Flow Diversion Valve for Downhole Tool Assembly

Abstract

A casing removal system includes a flow diversion valve. The flow diversion valve includes a flow switch that engages an upper end of an inner casing. When the flow switch engages the upper end of the inner casing, the flow diversion valve opens and at least a portion of the fluid flow through the casing removal system exhausts to the annulus. The remaining fluid flow below the flow diversion valve is insufficient to operate a mud motor that drives a casing cutter. In other embodiments, when the flow switch is not engaged with the inner wall of casing, the flow diversion valve prevents fluid flow to components that are downhole of the valve and when the flow switch is engaged with the inner wall of casing, the flow diversion valve allows for fluid flow to components that are downhole of the valve.

What is claimed is: 
     
         1 - 12 . (canceled) 
     
     
         13 . The system of  claim 31 , wherein in the second switch position, the flow switch is in contact with the casing. 
     
     
         14 . The system of  claim 31 , wherein the flow switch is configured to rotate from the first switch position to the second switch position based on a contact with an upper end of the casing. 
     
     
         15 . The system of  claim 14 , wherein when the flow switch rotates from the first switch position to the second switch position, the flow switch moves the flow diverter from the first diverter position to the second diverter position. 
     
     
         16 . A method for removing an inner casing internal to an outer casing, comprising:
 flowing a fluid flow through a flow diversion valve in a housing, the fluid flow comprising a first flow rate below the flow diversion valve;   lowering the housing through the outer casing to the inner casing;   engaging a flow switch of the flow diversion valve on the inner casing, the flow switch extending from inside the housing to outside the housing, wherein engaging the flow switch comprises moving a flow diverter such that the flow diverter opens a housing port in the housing; and   flowing at least a portion of the fluid flow through the housing port to reduce the fluid flow below the flow diversion valve to a second flow rate.   
     
     
         17 . The method of  claim 16 , comprising operating a mud motor in response to the first flow rate. 
     
     
         18 . The method of  claim 17 , wherein operating the mud motor drives a cutter that cuts the inner casing. 
     
     
         19 . The method of  claim 17 , comprising stopping operation of the mud motor in response to the second flow rate. 
     
     
         20 . The method of  claim 19 , comprising;
 raising the housing above the inner casing;   after raising the housing, disengaging the flow switch from the inner casing,   wherein disengaging the flow switch urges the flow diverter to block the housing port in the housing; and   after disengaging the flow switch, flowing the fluid flow through the housing with the first flow rate.   
     
     
         21 . A downhole tool assembly comprising a plurality of tools arranged for coupling to a drill or work string for being lowered into a wellbore and supplied with fluid under pressure, the plurality of tools comprising a first tool, a second tool, and an externally actuatable flow diversion valve positioned between the first and second tools for controlling fluid flow to at least the second tool, the externally actuatable flow diversion valve comprising:
 a body having an upper end and a lower end configured for communicating fluid received by the downhole tool assembly through the body along a flow path extending from the upper end to the lower end;   a valve interposed in the flow path to control fluid flow through the body;   at least one moveable switch comprising an actuation member that extends beyond an outer diameter of the body under the influence of a biasing force, the actuation member being configured to be moved inwardly with respect to the housing against the biasing force by the housing passing from a first casing into a second casing that has an inner diameter smaller than the inner diameter of the first casing, wherein movement of the actuation member actuates the valve to change a rate of fluid flow exiting the lower end of the housing.   
     
     
         22 . The downhole tool assembly of  claim 21 , wherein the valve is configured to divert at least a portion of fluid flowing in the flow path through an opening in the housing in response to an inward deflection of the actuation member, thereby reducing the rate of fluid flow from the lower end of the housing. 
     
     
         23 . The downhole tool assembly of  claim 21 , wherein:
 the valve is configured to have at least first and second fluid flow control states, the first fluid flow control state restricting fluid flow in the fluid flow path relative to fluid flow when the valve is in the second fluid flow control state; and   the valve switches fluid control states from the first fluid control state to the second fluid control state in response to actuation of the valve wherein actuation of the valve occurs in response to inward movement of the actuating member.   
     
     
         24 . The downhole tool assembly of claim of  claim 23  wherein:
 the actuatable flow diversion valve further comprises a mandrel disposed within the body and having a central bore at least partially defining the fluid flow path; 
 the mandrel shifts axially within the body in response to movement of the actuating member; and 
 shifting of the mandrel switches the valve between the at least first and second fluid flow control states. 
 
     
     
         25 . The downhole tool assembly of claim of  claim 24 , wherein the at least one moveable switch comprises at least one block partially extending from the housing and mounted to it to allow for translation of the block in a direction oblique to a central axis of the flow diversion valve, whereby movement of the block causes the mandrel to shift. 
     
     
         26 . The downhole tool assembly of claim of  claim 25 , wherein the biasing force acts against the mandrel, which in turn pushes against the at least one block to cause it to translate in an outward and downhole direction, and wherein the housing passing from a first casing into a second casing that has an inner diameter smaller than the inner diameter of the first casing causes the at least one block to translate inwardly and in an up hole direction to thereby cause the mandrel to shift against the biasing force. 
     
     
         27 . The downhole tool assembly of  claim 25 , wherein translation of the at least one block from a fully extended to a partially extended position causes the mandrel to shift and causes the valve to change from the first fluid control state to the second fluid control state, and further translation of the block inwardly to a fully retracted position further shifts the mandrel without the changing the valve from the second fluid flow control state. 
     
     
         28 . The downhole tool assembly of  claim 24 , wherein the valve comprises a valve housing cooperating with a valve seat disposed on a lower end of the mandrel and moving axially within the valve housing, the valve housing having at least one port for communicating fluid from the central bore of the mandrel to the lower end of the body, the fluid flow through the port being controlled at least in part by axial movement of the valve seat in response to shifting of the mandrel. 
     
     
         29 . The downhole tool assembly of  claim 23 , wherein, in the first fluid flow control state, the valve blocks fluid along the fluid flow path and in the second fluid flow state the valve opens the fluid flow path. 
     
     
         30 . The downhole tool assembly of  claim 21 , wherein the first tool comprises a jack and the second tool comprises at least a mud motor driving a cutter capable of cutting or milling casing. 
     
     
         31 . A system for removing a casing from a wellbore, comprising:
 a string of tools comprising:   a jack configured to exert an upward force on tools that are downhole from the jack;   a spear configured to attach to a casing;   a mud motor downhole of the spear, the mud motor operating in response to a minimum fluid flow of a fluid flow;   a flow diversion valve located between the jack and the mud motor, the flow diversion valve comprising:   a housing having an opening between an interior of the housing to an exterior of the housing;   a flow diverter in the interior of the housing, the flow diverter being movable between a first diverter position and a second diverter position, wherein in the first diverter position, the fluid flow flows through the interior of the housing to operate the mud motor with at least the minimum fluid flow, and in the second diverter position less than the minimum fluid flow flows to the mud motor; and   a flow switch extending through the opening to engage the flow diverter, the flow switch being movable relative to the opening between a first switch position and a second switch position, wherein in the first switch position the flow diverter is in the first diverter position and in the second switch position the flow diverter is in the second diverter position.