Downhole tool, method and assembly

Abstract

A tool assembly ( 10 ) comprises a casing section ( 12 ), and a downhole tool ( 14 ) comprising a rotary drive ( 16 ) and a cutting member ( 18 ). In use, the tool assembly ( 10 ) is disposed in a well borehole (B) and the rotary drive ( 16 ) operated to drive rotation of the cutting member ( 18 ) to cut the borehole (B). The downhole tool ( 14 ) comprises a tubular housing ( 20 ) and a cartridge assembly ( 36 ), the cartridge assembly ( 36 ) disposed within the housing ( 20 ) of the downhole tool ( 14 ) and comprising the rotary drive ( 16 ) of the downhole tool ( 14 ). A clutch ( 78 ) is provided to enable free movement of the cutting member ( 18 ) during normal operation, engagement of the clutch ( 78 ) preventing rotation of the cutting member ( 18 ) and the housing ( 20 ).

What is claimed is: 
     
         1 . A downhole tool comprising:
 a housing; and   a cartridge assembly configured for location within the housing, the cartridge assembly comprising a rotary drive of the downhole tool.   
     
     
         2 . The downhole tool of  claim 1 , wherein the cartridge assembly comprises a housing and a shaft, the housing of the cartridge assembly comprises a stator of the rotary drive and the shaft of the cartridge assembly comprises a rotor of the rotary drive. 
     
     
         3 . The downhole tool of  claim 1 , wherein the rotary drive comprises a fluid driven rotary drive. 
     
     
         4 . The downhole tool of  claim 3 , wherein the rotary drive comprises one of: a positive displacement motor; a turbine; an axial flow reaction turbine. 
     
     
         5 . The downhole tool of  claim 2 , wherein the housing of the cartridge assembly is coupled to a housing of the downhole tool, the housing of the cartridge assembly secured to the housing of the downhole tool by at least one retainer, the retainer preventing axial and rotational movement of the housing of the cartridge assembly relative to the housing of the downhole tool. 
     
     
         6 . The downhole tool of  claim 1 , wherein all or substantially all of the cartridge assembly is disposed within a drill through diameter of the downhole tool such that the cartridge assembly is removable in a drill through operation. 
     
     
         7 . The downhole tool of  claim 1 , further comprising a cutting member configured for rotation relative to a housing of the downhole tool by the rotary drive of the cartridge assembly. 
     
     
         8 . The downhole tool of  claim 1 , comprising a bearing. 
     
     
         9 . The downhole tool of  claim 8 , wherein the bearing is fluid lubricated by fluid from the rotary drive. 
     
     
         10 . The downhole tool of  claim 9 , wherein the bearing is disposed outside a drill through diameter of the downhole tool such that the bearing is retained in a drill through operation. 
     
     
         11 . The downhole tool of  claim 1 , comprising a clutch. 
     
     
         12 . The downhole tool of  claim 11 , wherein the clutch is a cone clutch. 
     
     
         13 . A cartridge assembly for a downhole tool, the cartridge assembly comprising a rotary drive of the downhole tool. 
     
     
         14 . A downhole tool assembly comprising:
 a tubular component;   a downhole tool; and   the cartridge assembly comprising a rotary drive of the downhole tool assembly.   
     
     
         15 . A method of running a tubular string into a borehole, comprising:
 running a downhole tool into a borehole, the downhole tool comprising;   a housing, and   a cartridge assembly configured for location within the housing, the cartridge assembly comprising a rotary drive of the downhole tool, or the downhole tool comprising;   a tubular component,   a downhole tool, and   a cartridge assembly, the cartridge assembly comprising at least one of,
 a housing and a shaft, the housing of the cartridge assembly comprising a stator of the rotary drive and the shaft of the cartridge assembly comprising a rotor of the rotary drive, the rotary drive comprising at least one of 
   (i) a fluid driven rotary drive, and   (ii) a positive displacement motor;   and directing fluid through the rotary drive to operate the downhole tool.   
     
     
         16 . A clutch for a downhole tool, the clutch comprising:
 a male cone provided on one of a rotor of a downhole tool and a stator of the downhole tool;   a female cone provided on the other of the rotor of the downhole tool and the stator of the downhole tool and being operatively associated with the male cone, the male cone and the female cone configured to engage to rotationally fix the rotor of the downhole tool and the stator of the downhole tool, wherein at least one of the male cone and the female cone comprises at least one axial slot extending at least partially along the length of the male cone and/or the female cone.   
     
     
         17 . A downhole tool comprising a clutch, the clutch comprising:
 a male cone provided on one of a rotor of a downhole tool and a stator of the downhole tool;   a female cone provided on the other of the rotor of the downhole tool and the stator of the downhole tool and being operatively associated with the male cone, the male cone and the female cone configured to engage to rotationally fix the rotor of the downhole tool and the stator of the downhole tool, wherein at least one of the male cone and the female cone comprises at least one axial slot extending at least partially along the length of the male cone and/or the female cone.   
     
     
         18 . A downhole tool assembly comprising:
 a tubular component;   a downhole tool; and   a clutch comprising a male cone provided on one of a rotor of a downhole tool and a stator of the downhole tool and a female cone provided on the other of the rotor of the downhole tool and the stator of the downhole tool and being operatively associated with the male cone, the male cone and the female cone configured to engage to rotationally fix the rotor of the downhole tool and the stator of the downhole tool,   wherein at least one of the male cone and the female cone comprises at least one axial slot extending at least partially along the length of the male cone and/or the female cone.   
     
     
         19 . The downhole tool of assembly of  claim 18 , wherein the clutch comprises a male cone and a female cone, wherein at least one of the male cone and the female cone comprises at least one axial slot extending at least partially along the length of the male cone and/or the female cone. 
     
     
         20 . A method of running a tubular string into a borehole, the method comprising:
 running a downhole tool into a borehole, the downhole tool comprising;   a tubular component,   a downhole tool, and   a male cone provided on one of a rotor of a downhole tool and a stator of the downhole tool and a female cone provided on the other of the rotor of the downhole tool and the stator of the downhole tool and being operatively associated with the male cone, the male cone and the female cone configured to engage to rotationally fix the rotor of the downhole tool and the stator of the downhole tool, wherein at least one of the male cone and the female cone comprises at least one axial slot extending at least partially along the length of the male cone and/or the female cone; and   directing fluid, such as drill fluid, through the rotary drive to operate the downhole tool.