted within a housing of a downhole tool.

The catching apparatus may comprise a plurality of radially moveable seat members arranged circumferentially around a longitudinal axis.

The catching apparatus may define a catching sleeve. In such an arrangement the apparatus may be provided in the form of a sleeve.

The catching apparatus may be configured to function as a flow diverter when an object is caught.

The catching apparatus may be configured to function as an actuator when an object is caught. For example, the catching apparatus may be configured to actuate another component, structure, apparatus, tool or the like. For example, when an object is caught by the catching apparatus, the object may facilitate movement of the catching apparatus, for example by impact of the object against the apparatus, by a pressure differential established across the object/catching apparatus, or the like.

The catching apparatus may be provided in combination with a j-slot actuator arrangement.

The catching apparatus may be configured to function as a bore plug when an object is caught, for example to isolate a region within a tubing structure. Such an arrangement may facilitate pressure to be controlled, for example elevated, in a section of a tubing structure. Such an arrangement may facilitate pressure actuation of a further component, structure, apparatus, tool or the like, such as packers, slips, rupture disks and the like.

The catching apparatus may be configured to function as a flow restrictor when an object is caught. For example, the catching apparatus may be configured to function as a choke.

The catching apparatus may be configured for use within a fracturing system or operation. For example, the catching apparatus may be configured to actuate or open one or more fracturing valves to permit a fracturing fluid to be delivered into a surrounding formation. Alternatively, or additionally, the catching apparatus may be configured to function as a flow diverter when an object is caught to divert flow of fracturing fluid outwardly through opened ports and into a surrounding formation.

The seat members may be radially moveable to be radially extended and retracted relative to a central bore of the catching apparatus. That is, the seat members may be moveable radially inwardly to be retracted into the central bore to define a reduced effective inner diameter. The seat members may be moveable radially outwardly to be radially extended from the central bore to define an increased effective inner diameter. When the seat members are positioned radially inwardly and retracted into the central bore said members may be positioned into the path of an object passing through the catching apparatus. When in such a configuration the seat members may be engaged by an object. When the seat members are positioned radially outwardly and extended from the central bore said members may be outside the path of an object passing through the catching apparatus.

The catching apparatus may be configurable from a free configuration in which the seat members permit an object to pass the catching apparatus, to a catching configuration in which the seat members catch an object.

The catching apparatus may be reconfigured to or in its catching configuration by radially supporting the seat members in a radially inward position such that outward radial movement is prevented. In such a configuration an object passing through the catching apparatus may become seated against the radially supported seat members.

The catching apparatus may comprise a cylindrical portion at or near a first end of the catching apparatus.

The catching apparatus may comprise a plurality of radially moveable seat members arranged circumferentially around a longitudinal axis. The plurality of radially moveable seat members may be provided at or near a second end of the catching apparatus.

The catching apparatus may comprise a plurality of fingers which extend, e.g. in a tapering manner, between the cylindrical portion and the seat members.

The fingers and associated seat members may define a plurality of collet fingers.

At least a portion of the metal structure, e.g. the whole metal structure, may comprise steel, and/or any other suitable metal or metal alloy.

The method may comprise plastically deforming at least a portion of the metal structure.

Plastic deformation is understood to result from deformation of a metal beyond its elastic limit or yield point. Unlike elastic deformation, where a material will return to its original shape when the applied stress is removed, plastic deformation involves applying a level of stress beyond the yield point of the material, thereby causing permanent deformation.

In known methods of manufacturing a catching apparatus, plastic deformation forced on to the collet fingers induces some stress into the collet fingers. Without wishing to be bound by theory, it is believed that the inwards movement of the collet fingers resulting from the impacts with the actuating objects dropped into the downhole system, may be due to the energy provided by the shock of the actuating object onto the collet fingers. It is believed that the energy absorbed by the collet fingers may cause some of the residual stress to be relieved, and may cause the collet fingers to move against the direction of deformation and/or towards a pre-deformed configuration.

The present inventors have discovered that, by heating at least the deformed portion of a metal structure, e.g. a catching apparatus, the deformed portion, e.g. collet fingers, may undergo stress relief. This stress relief was observed to reduce the propensity of the deformed portion, e.g. collet fingers, to move against the direction of deformation after impact(s) and/or shock(s) from moving objects, in use.

The method may comprise providing or arranging the metal structure onto a production fixture. The method may comprise sliding the metal structure onto the production fixture. The production fixture may comprise a mandrel.

The production fixture may define a substantially cylindrical outer surface.

The production fixture may define a tapered profile, e.g. may define a substantially conical or frusto-conical outer surface.

The method may comprise forcing the metal structure onto the production fixture. The method may comprise deforming, e.g. plastically deforming, at least a portion of the metal structure by forcing the metal structure onto the production fixture.

The method may comprise deforming, e.g. plastically deforming, at least a portion of the metal structure by using a suitable tool, e.g. an articulated arm, pliers, lever, or the like.

The method may comprise securing the metal structure to the production fixture.

The method may comprise securing the metal structure to the production fixture by use of a fixing mechanism or arrangement such as screws, clamps, or the like.

The method may comprise securing the metal structure to the production fixture by use of a housing. The housing may be configured to contact and/or restrict movement of the metal structure, e.g. on the production fixture. In one embodiment, the shape of the housing may be substantially complementary to the shape of the metal structure, and/or the housing may be shaped to substantially contact at least a portion of an outer surface of the metal structure.

The method may comprise securing the housing to the production fixture, e.g. by use of a fixing mechanism or arrangement such as screws, clamps, or the like. By such provision, the metal structure may be securely positioned between the production fixture and the housing. The fixing mechanism or arrangement may form part of the housing and/or of the production fixture.

The production fixture, housing, and/or fixing mechanism or arrangement may be configured to be heated, e.g. may be made from a material, such as metal, suitable to withstand a temperature below and/or up to the critical and/or transformation temperature of the metal structure.

The method may comprise heating at least the deformed portion of the metal structure to a temperature below its critical and/or transformation temperature, e.g. below its lower critical and/or transformation temperature. The critical and/or transformation temperature may be defined as the temperature at which the metal may undergo molecular changes affecting its crystallinity, and/or the temperature at which the crystalline structure of the metal is modified. By heating at least the deformed portion of the metal structure to a temperature below its critical and/or transformation temperature, the metal structure may undergo stress relief, which may help prevent undesirable movement of the deformed portion, e.g. collet fingers, against the direction of deformation after impact(s) and/or shock(s) from moving objects, in use. Further, by maintaining temperature below the critical and/or transformation temperature, e.g. below the lower critical and/or transformation temperature, of the metal, the method may not significantly affect the crystallinity or structural integrity and/or properties of the material.

The method may comprise heating at least the deformed portion of the metal structure to a temperature in the range of 10-100Â° C., e.g. 20-90Â° C., e.g. 40-80Â° C., below its critical and/or transformation temperature. By such provision the heating temperature may be sufficiently high to relieve stress in a portion of interest, but sufficiently removed from the critical and/or transformation temperature, e.g. the lower critical and/or transformation temperature, to avoid affecting the crystallinity or structural integrity and/or properties of the material, e.g. at a molecular level. In one embodiment, the method may comprise heating at least the deformed portion of the metal structure to a temperature approximately 50Â° C. below its critical and/or transformation temperature, e.g. approximately 50Â° C. below its lower critical and/or transformation temperature.

The method may comprise heating at least the deformed portion of the metal structure to a temperature in the range of 450-580Â° C., e.g. 450-550Â° C., e.g. 500-550Â° C. Such a temperature range may be particularly useful when the metal structure comprises steel.

The method may comprise heating the metal structure at a predetermined temperature, e.g. in a pre-heated environment.

The method may comprise heating the metal structure at a predetermined rate.

The method may comprise the step of heating after the step of deforming.

The method may comprise heating and deforming simultaneously.

The method may comprise heating prior to deforming. In such instance, the method may comprise carrying out deforming while the temperature of at least the deformed portion remains within a range of temperature capable of relieving stress within the metal.

The method may comprise heating at least the deformed portion of the metal structure at a temperature below its critical and/or transformation temperature for a predetermined amount of time. The method may comprise heating the deformed portion for a period of time sufficient to remove a predetermined level of stress in the deformed portion of the metal structure, e.g. at least 25%, at least 50%, at least 75%, or at least 90%. The method may comprise heating the deformed portion at a predetermined temperature for e.g. at least 1 hour, at least 2 hours, at least 4 hours, at least 12 hours, at least 24 hours, at least 48 hours, at least 72 hours, or at least 96 hours.

The method may comprise heating the entire metal structure.

The method may comprise providing the metal structure in a heating apparatus, e.g. a furnace and/or an oven. The method may comprise providing the metal structure in position on the production fixture in the heating apparatus. The method may comprise providing the metal structure, the production fixture, and the housing in the heating apparatus.

The method may comprise cooling at least the deformed portion.

The method may comprise removing the metal structure from the heating apparatus, e.g. furnace and/or oven.

The method may comprise cooling at least the deformed portion at a predetermined temperature, e.g. at ambient temperature.

The method may comprise regulating and/or controlling cooling of at least the deformed portion so as to avoid and/or minimise stress resulting from temperature change. By such provision, the method may at least partially relieve stress in at least the deformed portion from the heating step, without incurring significant stress from the cooling step. This may be performed either in the furnace, or after removal of the metal structure from the furnace.

The method may comprise cooling the metal structure at a predetermined rate.

The method may comprise treating, e.g. surface treating, the metal structure.

The method may comprise coating at least a portion of the metal structure, e.g. with a hardening and/or lubricating coating. The coating may comprise a nitride coating comprising e.g., titanium nitride, silicon nitride, boron nitride, carbon nitride, and the like. The method may comprise coating at least a portion of the metal structure before, during, and/or after the heating step.

The method may comprise hardening at least a portion of the metal structure.

The method may comprise forming a hardened layer of a material, e.g. at or near the surface of at least a portion of the metal structure. In one embodiment, the hardened layer may comprise a nitrogen or nitride compound. The method may comprise nitriding at least a portion of the metal structure.

The method may comprise gas nitriding at least a portion of the metal structure. The method may comprise contacting at least a portion of the metal structure with a nitrogen-containing gas, e.g. ammonia. The method may comprise injecting a nitrogen-containing gas, e.g. ammonia, in the heating apparatus, e.g. furnace and/or oven. Without wishing to be bound by theory, it is understood that, when a nitrogen-containing gas, e.g. ammonia, comes into contact with the heated portion of the metal structure, nitrogen reacts with and diffuses into the surface of the heated portion of the metal structure, to form a nitride layer. It is believed that, when the metal structure comprises steel, the nitrogen-containing gas, e.g. ammonia, may react with the heated portion of the metal structure to form nitride compounds such as iron nitrides. Depending on the type of metal used, e.g. the type of steel employed, the process may comprise forming other nitride compounds such as titanium nitrides, chromium nitrides, molybdenum nitrides and/or aluminium nitrides.

The method may comprise hardening, e.g. nitriding, the entire metal structure. The method may comprise providing the metal structure in a heating apparatus, e.g. a furnace and/or an oven, and injecting a nitrogen-containing gas, e.g. ammonia in the heating apparatus.

The method may comprise hardening, e.g. nitriding, a portion of the metal structure. In one embodiment, the method may comprise providing a portion of the metal structure in a heating apparatus, e.g. a furnace and/or an oven, and injecting a nitrogen-containing gas, e.g. ammonia in the heating apparatus. In another embodiment, the method may comprise protecting, e.g. by masking and/or by providing a protective coating on, a portion of the metal structure, providing the metal structure in a heating apparatus, e.g. a furnace and/or an oven, and injecting a nitrogen-containing gas, e.g. ammonia in the heating apparatus. By such provision, despite placing the entire metal structure in the heating apparatus, the method may comprise hardening only a selected portion of the metal apparatus.

The method may comprise simultaneously heating at least the deformed portion of the metal structure, and hardening at least a portion of the metal structure. The method may comprise heating at least the deformed portion of the metal structure to a temperature in the range of 10-100Â° C., e.g. 20-90Â° C., e.g. 40-80Â° C., below its critical and/or transformation temperature, and injecting a nitrogen-containing gas, e.g. ammonia, in the heating apparatus. By such provision, the method may allow simultaneously relieving stress from at least the deformed portion of the metal structure, and hardening at least a portion of the metal structure. Advantageously, this may allow reducing manufacturing costs by performing in a single step two separate treatments on the metal structure.

The deformed portion of the metal structure, and the portion of the metal structure to be hardened, may be the same or different. In one embodiment, the method may comprise heating and hardening the same portion of the metal structure, e.g. the entire metal structure. In another embodiment, the method may comprise heating the entire metal structure, and hardening only a portion of the metal structure, for example by protecting, e.g. by masking and/or by providing a protective coating on, a portion of the metal structure prior to placing the metal structure in the heating apparatus.

The method may comprise selecting time and/or temperature of the hardening step to provide one or more desired property of the hardened layer. In one embodiment, the hardening step may comprise hardening for a relatively short amount of time at a relatively high temperature. This may provide a relatively thin layer of hardened material, e.g. nitride. In another embodiment, the hardening step may comprise hardening for a relatively long amount of time. This may provide a relatively thick layer of hardened material.

The method may comprise providing a hardened and/or nitride layer having a thickness in the region of approximately 0.012â€³-0.020â€³ (0.3-0.5 mm).

The method may comprise providing a hardened and/or nitride layer having a hardness of at least 550 HV, e.g. between 550 HV10 and 750 HV10. Hardness may be measured in accordance with ASTM E384.

According to a second aspect of the invention there is provided an assembly for manufacturing a metal structure for use in a downhole assembly, the assembly comprising a production fixture configured to receive the metal structure,

wherein the production fixture is adapted to undergo heating to a temperature below the critical and/or transformation temperature of the metal structure.

The assembly may be configured to be placed in a heating apparatus, e.g. a furnace and/or an oven.

The production fixture may be configured to receive the metal structure in a sliding arrangement. The production fixture may comprise a mandrel.

The production fixture may define a substantially cylindrical outer surface.

The production fixture may define a tapered profile, e.g. may define a substantially conical or frusto-conical outer surface.

The assembly may comprise a housing adapted to secure the metal structure to the production fixture.

The housing may be configured to contact and/or restrict movement of the metal structure, e.g. on the production fixture. In one embodiment, the shape of the housing is substantially complementary to the shape of the metal structure, and/or the housing is shaped to substantially contact at least a portion of an outer surface of the metal structure.

The assembly may comprise a fixing arrangement such as screws, clamps, or the like, for securing the housing to the production fixture. By such provision, the metal structure may be securely positioned between the production fixture and the housing. The fixing arrangement may form part of the housing and/or of the production fixture.

The assembly, e.g. production fixture, housing, and/or fixing means, may be configured to be heated, e.g. may be made from a material, such as metal, suitable to withstand a temperature below and/or up to the critical and/or transformation temperature.

The features described above in relation to the method according to a first aspect of the present invention, can apply in respect of the assembly according to a second aspect of the present invention, and are therefore not repeated here for brevity.

According to a third aspect of the present invention there is provided a metal structure for use in a downhole assembly, obtainable by the method according to a first aspect of the present invention.