System, apparatus and method for abrasive jet fluid cutting

Abstract

A system, apparatus and method for abrasive jet fluid cutting. An abrasive jet fluid cutting nozzle assembly comprises a hose 49 for receiving an abrasive jet cutting fluid; a helix/spring 40 rotatably attached inside the high pressure hose 49 ; and a nozzle 46 connected to the hose 49 . The helix/spring 40 is tapered such that the turn ratio of the helix 40 varies from the proximate end to the distal end. The rotation of the helix 40 creates a vortex and increases the pressure of an abrasive jet cutting fluid as it passes from the proximate end to the distal end. The disclosed subject matter further includes a system and method for using the abrasive jet fluid cutting nozzle assembly.

1 . Apparatus for cutting shape or window profile(s) through casing, cement and formation rock using abrasive-jet-fluid flowing through a jet-nozzle, the apparatus comprising:
 profile generation system which simultaneously directs the movements of a jetting-shoe in a vertical axis and 360 degree horizontal rotary axis via servo drives to allow cutting at least one of a casing, cement or formation rock, in any programmed shape or window profile(s);   coiled fluid tubing for delivering a coherent high pressure abrasive-jet-fluid through a single tube;   a helix rotatably attached inside said tube, said helix tapered such that the turn ratio of the helix varies from the proximate end to the distal end, wherein the rotation of said helix creates a vortex and increases the pressure of said abrasive-jet-fluid as it passes from the proximate end to the distal end;   a jet-nozzle for ejecting an abrasive-jet-fluid under high pressure from a jetting-shoe;   a jetting-shoe unit, the jetting-shoe unit is coupled to the jetting-shoe and is capable of manipulating the jetting-shoe via simultaneous movements in a vertical axis and 360 degree horizontal rotary; and   a computer controller, the computer controller capable of:   storing shape or window profile(s) templates for cutting a shape or window profile in at least one of a casing;   accepting user input to program new shape or window profile(s) based on user criteria;   controlling the profile generation servo drive systems;   controlling an abrasive mixture percent to total fluid volume;   controlling the pressure and flow rates of the high pressure pump and drive;   controlling feed and speed of a coiled fluid tubing unit and a coiled tubing injector head;   controlling the simultaneous vertical and horizontal directional movements of the coiled tubing;   scanning the cut shape or window profile(s) after the casing, cement or rock formation has been cut.   
   
   
       2 . The apparatus according to  claim 1 , further comprising a chamber between said helix and said jet-nozzle. 
   
   
       3 . The apparatus according to  claim 1 , wherein the distal end of said jet-nozzle is tapered. 
   
   
       4 . The apparatus according to  claim 3 , wherein the tapering of the distal end of said nozzle is approximately 30 degrees. 
   
   
       5 . The apparatus according to  claim 3 , wherein the tapering of the distal end of said nozzle results in the formation of a void between exiting abrasive jet cutting fluid and said nozzle, allowing for a cutting action that creates an opening in a target of a diameter greater than the cutting fluid diameter exiting said nozzle. 
   
   
       6 . The apparatus according to  claim 1 , wherein the coiled fluid tubing is inserted into an inner bore of a drill or tubing string. 
   
   
       7 . The apparatus according to  claim 1 , wherein the coiled fluid-tube transitions from a vertical to horizontal orientation inside of the jetting-shoe, to direct a high pressure, high velocity, abrasive-jet-fluid from a jet-nozzle that is attached to the end of the said fluid-tube. 
   
   
       8 . The apparatus according to  claim 1 , wherein the jetting-shoe has a battery operated sonic transmitter that is activated by a magnetic proximity switch in the jetting-shoe. 
   
   
       9 . The apparatus according to  claim 1 , wherein the coherent abrasive-jet-fluid is comprised of a fluid pumped under high pressure between a range of 5,000 PSI to 40,000 PSI, through a single coiled fluid tube to the jet-nozzle, wherein the fluid contains an abrasive material. 
   
   
       10 . The apparatus according to  claim 1 , wherein the profile generation system further includes a 360-degree rotator, a jack and a two-axis user programmable computer controlled system, servomotors and servo drives. 
   
   
       11 . A down hole jet-fluid cutting apparatus, the apparatus comprising:
 a jet-fluid nozzle;   a high pressure pump, wherein the high pressure pump is capable of delivering a fluid abrasive mixture at high pressure to the jet-fluid nozzle;   an abrasive fluid mixing unit, wherein the abrasive fluid mixing unit is capable of maintaining a coherent abrasive fluid mixture;   a flexible tubing for delivering the coherent high pressure jet-fluid abrasive mixture to the jet-fluid nozzle;   a helix rotatably attached inside said flexible tubing, said helix tapered such that the turn ratio of the helix varies from the proximate end to the distal end, wherein the rotation of said helix creates a vortex and increases the pressure of said high pressure jet-fluid abrasive mixture as it passes from the proximate end to the distal end;   a jet-fluid nozzle jetting shoe, wherein the jetting shoe is adapted to receive the jet-fluid nozzle and flexible tubing and direct the coherent high pressure jet fluid abrasive mixture towards a work piece;   a flexible tubing controlling unit, wherein the controlling unit further includes at least one servomotor for manipulating the flexible tubing in a vertical and horizontal direction;   a jetting shoe controlling unit, wherein the jetting shoe controlling unit further includes at least one servomotor for manipulating the jetting shoe along a vertical and horizontal axis; and   a central processing unit, wherein the central processing unit includes:   a memory unit, wherein the memory unit is capable of storing profile generation data for cutting a predefined shape or window profile in the work piece;   software, wherein the software is capable of directing the central processing unit to perform the steps of:   controlling the jetting shoe control unit to manipulate the jetting shoe along the vertical and horizontal axis to cut a predefined shape or window profile in the work piece;   controlling the flexible tubing control unit to manipulate speed feed and the vertical and horizontal axial movement of the flexible tubing to cut a predefined shape or window profile in the work piece;   controlling percentage of the abrasive fluid mixture to total fluid volume; and   controlling pressure and flow rates of the high pressure pump.   
   
   
       12 . The apparatus according to  claim 11 , further comprising a chamber between said helix and said jet-fluid nozzle. 
   
   
       13 . The apparatus according to  claim 11 , wherein the distal end of said jet-fluid nozzle is tapered. 
   
   
       14 . The apparatus according to  claim 13 , wherein the tapering of the distal end of said jet-fluid nozzle is approximately 30 degrees. 
   
   
       15 . The apparatus according to  claim 13 , wherein the tapering of the distal end of said jet-fluid nozzle results in the formation of a void between exiting abrasive jet cutting fluid and said nozzle, allowing for a cutting action that creates an opening in a target of a diameter greater than the cutting fluid diameter exiting said nozzle. 
   
   
       16 . The down hole jet-fluid cutting apparatus of  claim 11 , wherein the jetting shoe is manipulated in a vertical axis and a 360 degree radius of the horizontal axis. 
   
   
       17 . The down hole jet-fluid cutting apparatus of  claim 11 , wherein the flexible fluid tube transitions from a vertical to a horizontal orientation when disposed within the jetting-shoe. 
   
   
       18 . The down hole jet-fluid cutting apparatus of  claim 11 , wherein the jet-nozzle is disposed approximately perpendicularly with the work piece when disposed within the jetting-shoe. 
   
   
       19 . The down hole jet-fluid cutting apparatus of  claim 11 , wherein a sonic transmitter is disposed within the jetting-shoe and when activated by a magnetic proximity switch transmits telemetry to the central processing unit. 
   
   
       20 . A method to cut user programmable shapes or window profile(s) through down hole casing, cement, and formation rock using abrasive-jet-fluid flowing from a jet-nozzle, the method comprising the steps of:
 inserting an electric line unit and bottom trip anchor annulus an electric line operated top keyed in an annulus a predetermined depth below a bottom elevation depth where a shape or window profile(s) are to be cut and anchoring the bottom trip anchor to said casing;   removing the electric line unit;   inserting into the annulus an electrical line operated directional gyro, wherein the directional gyro is seated onto the bottom trip anchor and obtains directional references of the position of the bottom trip anchor; and   removing the gyro from the annulus and inputting into a computer control unit the directional references of the bottom trip anchor.   connecting a profile generation system onto a well head or a blow out preventor stack and connecting the computer controller unit to axis drive servos;   inserting a jetting-shoe and a tubing string into the annulus of the casing to a level in the annulus, where the user programmable shape or window profile(s) is to be abrasive-jet-fluid cut through the casing and cement to expose formation rock;   attaching rotating centralizers on an outside diameter of the tubing string to keep the tubing string centered in the annulus;   feeding the jetting-shoe onto the top keyed bottom trip anchor, if a specific rotational direction is required, so that the jetting-shoe rotational direction and depth are established, and inputting into the computer control unit the established rotational direction and depth of the jetting-shoe;   lifting the tubing string sufficiently to allow setting air and/or slips around the tubing string in the tubing rotator, to suspend and hold the tubing string, allowing the shape or window profile generation system to be able to simultaneously move the vertical axis and 360 degree horizontal rotary axis of the tubing string under computer program control, after removing the jetting-shoe from the bottom trip anchor;   inserting a fluid-tube, wherein the fluid tube is fed from a coiled tubing unit and tubing injector head, into the bore of a tubing string, wherein the tubing string is suspended by a rotator and jack of the profile generation system, such that a jet-nozzle attached to an end of the fluid-tube is fed through the jetting-shoe to face the inner surface of said casing, a helix rotatably attached inside said fluid-tube, said helix tapered such that the turn ratio of the helix varies from the proximate end to the distal end, wherein the rotation of said helix creates a vortex and increases the pressure of said high pressure jet-fluid abrasive mixture as it passes from the proximate end to the distal end;   starting an operational cycle of the computer control unit, wherein the computer control unit performs the steps of:   positioning a jetting-shoe and jet-nozzle into a proper location for cutting the user programmable shapes or window profile(s);   turning on the high pressure pump;   driving a two-axis programmable computer servo controller unit at to generate the user programmable shape or window profile(s) cuts through said casing or through a plurality of metal casings;   controlling the coiled tube unit and a feed speed of the tubing injector and depth location of the jet-nozzle attached to the end of the fluid-tube;   measuring co-ordinates of the cut shapes or window profile(s), by scanning with a magnetic proximity switch disposed on the jetting-shoe such that it faces the inner surface of the annulus, as the jetting shoe is vertically and horizontally manipulated by the profile generation system; and   sensing the casing in place or the absence of the casing by a magnetic proximity switch, which then activates a battery operated sonic transmitter mounted in the jetting-shoe and, wherein the sonic generator transmits a signal to a surface receiver coupled to the computer control unit for comparison to the user programmed shape or window profile(s).