Method and apparatus for casing exit system using coiled tubing

Abstract

A system and method for setting an anchor and/or whipstock attached to a downhole motor having a cutting tool attached to a tubular member, such as coiled tubing. In one aspect, the motor allows flow therethrough sufficient to actuate an upstream MWD or other position measuring tool, and an orienter if so equipped, and retain the orientation of the motor with the attached whipstock. An increased flow rate or pressure actuates the motor once the whipstock is set and rotation of the cutting tool or other equipment can begin.

1. A method of cutting a hole at an angle to a wellbore, comprising;
 a) coupling a position measuring tool, a downhole motor, a cutting tool, a whipstock and an anchor to a tubular member; 
 b) selectively maintaining the motor in a substantially unactuated condition while flowing a fluid through the motor sufficient to operate the position measuring tool; and 
 c) actuating the anchor. 
 
     
     
       2. The method of  claim 1 , wherein actuating the anchor occurs without substantially changing an orientation of the whipstock. 
     
     
       3. The method of  claim 1 , further comprising measuring the orientation of the whipstock in-situ prior to actuating the anchor. 
     
     
       4. The method of  claim 1 , wherein the tubular member is coiled tubing. 
     
     
       5. The method of  claim 1 , further comprising lowering the position measuring tool, downhole motor, cutting tool, whipstock and anchor into the wellbore and wherein lowering into the wellbore, orienting the whipstock, and actuating the anchor occurs in a single trip. 
     
     
       6. The method of  claim 1 , further comprising lowering the anchor into the wellbore and actuating the anchor in position prior to lowering the position measuring tool, downhole motor, cutting tool and whipstock into the wellbore and orienting the whipstock. 
     
     
       7. The method of  claim 1 , wherein maintaining the motor includes flowing fluid through a hollow motor shaft of the motor. 
     
     
       8. The method of  claim 7 , wherein flowing the fluid through the hollow motor shaft comprises flowing at a first flow rate while orienting the whipstock and flowing at a second flow rate while actuating the motor to rotate the cutting tool. 
     
     
       9. The method of  claim 1 , wherein selectively maintaining the motor in a stationary rotational position comprises locking a motor shaft of the motor in rotational position. 
     
     
       10. The method of  claim 9 , further comprising creating sufficient torque on the motor shaft to unlock the motor shaft and rotate the cutting tool. 
     
     
       11. The method of  claim 9 , further comprising increasing a pressure of the fluid to unlock the motor shaft. 
     
     
       12. The method of  claim 1 , further comprising orienting the whipstock before actuating the anchor. 
     
     
       13. The method of  claim 12 , wherein orienting the whipstock comprises using an orienter to orient the whipstock. 
     
     
       14. The method of  claim 13 , wherein the position measuring tool is arranged between the orienter and the motor. 
     
     
       15. A system for cutting a hole at an angle to a wellbore, comprising:
 a) a tubular member; and 
 b) a plurality of components including a position measuring tool, a downhole motor, a cutting tool, a whipstock, and an anchor coupled to the tubular member, the motor comprising a motor shaft that is rotationally stationary relative to the whipstock while a fluid flows through the motor to operate one or more of the other components. 
 
     
     
       16. The system of  claim 15 , wherein the components further comprise an orienter coupled to the tubular member. 
     
     
       17. The system of  claim 16 , wherein the tubular member is a coiled tubing. 
     
     
       18. The system of  claim 17 , wherein the components are arranged in an order of the orienter, the motor, the cutting tool, and the whipstock. 
     
     
       19. The system of  claim 18 , wherein the position measuring tool is arranged between the orienter and the motor. 
     
     
       20. The system of  claim 15 , wherein the motor shaft comprises a hollow motor shaft. 
     
     
       21. The system of  claim 20 , wherein the hollow motor shaft is sized to allow the fluid to flow through the shaft at a first flow rate while maintaining the rotationally, stationary position and to allow the fluid to rotate the motor shaft at a second flow rate. 
     
     
       22. The system of  claim 15 , wherein the stationary motor shaft comprises a locked motor shaft while fluid flows through the motor at a first pressure and the whipstock is at least partially oriented. 
     
     
       23. The system of  claim 22 , further comprising a shear member to lock the motor shaft. 
     
     
       24. The system of  claim 23  , wherein the shear member is sized to shear and unlock the motor shaft when the pressure of the fluid is increased to a second pressure. 
     
     
       25. A method of cutting a hole at an angle to a wellbore, comprising:
 a) coupling an anchor to a coiled tubing; 
 b) actuating the anchor in the wellbore; 
 c) coupling a position measuring tool, a downhole motor, a whipstock, and a cutting tool to the coiled tubing; 
 d) selectively maintaining the motor in a substantially unactuated condition while flowing a fluid through the motor and at least partially orienting the whipstock; 
 e) orienting the whipstock to a desired orientation; and 
 f) actuating the motor to turn the cutting tool to cut the hole. 
 
     
     
       26. The method of  claim 25 , wherein orienting the whipstock comprises using an orienter to orient the whipstock. 
     
     
       27. The method of  claim 25 , further comprising flowing fluid through a hollow motor shaft of the motor at a first flow rate while orienting the whipstock and flowing at a second flow rate while actuating the motor to rotate the cutting tool. 
     
     
       28. The method of  claim 25 , further comprising locking a motor shaft of the motor in a non-rotational position while flowing the fluid through the motor and while orienting the whipstock. 
     
     
       29. The method of  claim 28 , further comprising creating sufficient torque on the motor shaft to unlock the motor shaft and rotate the cutting tool. 
     
     
       30. An apparatus for use in a wellbore, comprising:
 a) a tubular; 
 b) a motor body disposed in the tubular, the motor body having an axial channel extending through the motor body; 
 c) a motor shaft at least partially disposed in the axial channel, the motor shaft having a channel in fluid communication with the channel of the motor body; and 
 d) an output shaft disposed below the motor shaft, wherein the motor shaft is substantially unactuated while a fluid flows through the motor body to actuate a downhole tool disposed below the motor body. 
 
     
     
       31. The apparatus of  claim 30 , further comprising a shear member disposed between the motor shaft and the motor body. 
     
     
       32. A system for cutting a hole at an angle to a wellbore, comprising:
 a) a coiled tubing; 
 b) an anchor coupled to the coiled tubing; and 
 c) a position measuring tool, a downhole motor, a cutting tool, and a whipstock coupled to the coiled tubing, the motor comprising:
 1) a tubular; 
 2) a motor body disposed in the tubular; the motor body having an axial channel extending through the motor body; 
 3) a motor shaft at least partially disposed in the axial channel, the motor shaft having a channel in fluid communication with the channel of the motor body; and 
 4) an output shaft disposed below the motor shaft, wherein the motor remains substantially unactuated while a fluid flows through the motor body to actuate a downhole tool disposed below the motor. 
 
 
     
     
       33. The apparatus of  claim 32 , wherein the motor further comprises a shear member disposed between the motor shaft and the motor body. 
     
     
       34. A system for cutting a wellbore, comprising:
 a tubular member; and   a plurality of components including a position measuring tool, a downhole motor, a cutting tool, and a whipstock coupled to the tubular member, the motor comprising a motor shaft that is rotationally stationary relative to the whipstock while a fluid flows through the motor to operate one or more of the other components.   
     
     
       35. A method of operating a downhole tool, comprising:
 coupling a downhole motor and the downhole tool to a tubular member;   selectively maintaining the downhole motor in a substantially unactuated condition while flowing a fluid through the downhole motor sufficient to operate the downhole tool; and   operating the downhole tool.   
     
     
       36. The method of claim 35, wherein the downhole tool is disposed downstream from the downhole motor. 
     
     
       37. The method of claim 35, further comprising increasing the fluid flow to actuate the downhole motor. 
     
     
       38. A method of operating a downhole tool, comprising:
 coupling a downhole motor and the downhole tool to a tubular member;   supplying a fluid at a first flow rate through the tubular member and the downhole motor to operate the downhole tool while selectively maintaining the motor in a substantially unactuated condition; and   supplying the fluid at a second flow rate to operate the downhole motor.   
     
     
       39. A system for cutting a hole at an angle to a wellbore, comprising:
 a coiled tubing;   an anchor coupled to the coiled tubing; and   a position measuring tool, a downhole motor, and a cutting tool coupled to the coiled tubing, the motor comprising:
 a tubular; 
 a motor body disposed in the tubular; the motor body having an axial channel extending through the motor body; 
 a motor shaft at least partially disposed in the axial channel, the motor shaft having a channel in fluid communication with the channel of the motor body; and 
 an output shaft disposed below the motor shaft, wherein the motor remains substantially unactuated while a fluid flows through the motor body to actuate a downhole tool disposed below the motor.