US20070151725A1 - Expanding a tubular member - Google Patents
Expanding a tubular member Download PDFInfo
- Publication number
- US20070151725A1 US20070151725A1 US11/553,240 US55324006A US2007151725A1 US 20070151725 A1 US20070151725 A1 US 20070151725A1 US 55324006 A US55324006 A US 55324006A US 2007151725 A1 US2007151725 A1 US 2007151725A1
- Authority
- US
- United States
- Prior art keywords
- tubular member
- mandrel
- coupled
- sealing
- annular
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000012530 fluid Substances 0.000 claims description 72
- 238000000034 method Methods 0.000 claims description 34
- 238000007789 sealing Methods 0.000 claims description 29
- 230000008878 coupling Effects 0.000 claims 4
- 238000010168 coupling process Methods 0.000 claims 4
- 238000005859 coupling reaction Methods 0.000 claims 4
- 230000002950 deficient Effects 0.000 claims 2
- 238000006073 displacement reaction Methods 0.000 claims 2
- 239000000463 material Substances 0.000 description 41
- 238000001125 extrusion Methods 0.000 description 16
- 239000004593 Epoxy Substances 0.000 description 8
- 239000010935 stainless steel Substances 0.000 description 8
- 229910001220 stainless steel Inorganic materials 0.000 description 8
- 229910000975 Carbon steel Inorganic materials 0.000 description 7
- 239000010962 carbon steel Substances 0.000 description 7
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 7
- 229910000851 Alloy steel Inorganic materials 0.000 description 6
- 239000004568 cement Substances 0.000 description 6
- 229920001971 elastomer Polymers 0.000 description 6
- 239000000203 mixture Substances 0.000 description 6
- 230000035939 shock Effects 0.000 description 6
- 239000002893 slag Substances 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- 239000000314 lubricant Substances 0.000 description 5
- 238000005086 pumping Methods 0.000 description 5
- 239000005060 rubber Substances 0.000 description 4
- 229920000459 Nitrile rubber Polymers 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 239000004809 Teflon Substances 0.000 description 2
- 229920006362 Teflon® Polymers 0.000 description 2
- 229920006172 Tetrafluoroethylene propylene Polymers 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- 229910001315 Tool steel Inorganic materials 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 239000006096 absorbing agent Substances 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 238000005553 drilling Methods 0.000 description 2
- 239000000806 elastomer Substances 0.000 description 2
- 230000000977 initiatory effect Effects 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- -1 for example Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000011499 joint compound Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000003566 sealing material Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/08—Tube expanders
- B21D39/20—Tube expanders with mandrels, e.g. expandable
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/10—Setting of casings, screens, liners or the like in wells
- E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
- E21B43/105—Expanding tools specially adapted therefor
Definitions
- This invention relates generally to wellbore casings, and in particular to wellbore casings that are formed using expandable tubing.
- the present invention is directed to overcoming one or more of the limitations of the existing procedures for forming wellbores and wellheads.
- FIG. 1 a is a fragmentary cross-section illustration of an embodiment of an apparatus and method for expanding tubular members.
- FIG. 1 b is another fragmentary cross-sectional illustration of the apparatus of FIG. 1 a.
- FIG. 1 c is another fragmentary cross-sectional illustration of the apparatus of FIG. 1 a.
- FIG. 2 a is a fragmentary cross-section illustration of an embodiment of an apparatus and method for expanding tubular members.
- FIG. 2 b is another fragmentary cross-sectional illustration of the apparatus of FIG. 2 a.
- FIG. 2 c is another fragmentary cross-sectional illustration of the apparatus of FIG. 2 a.
- FIG. 2 d is another fragmentary cross-sectional illustration of the apparatus of FIG. 2 a.
- FIG. 2 e is another fragmentary cross-sectional illustration of the apparatus of FIG. 2 a.
- the apparatus 100 includes a support member 105 , a packer 110 , a firstfluid conduit 115 , an annular fluid passage 120 , fluid inlets 125 , an annular seal 130 , a second fluid conduit 135 , a fluid passage 140 , a mandrel 145 , a mandrel launcher 150 , a tubular member 155 , slips 160 , and seals 165 .
- the apparatus 100 is used to radially expand the tubular member 155 .
- the apparatus 100 may be used to form a wellbore casing, line a wellbore casing, form a pipeline, line a pipeline, form a structural support member, or repair a wellbore casing, pipeline or structural support member.
- the apparatus 100 is used to clad at least a portion of the tubular member 155 onto a preexisting tubular member.
- the support member 105 is preferably coupled to the packer 110 and the mandrel launcher 150 .
- the support member 105 preferably is a tubular member fabricated from any number of conventional commercially available materials such as, for example, oilfield country tubular goods, low alloy steel, carbon steel, or stainless steel.
- the support member 105 is preferably selected to fit through a preexisting section of wellbore casing 170 . In this manner, the apparatus 100 may be positioned within the wellbore casing 170 . In a preferred embodiment, the support member 105 is releasably coupled to the mandrel launcher 150 . In this manner, the support member 105 may be decoupled from the mandrel launcher 150 upon the completion of an extrusion operation.
- the packer 110 is coupled to the support member 105 and the first fluid conduit 115 .
- the packer 110 preferably provides a fluid seal between the outside surface of the first fluid conduit 115 and the inside surface of the support member 105 . In this manner, the packer 110 preferably seals off and, in combination with the support member 105 , first fluid conduit 115 , second fluid conduit 135 , and mandrel 145 , defines an annular chamber 175 .
- the packer 110 may be any number of conventional commercially available packers modified in accordance with the teachings of the present disclosure.
- the packer 110 is an RTTS packer available from Halliburton Energy Services in order to optimally provide high load and pressure containment capacity while also allowing the packer to be set and unset multiple times without having to pull the packer out of the wellbore.
- the first fluid conduit 115 is coupled to the packer 110 and the annular seal 130 .
- the first fluid conduit 115 preferably is an annular member fabricated from any number of conventional commercially available materials such as, for example, oilfield country tubular goods, low alloy steel, carbon steel, or stainless steel.
- the first fluid conduit 115 includes one or more fluid inlets 125 for conveying fluidic materials from the annular fluid passage 120 into the chamber 175 .
- the annular fluid passage 120 is defined by and positioned between the interior surface of the first fluid conduit 115 and the interior surface of the second fluid conduit 135 .
- the annular fluid passage 120 is preferably adapted to convey fluidic materials such as cement, water, epoxy, lubricants, and slag mix at operating pressures and flow rates ranging from about 0 to 3,000 gallons/minute and 0 to 9,000 psi in order to optimally provide flow rates and operational pressures for the radial expansion process.
- the fluid inlets 125 are positioned in an end portion of the first fluid conduit 115 .
- the fluid inlets 125 preferably are adapted to convey fluidic materials such as cement, water, epoxy, lubricants, and slag mix at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provide flow rates and operational pressures for the radial expansion process.
- the annular seal 130 is coupled to the first fluid conduit 115 and the second fluid conduit 135 .
- the annular seal 130 preferably provides a fluid seat between the interior surface of the first fluid conduit 115 and the exterior surface of the second fluid conduit 135 .
- the annular seal 130 preferably provides a fluid seal between the interior surface of the first fluid conduit 115 and the exterior surface of the second fluid conduit 135 during relative axial motion of the first fluid conduit 115 and the second fluid conduit 135 .
- the annular seal 130 may be any number of conventional commercially available seals such as, for example, O-rings, polypak seals, or metal spring energized seals. In a preferred embodiment, the annular seal 130 is a polypak seal available from Parker Seals.
- the second fluid conduit 135 is coupled to the annular seal 130 and the mandrel 145 .
- the second fluid conduit preferably is a tubular member fabricated from any number of conventional commercially available materials such as, for example, coiled tubing, oilfield country tubular goods, low alloy steel, stainless steel, or low carbon steel.
- the second fluid conduit 135 is adapted to convey fluidic materials such as cement, water, epoxy, lubricants, and slag mix at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provide flow rates and operational pressures for the radial expansion process.
- the fluid passage 140 is coupled to the second fluid conduit 135 and the mandrel 145 .
- the fluid passage 140 is adapted to convey fluidic materials such as cement, water, epoxy, lubricants, and slag mix at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provide flow rates and operational pressures for the radial expansion process.
- the mandrel 145 is coupled to the second fluid conduit 135 and the mandrel launcher 150 .
- the mandrel 145 preferably are an annular member having a conic section fabricated from any number of conventional commercially available materials such as, for example, machine tool steel, ceramics, tungsten carbide, titanium or other high strength alloys.
- the angle of the conic section of the mandrel 145 ranges from about 0 to 30 degrees in order to optimally expand the mandrel launcher 150 and tubular member 155 in the radial direction.
- the surface of the conic section ranges from about 58 to 62 Rockwell C in order to optimally provide high yield strength.
- the expansion cone 145 is heat treated in order to optimally provide a hard outer surface and a resilient interior body in order to optimally provide abrasion resistance and fracture toughness.
- the mandrel 145 is expandible in order to further optimally augment the radial expansion process.
- the mandrel launcher 150 is coupled to the support member 105 , the mandrel 145 , and the tubular member 155 .
- the mandrel launcher 150 preferably are a tubular member having a variable cross-section and a reduced wall thickness in order to facilitate the radial expansion process.
- the cross-sectional area of the mandrel launcher 150 at one end is adapted to mate with the mandrel 145 , and at the other end, the cross-sectional area of the mandrel launcher 150 is adapted to match the cross-sectional area of the tubular member 155 .
- the wall thickness of the mandrel launcher 150 ranges from about 50 to 100% of the wall thickness of the tubular member 155 in order to facilitate the initiation of the radial expansion process,
- the mandrel launcher 150 may be fabricated from any number of conventional commercially available materials such as, for example, oilfield country tubular goods, low allow steel, stainless steel, or carbon steel.
- the mandrel launcher 150 is fabricated from oilfield country tubular goods having higher strength but lower wall thickness than the tubular member 155 in order to optimally match the burst strength of the tubular member 155 .
- the mandrel launcher 150 is removably coupled to the tubular member 155 . In this manner, the mandrel launcher 150 may be removed from the wellbore 180 upon the completion of an extrusion operation.
- the support member 105 and the mandrel launcher 150 are integrally formed.
- the support member 105 preferably terminates above the top of the packer 110 .
- the fluid conduits 115 and/or 135 provide structural support for the apparatus 100 , using the packer 110 to couple together the elements of the apparatus 100 .
- the packer 110 may be unset and reset, after the slips 160 have anchored the tubular member 155 to the previous casing 170 , within the tubular member 155 , between radial expansion operations. In this manner, the packer 110 is moved downhole and the apparatus 100 is re-stroked.
- the tubular member 155 is coupled to the mandrel launcher, the slips 160 and the seals 165 .
- the tubular member 155 preferably is a tubular member fabricated from any number of conventional commercially available materials such as, for example, low alloy steel, carbon steel, stainless steel, or oilfield country tubular goods. In a preferred embodiment, the tubular member 155 is fabricated from oilfield country tubular goods.
- the slips 160 are coupled to the outside surface of the tubular member 155 .
- the slips 160 preferably are adapted to couple to the interior walls of a casing, pipeline or other structure upon the radial expansion of the tubular member 155 . In this manner, the slips 160 provide structural support for the expanded tubular member 155 .
- the slips 160 may be any number of conventional commercially available slips such as, for example, RTTS packer tungsten carbide slips, RTTS packer wicker type mechanical slips or Model 3L retrievable bridge plug tungsten carbide upper mechanical slips.
- the slips 160 are RTTS packer tungsten carbide mechanical slips available from Halliburton Energy Services.
- the slips 160 are adapted to support axial forces ranging from about 0 to 750,000 lbf.
- the seals 165 are coupled to the outside surface of the tubular member 155 .
- the seals 165 preferably provide a fluidic seal between the outside surface of the expanded tubular member 155 and the interior walls of a casing, pipeline or other structure upon the radial expansion of the tubular member 155 . In this manner, the seals 165 provide a fluidic seal for the expanded tubular member 155 .
- the seals 165 may be any number of conventional commercially available seals such as, for example, nitrile rubber, lead, Aflas rubber, Teflon, epoxy, or other elastomers.
- the seals 165 are rubber seals available from numerous commercial vendors in order to optimally provide pressure sealing and load bearing capacity.
- the apparatus 100 is preferably lowered into a wellbore 180 having a preexisting section of wellbore casing 170 .
- the apparatus 100 is positioned with at least a portion of the tubular member 155 overlapping with a portion of the wellbore casing 170 .
- the radial expansion of the tubular member 155 will preferably cause the outside surface of the expanded tubular member 155 to couple with the inside surface of the wellbore casing 170 .
- the radial expansion of the tubular member 155 will also cause the slips 160 and seals 165 to engage with the interior surface of the wellbore casing 170 .
- the expanded tubular member 155 is provided with enhanced structural support by the slips 160 and an enhanced fluid seal by the seals 165 .
- a fluidic material 185 is preferably pumped into the chamber 175 using the fluid passage 120 and the inlet passages 125 .
- the fluidic material is pumped into the chamber 175 at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provide flow rates and operational pressures for the radial expansion process.
- the pumped fluidic material 185 increase the operating pressure within the chamber 175 .
- the increased operating pressure in the chamber 175 then causes the mandrel 145 to extrude the mandrel launcher 150 and tubular member 155 off of the face of the mandrel 145 .
- the extrusion of the mandrel launcher 150 and tubular member 155 off of the face of the mandrel 145 causes the mandrel launcher 150 and tubular member 155 to expand in the radial direction.
- Continued pumping of the fluidic material 185 preferably causes the entire length of the tubular member 155 to expand in the radial direction.
- the pumping rate and pressure of the fluidic material 185 is reduced during the latter stages of the extrusion process in order to minimize shock to the apparatus 100 .
- the apparatus 100 includes shock absorbers for absorbing the shock caused by the completion of the extrusion process.
- the extrusion process causes the mandrel 145 to move in an axial direction 185 .
- the fluid passage 140 conveys fluidic material 190 displaced by the moving mandrel 145 out of the wellbore 180 . In this manner, the operational efficiency and speed of the extrusion process is enhanced.
- the extrusion process includes the injection of a hardenable fluidic material into the annular region between the tubular member 155 and the bore hole 180 .
- a hardened sealing layer is provided between the expanded tubular member 155 and the interior walls of the wellbore 180 .
- the support member 105 , packer 110 , first fluid conduit 115 , annular seal 130 , second fluid conduit 135 , mandrel 145 , and mandrel launcher 150 are moved from the wellbore 180 .
- the apparatus 100 is used to repair a preexisting wellbore casing or pipeline.
- both ends of the tubular member 155 preferably include slips 160 and seals 165 .
- the apparatus 100 is used to form a tubular structural support for a building or offshore structure.
- the apparatus 200 includes a support member 205 , a mandrel launcher 210 , a mandrel 215 , a first fluid passage 220 , a tubular member 225 , slips 230 , seals 235 , a shoe 240 , and a second fluid passage 245 .
- the apparatus 200 is used to radially expand the mandrel launcher 210 and tubular member 225 .
- the apparatus 200 may be used to form a wellbore casing, line a wellbore casing, form a pipeline, line a pipeline, form a structural support member, or repair a wellbore casing, pipeline or structural support member.
- the apparatus 200 is used to clad at least a portion of the tubular member 225 onto a preexisting structural member.
- the support member 205 is preferably coupled to the mandrel launcher 210 .
- the support member 205 preferably is a tubular member fabricated from any number of conventional commercially available materials such as, for example, oilfield country tubular goods, low alloy steel, carbon steel, or stainless steel.
- the support member 205 , the mandrel launcher 210 , the tubular member 225 , and the shoe 240 are preferably selected to fit through a preexisting section of wellbore casing 250 . In this manner, the apparatus 200 may be positioned within the wellbore casing 270 .
- the support member 205 is releasably coupled to the mandrel launcher 210 . In this manner, the support member 205 may be decoupled from the mandrel launcher 210 upon the completion of an extrusion operation.
- the mandrel launcher 210 is coupled to the support member 205 and the tubular member 225 .
- the mandrel launcher 210 preferably are a tubular member having a variable cross-section and a reduced wall thickness in order to facilitate the radial expansion process.
- the cross-sectional area of the mandrel launcher 210 at one end is adapted to mate with the mandrel 215 , and at the other end, the cross-sectional area of the mandrel launcher 210 is adapted to match the cross-sectional area of the tubular member 225 .
- the wall thickness of the mandrel launcher 210 ranges from about 50 to 100% of the wall thickness of the tubular member 225 in order to facilitate the initiation of the radial expansion process.
- the mandrel launcher 210 may be fabricated from any number of conventional commercially available materials such as, for example, oilfield country tubular goods, low allow steel, stainless steel, or carbon steel.
- the mandrel launcher 210 is fabricated from oilfield country tubular goods having higher strength but lower wall thickness than the tubular member 225 in order to optimally match the burst strength of the tubular member 225 .
- the mandrel launcher 210 is removably coupled to the tubular member 225 . In this manner, the mandrel launcher 210 may be removed from the wellbore 260 upon the completion of an extrusion operation.
- the mandrel 215 is coupled to the mandrel launcher 210 .
- the mandrel 215 preferably are an annular member having a conic section fabricated from any number of conventional commercially available materials such as, for example, machine tool steel, ceramics, tungsten carbide, titanium or other high strength alloys.
- the angle of the conic section of the mandrel 215 ranges from about 0 to 30 degrees in order to optimally expand the mandrel launcher 210 and the tubular member 225 in the radial direction.
- the surface of the conic section ranges from about 58 to 62 Rockwell C in order to optimally provide high yield strength.
- the expansion cone 215 is heat treated in order to optimally provide a hard outer surface and a resilient interior body in order to optimally provide abrasion resistance and fracture toughness.
- the mandrel 215 is expandible in order to further optimally augment the radial expansion process.
- the fluid passage 220 is positioned within the mandrel 215 .
- the fluid passage 220 is preferably adapted to convey fluidic materials such as cement, water, epoxy, lubricants, and slag mix at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provide flow rates and operational pressures for the radial expansion process.
- the fluid passage 220 preferably includes an inlet 265 adapted to receive a plug, or other similar device. In this manner, the interior chamber 270 above the mandrel 215 may be fluidicly isolated from the interior chamber 275 below the mandrel 215 .
- the tubular member 225 is coupled to the mandrel launcher 210 , the slips 230 and the seals 235 .
- the tubular member 225 preferably is a tubular member fabricated from any number of conventional commercially available materials such as, for example, low alloy steel, carbon steel, stainless steel, or oilfield country tubular goods. In a preferred embodiment, the tubular member 225 is fabricated from oilfield country tubular goods.
- the slips 230 are coupled to the outside surface of the tubular member 225 .
- the slips 230 preferably are adapted to couple to the interior walls of a casing, pipeline or other structure upon the radial expansion of the tubular member 225 . In this manner, the slips 230 provide structural support for the expanded tubular member 225 .
- the slips 230 may be any number of conventional commercially available slips such as, for example, RTTS packer tungsten carbide mechanical slips, RTTS packer wicker type mechanical slips, or Model 3L retrievable bridge plug tungsten carbide upper mechanical slips.
- the slips 230 are adapted to support axial forces ranging from about 0 to 750,000 lbf.
- the seals 235 are coupled to the outside surface of the tubular member 225 .
- the seals 235 preferably provide a fluidic seal between the outside surface of the expanded tubular member 225 and the interior walls of a casing, pipeline or other structure upon the radial expansion of the tubular member 225 . In this manner, the seals 235 provide a fluidic seal for the expanded tubular member 225 .
- the seals 235 may be any number of conventional commercially available seals such as, for example, nitrile rubber, lead, Aflas rubber, Teflon, epoxy or other elastomers.
- the seals 235 are conventional rubber seals available from various commercial vendors in order to optimally provide pressure sealing and load bearing capacity.
- the shoe 240 is coupled to the tubular member 225 .
- the shoe 240 preferably is a substantially tubular member having a fluid passage 245 for conveying fluidic materials from the chamber 275 to the annular region 270 outside of the apparatus 200 .
- the shoe 240 may be any number of conventional commercially available shoes such as, for example, a Super Seal II float shoe, a Super Seal II Down-Jet float shoe, or a guide shoe with a sealing sleeve for a latch down plug modified in accordance with the teachings of the present disclosure.
- the shoe 240 is an aluminum down-jet guide shoe with a sealing sleeve for a latch down plug, available from Halliburton Energy Services, modified in accordance with the teachings of the present disclosure, in order to optimally guide the tubular member 225 in the wellbore, optimally provide a fluidic seal between the interior and exterior diameters of the overlapping joint between the tubular members, and optimally facilitate the complete drilling out of the shoe and plug upon the completion of the cementing and radial expansion operations.
- the apparatus 200 is preferably lowered into a wellbore 260 having a preexisting section of wellbore casing 275 .
- the apparatus 200 is positioned with at least a portion of the tubular member 225 overlapping with a portion of the wellbore casing 275 .
- the radial expansion of the tubular member 225 will preferably cause the outside surface of the expanded tubular member 225 to couple with the inside surface of the wellbore casing 275 .
- the radial expansion of the tubular member 225 will also cause the slips 230 and seals 235 to engage with the interior surface of the wellbore casing 275 .
- the expanded tubular member 225 is provided with enhanced structural support by the slips 230 and an enhanced fluid seal by the seals 235 .
- a fluidic material 280 is preferably pumped into the chamber 270 .
- the fluidic material 280 then passes through the fluid passage 220 into the chamber 275 .
- the fluidic material 280 then passes out of the chamber 275 , through the fluid passage 245 , and into the annular region 270 .
- the fluidic material 280 is pumped into the chamber 270 at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provide flow rates and operational pressures for the radial expansion process.
- the fluidic material 280 is a hardenable fluidic sealing material in order to form a hardened outer annular member around the expanded tubular member 225 .
- a ball 285 is introduced into the pumped fluidic material 280 .
- the ball 285 mates with and seals off the inlet 265 of the fluid passage 220 .
- the chamber 270 is fluidicly isolated from the chamber 275 .
- a fluidic material 290 is pumped into the chamber 270 .
- the fluidic material is preferably pumped into the chamber 270 at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to provide optimal operating efficiency.
- the fluidic material 290 may be any number of conventional commercially available materials such as, for example, water, drilling mud, cement, epoxy, or slag mix.
- the fluidic material 290 is a non-hardenable fluidic material in order to maximize operational efficiency.
- fluidic material 280 increases the operating pressure within the chamber 270 .
- the increased operating pressure in the chamber 270 then causes the mandrel 215 to extrude the mandrel launcher 210 and tubular member 225 off of the conical face of the mandrel 215 .
- the extrusion of the mandrel launcher 210 and tubular member 225 off of the conical face of the mandrel 215 causes the mandrel launcher 210 and tubular member 225 to expand in the radial direction.
- Continued pumping of the fluidic material 290 preferably causes the entire length of the tubular member 225 to expand in the radial direction.
- the pumping rate and pressure of the fluidic material 290 is reduced during the latter stages of the extrusion process in order to minimize shock to the apparatus 200 .
- the apparatus 200 includes shock absorbers for absorbing the shock caused by the completion of the extrusion process.
- the extrusion process causes the mandrel 215 to move in an axial direction 295 .
- the support member 205 , packer 210 , first fluid conduit 215 , annular seal 230 , second fluid conduit 235 , mandrel 245 , and mandrel launcher 250 are removed from the wellbore 280 .
- the resulting new section of wellbore casing includes the preexisting wellbore casing 275 , the expanded tubular member 225 , the slips 230 , the seals 235 , the shoe 240 , and an outer annular layer 4000 of hardened fluidic material.
- the apparatus 200 is used to repair a preexisting wellbore casing or pipeline.
- both ends of the tubular member 255 preferably include slips 260 and seals 265 .
- the apparatus 200 is used to form a tubular structural support for a building or offshore structure.
- tubular members 105 and 225 ; shoes 240 ; expansion cone launchers 150 and 210 ; and expansion cones 145 and 215 are provided substantially as described in one or more of the following U.S. patent applications: (1) utility patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of provisional patent application No. 60/108,558, attorney docket number 25791.9, filed on Nov. 16, 1998; (2) utility patent application Ser. No. 09/454,139, attorney docket number 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of provisional patent application No.
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Abstract
A tubular member is expanded by pressurizing an interior region within the tubular member.
Description
- This application is a divisional of U.S. utility patent application Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Feb. 18, 2003, which was the National Stage of PCT application Ser. No. PCT/US01/04753, attorney docket no. 25791.10.02, filed on Feb. 14, 2001, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/183,546, attorney docket no. 25791.10, filed on Feb. 18, 2000, which was a continuation-in-part of U.S. Ser. No. 09/559,122, attorney docket number 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/131,106, filed on Apr. 26, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/523,460, attorney docket number 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/124,042, filed on Mar. 11, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/510,913, attorney docket number 25791.7.02, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/121,702, filed on Feb. 25, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/502,350, attorney docket number 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/119,611, attorney docket number 25791.8, filed on Feb. 11, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/454,139, attorney docket number 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, filed on Dec. 12, 7, 1998.
- The present application is related to the following U.S. patent applications: (1) utility patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of provisional patent application No. 60/108,558, attorney docket number 25791.9, filed on Nov. 16, 1998; (2) utility patent application Ser. No. 09/454,139, attorney docket number 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of provisional patent application No. 60/111,293, attorney docket number 25791.3, filed on Dec. 7, 1998; (3) utility patent application Ser. No. 09/502,350, attorney docket number 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of provisional patent application No. 60/119,611, attorney docket number 25791.8, filed on Feb. 11, 1999; (4) provisional patent application No. 60/121 702, attorney docket number 25791.7, filed on Feb. 25, 1999; (5) provisional patent No. application No. 60/121,841, attorney docket number 25791.12, filed on Feb. 26, 1999; (6) provisional patent application No. 60/121,907, attorney docket number 25791.16, filed on Feb. 26, 1999; (7) provisional patent application No. 60/124,042, attorney docket number 25791.11, filed on Mar. 11, 1999; (8) provisional patent application No. 60/131,106, attorney docket number 25791.23, filed on Mar. 26, 1999; (9) provisional patent application No. 60/137,998, attorney docket number 25791.17, filed on Jun. 7, 1999; (10) provisional patent application No. 60/143,039, attorney docket number 25791.26, filed on Jul. 9, 1999; (11) provisional patent application No. 60/146,203, attorney docket number 25791.25, filed on Jul. 29, 1999; (12) provisional patent application No. 60/154,047, attorney docket number 25791.29, filed on Sep. 16, 1999; (13) provisional patent application No. 60/159,082, attorney docket number 25791.34, filed on Oct. 12, 1999; (14) provisional patent application No. 60/159,039, attorney docket number 25791.36, filed on Oct. 12, 1999; (13) provisional patent application No. 60/159,033, attorney docket number 25791.37, filed on Oct. 12, 1999; (15) provisional patent application No. 60/162,671, attorney docket number 25791.27, filed on Nov. 1, 1999, the disclosures of which are incorporated by reference.
- This invention relates generally to wellbore casings, and in particular to wellbore casings that are formed using expandable tubing.
- The present invention is directed to overcoming one or more of the limitations of the existing procedures for forming wellbores and wellheads.
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FIG. 1 a is a fragmentary cross-section illustration of an embodiment of an apparatus and method for expanding tubular members. -
FIG. 1 b is another fragmentary cross-sectional illustration of the apparatus ofFIG. 1 a. -
FIG. 1 c is another fragmentary cross-sectional illustration of the apparatus ofFIG. 1 a. -
FIG. 2 a is a fragmentary cross-section illustration of an embodiment of an apparatus and method for expanding tubular members. -
FIG. 2 b is another fragmentary cross-sectional illustration of the apparatus ofFIG. 2 a. -
FIG. 2 c is another fragmentary cross-sectional illustration of the apparatus ofFIG. 2 a. -
FIG. 2 d is another fragmentary cross-sectional illustration of the apparatus ofFIG. 2 a. -
FIG. 2 e is another fragmentary cross-sectional illustration of the apparatus ofFIG. 2 a. - Referring now to
FIGS. 1 a, 1 b and 1 c, anapparatus 100 for expanding a tubular member will be described. In a preferred embodiment, theapparatus 100 includes asupport member 105, apacker 110, afirstfluid conduit 115, anannular fluid passage 120,fluid inlets 125, anannular seal 130, asecond fluid conduit 135, afluid passage 140, amandrel 145, amandrel launcher 150, atubular member 155,slips 160, andseals 165. In a preferred embodiment, theapparatus 100 is used to radially expand thetubular member 155. In this manner, theapparatus 100 may be used to form a wellbore casing, line a wellbore casing, form a pipeline, line a pipeline, form a structural support member, or repair a wellbore casing, pipeline or structural support member. In a preferred embodiment, theapparatus 100 is used to clad at least a portion of thetubular member 155 onto a preexisting tubular member. Thesupport member 105 is preferably coupled to thepacker 110 and themandrel launcher 150. Thesupport member 105 preferably is a tubular member fabricated from any number of conventional commercially available materials such as, for example, oilfield country tubular goods, low alloy steel, carbon steel, or stainless steel. Thesupport member 105 is preferably selected to fit through a preexisting section ofwellbore casing 170. In this manner, theapparatus 100 may be positioned within thewellbore casing 170. In a preferred embodiment, thesupport member 105 is releasably coupled to themandrel launcher 150. In this manner, thesupport member 105 may be decoupled from themandrel launcher 150 upon the completion of an extrusion operation. - The
packer 110 is coupled to thesupport member 105 and thefirst fluid conduit 115. Thepacker 110 preferably provides a fluid seal between the outside surface of thefirst fluid conduit 115 and the inside surface of thesupport member 105. In this manner, thepacker 110 preferably seals off and, in combination with thesupport member 105,first fluid conduit 115,second fluid conduit 135, andmandrel 145, defines anannular chamber 175. Thepacker 110 may be any number of conventional commercially available packers modified in accordance with the teachings of the present disclosure. In a preferred embodiment, thepacker 110 is an RTTS packer available from Halliburton Energy Services in order to optimally provide high load and pressure containment capacity while also allowing the packer to be set and unset multiple times without having to pull the packer out of the wellbore. - The
first fluid conduit 115 is coupled to thepacker 110 and theannular seal 130. Thefirst fluid conduit 115 preferably is an annular member fabricated from any number of conventional commercially available materials such as, for example, oilfield country tubular goods, low alloy steel, carbon steel, or stainless steel. In a preferred embodiment, thefirst fluid conduit 115 includes one ormore fluid inlets 125 for conveying fluidic materials from theannular fluid passage 120 into thechamber 175. - The
annular fluid passage 120 is defined by and positioned between the interior surface of thefirst fluid conduit 115 and the interior surface of thesecond fluid conduit 135. Theannular fluid passage 120 is preferably adapted to convey fluidic materials such as cement, water, epoxy, lubricants, and slag mix at operating pressures and flow rates ranging from about 0 to 3,000 gallons/minute and 0 to 9,000 psi in order to optimally provide flow rates and operational pressures for the radial expansion process. - The
fluid inlets 125 are positioned in an end portion of thefirst fluid conduit 115. Thefluid inlets 125 preferably are adapted to convey fluidic materials such as cement, water, epoxy, lubricants, and slag mix at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provide flow rates and operational pressures for the radial expansion process. - The
annular seal 130 is coupled to thefirst fluid conduit 115 and thesecond fluid conduit 135. Theannular seal 130 preferably provides a fluid seat between the interior surface of thefirst fluid conduit 115 and the exterior surface of thesecond fluid conduit 135. Theannular seal 130 preferably provides a fluid seal between the interior surface of thefirst fluid conduit 115 and the exterior surface of thesecond fluid conduit 135 during relative axial motion of thefirst fluid conduit 115 and thesecond fluid conduit 135. Theannular seal 130 may be any number of conventional commercially available seals such as, for example, O-rings, polypak seals, or metal spring energized seals. In a preferred embodiment, theannular seal 130 is a polypak seal available from Parker Seals. - The
second fluid conduit 135 is coupled to theannular seal 130 and themandrel 145. The second fluid conduit preferably is a tubular member fabricated from any number of conventional commercially available materials such as, for example, coiled tubing, oilfield country tubular goods, low alloy steel, stainless steel, or low carbon steel. In a preferred embodiment, thesecond fluid conduit 135 is adapted to convey fluidic materials such as cement, water, epoxy, lubricants, and slag mix at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provide flow rates and operational pressures for the radial expansion process. - The
fluid passage 140 is coupled to thesecond fluid conduit 135 and themandrel 145. In a preferred embodiment, thefluid passage 140 is adapted to convey fluidic materials such as cement, water, epoxy, lubricants, and slag mix at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provide flow rates and operational pressures for the radial expansion process. - The
mandrel 145 is coupled to thesecond fluid conduit 135 and themandrel launcher 150. Themandrel 145 preferably are an annular member having a conic section fabricated from any number of conventional commercially available materials such as, for example, machine tool steel, ceramics, tungsten carbide, titanium or other high strength alloys. In a preferred embodiment, the angle of the conic section of themandrel 145 ranges from about 0 to 30 degrees in order to optimally expand themandrel launcher 150 andtubular member 155 in the radial direction. In a preferred embodiment, the surface of the conic section ranges from about 58 to 62 Rockwell C in order to optimally provide high yield strength. In a preferred embodiment, theexpansion cone 145 is heat treated in order to optimally provide a hard outer surface and a resilient interior body in order to optimally provide abrasion resistance and fracture toughness. In an alternative embodiment, themandrel 145 is expandible in order to further optimally augment the radial expansion process. - The
mandrel launcher 150 is coupled to thesupport member 105, themandrel 145, and thetubular member 155. Themandrel launcher 150 preferably are a tubular member having a variable cross-section and a reduced wall thickness in order to facilitate the radial expansion process. In a preferred embodiment, the cross-sectional area of themandrel launcher 150 at one end is adapted to mate with themandrel 145, and at the other end, the cross-sectional area of themandrel launcher 150 is adapted to match the cross-sectional area of thetubular member 155. In a preferred embodiment, the wall thickness of themandrel launcher 150 ranges from about 50 to 100% of the wall thickness of thetubular member 155 in order to facilitate the initiation of the radial expansion process, - The
mandrel launcher 150 may be fabricated from any number of conventional commercially available materials such as, for example, oilfield country tubular goods, low allow steel, stainless steel, or carbon steel. In a preferred embodiment themandrel launcher 150 is fabricated from oilfield country tubular goods having higher strength but lower wall thickness than thetubular member 155 in order to optimally match the burst strength of thetubular member 155. In a preferred embodiment, themandrel launcher 150 is removably coupled to thetubular member 155. In this manner, themandrel launcher 150 may be removed from thewellbore 180 upon the completion of an extrusion operation. - In an alternative embodiment, the
support member 105 and themandrel launcher 150 are integrally formed. In this alternative embodiment, thesupport member 105 preferably terminates above the top of thepacker 110. In this alternative embodiment, thefluid conduits 115 and/or 135 provide structural support for theapparatus 100, using thepacker 110 to couple together the elements of theapparatus 100. In this alternative embodiment, in a preferred embodiment, during the radial expansion process, thepacker 110 may be unset and reset, after theslips 160 have anchored thetubular member 155 to theprevious casing 170, within thetubular member 155, between radial expansion operations. In this manner, thepacker 110 is moved downhole and theapparatus 100 is re-stroked. - The
tubular member 155 is coupled to the mandrel launcher, theslips 160 and theseals 165. Thetubular member 155 preferably is a tubular member fabricated from any number of conventional commercially available materials such as, for example, low alloy steel, carbon steel, stainless steel, or oilfield country tubular goods. In a preferred embodiment, thetubular member 155 is fabricated from oilfield country tubular goods. - The
slips 160 are coupled to the outside surface of thetubular member 155. Theslips 160 preferably are adapted to couple to the interior walls of a casing, pipeline or other structure upon the radial expansion of thetubular member 155. In this manner, theslips 160 provide structural support for the expandedtubular member 155. Theslips 160 may be any number of conventional commercially available slips such as, for example, RTTS packer tungsten carbide slips, RTTS packer wicker type mechanical slips or Model 3L retrievable bridge plug tungsten carbide upper mechanical slips. In a preferred embodiment, theslips 160 are RTTS packer tungsten carbide mechanical slips available from Halliburton Energy Services. In a preferred embodiment, theslips 160 are adapted to support axial forces ranging from about 0 to 750,000 lbf. - The
seals 165 are coupled to the outside surface of thetubular member 155. Theseals 165 preferably provide a fluidic seal between the outside surface of the expandedtubular member 155 and the interior walls of a casing, pipeline or other structure upon the radial expansion of thetubular member 155. In this manner, theseals 165 provide a fluidic seal for the expandedtubular member 155. Theseals 165 may be any number of conventional commercially available seals such as, for example, nitrile rubber, lead, Aflas rubber, Teflon, epoxy, or other elastomers. In a preferred embodiment, theseals 165 are rubber seals available from numerous commercial vendors in order to optimally provide pressure sealing and load bearing capacity. - During operation of the
apparatus 100, theapparatus 100 is preferably lowered into awellbore 180 having a preexisting section ofwellbore casing 170. In a preferred embodiment, theapparatus 100 is positioned with at least a portion of thetubular member 155 overlapping with a portion of thewellbore casing 170. In this manner, the radial expansion of thetubular member 155 will preferably cause the outside surface of the expandedtubular member 155 to couple with the inside surface of thewellbore casing 170. In a preferred embodiment, the radial expansion of thetubular member 155 will also cause theslips 160 andseals 165 to engage with the interior surface of thewellbore casing 170. In this manner, the expandedtubular member 155 is provided with enhanced structural support by theslips 160 and an enhanced fluid seal by theseals 165. - As illustrated in
FIG. 1 b, after placement of theapparatus 100 in an overlapping relationship with thewellbore casing 170, afluidic material 185 is preferably pumped into thechamber 175 using thefluid passage 120 and theinlet passages 125. In a preferred embodiment, the fluidic material is pumped into thechamber 175 at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provide flow rates and operational pressures for the radial expansion process. The pumpedfluidic material 185 increase the operating pressure within thechamber 175. The increased operating pressure in thechamber 175 then causes themandrel 145 to extrude themandrel launcher 150 andtubular member 155 off of the face of themandrel 145. The extrusion of themandrel launcher 150 andtubular member 155 off of the face of themandrel 145 causes themandrel launcher 150 andtubular member 155 to expand in the radial direction. Continued pumping of thefluidic material 185 preferably causes the entire length of thetubular member 155 to expand in the radial direction. - In a preferred embodiment, the pumping rate and pressure of the
fluidic material 185 is reduced during the latter stages of the extrusion process in order to minimize shock to theapparatus 100. In a preferred embodiment, theapparatus 100 includes shock absorbers for absorbing the shock caused by the completion of the extrusion process. - In a preferred embodiment, the extrusion process causes the
mandrel 145 to move in anaxial direction 185. During the axial movement of the mandrel, in a preferred embodiment, thefluid passage 140 conveysfluidic material 190 displaced by the movingmandrel 145 out of thewellbore 180. In this manner, the operational efficiency and speed of the extrusion process is enhanced. - In a preferred embodiment, the extrusion process includes the injection of a hardenable fluidic material into the annular region between the
tubular member 155 and thebore hole 180. In this manner, a hardened sealing layer is provided between the expandedtubular member 155 and the interior walls of thewellbore 180. - As illustrated in
FIG. 1 c, in a preferred embodiment, upon the completion of the extrusion process, thesupport member 105,packer 110, firstfluid conduit 115,annular seal 130, secondfluid conduit 135,mandrel 145, andmandrel launcher 150 are moved from thewellbore 180. - In an alternative embodiment, the
apparatus 100 is used to repair a preexisting wellbore casing or pipeline. In this alternative embodiment, both ends of thetubular member 155 preferably includeslips 160 and seals 165. - In an alternative embodiment, the
apparatus 100 is used to form a tubular structural support for a building or offshore structure. - Referring now to
FIGS. 2 a, 2 b, 2 c, 2 d, and 2 e, anapparatus 200 for expanding a tubular member will be described. In a preferred embodiment, theapparatus 200 includes asupport member 205, amandrel launcher 210, amandrel 215, afirst fluid passage 220, atubular member 225, slips 230, seals 235, ashoe 240, and asecond fluid passage 245. In a preferred embodiment, theapparatus 200 is used to radially expand themandrel launcher 210 andtubular member 225. In this manner, theapparatus 200 may be used to form a wellbore casing, line a wellbore casing, form a pipeline, line a pipeline, form a structural support member, or repair a wellbore casing, pipeline or structural support member. In a preferred embodiment, theapparatus 200 is used to clad at least a portion of thetubular member 225 onto a preexisting structural member. - The
support member 205 is preferably coupled to themandrel launcher 210. Thesupport member 205 preferably is a tubular member fabricated from any number of conventional commercially available materials such as, for example, oilfield country tubular goods, low alloy steel, carbon steel, or stainless steel. Thesupport member 205, themandrel launcher 210, thetubular member 225, and theshoe 240 are preferably selected to fit through a preexisting section of wellbore casing 250. In this manner, theapparatus 200 may be positioned within thewellbore casing 270. In a preferred embodiment, thesupport member 205 is releasably coupled to themandrel launcher 210. In this manner, thesupport member 205 may be decoupled from themandrel launcher 210 upon the completion of an extrusion operation. - The
mandrel launcher 210 is coupled to thesupport member 205 and thetubular member 225. Themandrel launcher 210 preferably are a tubular member having a variable cross-section and a reduced wall thickness in order to facilitate the radial expansion process. In a preferred embodiment, the cross-sectional area of themandrel launcher 210 at one end is adapted to mate with themandrel 215, and at the other end, the cross-sectional area of themandrel launcher 210 is adapted to match the cross-sectional area of thetubular member 225. In a preferred embodiment, the wall thickness of themandrel launcher 210 ranges from about 50 to 100% of the wall thickness of thetubular member 225 in order to facilitate the initiation of the radial expansion process. - The
mandrel launcher 210 may be fabricated from any number of conventional commercially available materials such as, for example, oilfield country tubular goods, low allow steel, stainless steel, or carbon steel. In a preferred embodiment, themandrel launcher 210 is fabricated from oilfield country tubular goods having higher strength but lower wall thickness than thetubular member 225 in order to optimally match the burst strength of thetubular member 225. In a preferred embodiment, themandrel launcher 210 is removably coupled to thetubular member 225. In this manner, themandrel launcher 210 may be removed from thewellbore 260 upon the completion of an extrusion operation. - The
mandrel 215 is coupled to themandrel launcher 210. Themandrel 215 preferably are an annular member having a conic section fabricated from any number of conventional commercially available materials such as, for example, machine tool steel, ceramics, tungsten carbide, titanium or other high strength alloys. In a preferred embodiment, the angle of the conic section of themandrel 215 ranges from about 0 to 30 degrees in order to optimally expand themandrel launcher 210 and thetubular member 225 in the radial direction. In a preferred embodiment, the surface of the conic section ranges from about 58 to 62 Rockwell C in order to optimally provide high yield strength. In a preferred embodiment, theexpansion cone 215 is heat treated in order to optimally provide a hard outer surface and a resilient interior body in order to optimally provide abrasion resistance and fracture toughness. In an alternative embodiment, themandrel 215 is expandible in order to further optimally augment the radial expansion process. - The
fluid passage 220 is positioned within themandrel 215. Thefluid passage 220 is preferably adapted to convey fluidic materials such as cement, water, epoxy, lubricants, and slag mix at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provide flow rates and operational pressures for the radial expansion process. Thefluid passage 220 preferably includes aninlet 265 adapted to receive a plug, or other similar device. In this manner, theinterior chamber 270 above themandrel 215 may be fluidicly isolated from theinterior chamber 275 below themandrel 215. - The
tubular member 225 is coupled to themandrel launcher 210, theslips 230 and theseals 235. Thetubular member 225 preferably is a tubular member fabricated from any number of conventional commercially available materials such as, for example, low alloy steel, carbon steel, stainless steel, or oilfield country tubular goods. In a preferred embodiment, thetubular member 225 is fabricated from oilfield country tubular goods. - The
slips 230 are coupled to the outside surface of thetubular member 225. Theslips 230 preferably are adapted to couple to the interior walls of a casing, pipeline or other structure upon the radial expansion of thetubular member 225. In this manner, theslips 230 provide structural support for the expandedtubular member 225. Theslips 230 may be any number of conventional commercially available slips such as, for example, RTTS packer tungsten carbide mechanical slips, RTTS packer wicker type mechanical slips, or Model 3L retrievable bridge plug tungsten carbide upper mechanical slips. In a preferred embodiment, theslips 230 are adapted to support axial forces ranging from about 0 to 750,000 lbf. Theseals 235 are coupled to the outside surface of thetubular member 225. Theseals 235 preferably provide a fluidic seal between the outside surface of the expandedtubular member 225 and the interior walls of a casing, pipeline or other structure upon the radial expansion of thetubular member 225. In this manner, theseals 235 provide a fluidic seal for the expandedtubular member 225. Theseals 235 may be any number of conventional commercially available seals such as, for example, nitrile rubber, lead, Aflas rubber, Teflon, epoxy or other elastomers. In a preferred embodiment, theseals 235 are conventional rubber seals available from various commercial vendors in order to optimally provide pressure sealing and load bearing capacity. - The
shoe 240 is coupled to thetubular member 225. Theshoe 240 preferably is a substantially tubular member having afluid passage 245 for conveying fluidic materials from thechamber 275 to theannular region 270 outside of theapparatus 200. Theshoe 240 may be any number of conventional commercially available shoes such as, for example, a Super Seal II float shoe, a Super Seal II Down-Jet float shoe, or a guide shoe with a sealing sleeve for a latch down plug modified in accordance with the teachings of the present disclosure. In a preferred embodiment, theshoe 240 is an aluminum down-jet guide shoe with a sealing sleeve for a latch down plug, available from Halliburton Energy Services, modified in accordance with the teachings of the present disclosure, in order to optimally guide thetubular member 225 in the wellbore, optimally provide a fluidic seal between the interior and exterior diameters of the overlapping joint between the tubular members, and optimally facilitate the complete drilling out of the shoe and plug upon the completion of the cementing and radial expansion operations. - During operation of the
apparatus 200, theapparatus 200 is preferably lowered into awellbore 260 having a preexisting section ofwellbore casing 275. In a preferred embodiment, theapparatus 200 is positioned with at least a portion of thetubular member 225 overlapping with a portion of thewellbore casing 275. In this manner, the radial expansion of thetubular member 225 will preferably cause the outside surface of the expandedtubular member 225 to couple with the inside surface of thewellbore casing 275. In a preferred embodiment, the radial expansion of thetubular member 225 will also cause theslips 230 andseals 235 to engage with the interior surface of thewellbore casing 275. In this manner, the expandedtubular member 225 is provided with enhanced structural support by theslips 230 and an enhanced fluid seal by theseals 235. - As illustrated in
FIG. 2 b, after placement of theapparatus 200 in an overlapping relationship with thewellbore casing 275, afluidic material 280 is preferably pumped into thechamber 270. Thefluidic material 280 then passes through thefluid passage 220 into thechamber 275. Thefluidic material 280 then passes out of thechamber 275, through thefluid passage 245, and into theannular region 270. In a preferred embodiment, thefluidic material 280 is pumped into thechamber 270 at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to optimally provide flow rates and operational pressures for the radial expansion process. In a preferred embodiment, thefluidic material 280 is a hardenable fluidic sealing material in order to form a hardened outer annular member around the expandedtubular member 225. - As illustrated in
FIG. 2 c, at some later point in the process, aball 285, plug or other similar device, is introduced into the pumpedfluidic material 280. In a preferred embodiment, theball 285 mates with and seals off theinlet 265 of thefluid passage 220. In this manner, thechamber 270 is fluidicly isolated from thechamber 275. - As illustrated in
FIG. 2 d, after placement of theball 285 in theinlet 265 of thefluid passage 220, afluidic material 290 is pumped into thechamber 270. The fluidic material is preferably pumped into thechamber 270 at operating pressures and flow rates ranging from about 0 to 9,000 psi and 0 to 3,000 gallons/minute in order to provide optimal operating efficiency. Thefluidic material 290 may be any number of conventional commercially available materials such as, for example, water, drilling mud, cement, epoxy, or slag mix. In a preferred embodiment, thefluidic material 290 is a non-hardenable fluidic material in order to maximize operational efficiency. - Continued pumping of the
fluidic material 290 increasesfluidic material 280 increases the operating pressure within thechamber 270. The increased operating pressure in thechamber 270 then causes themandrel 215 to extrude themandrel launcher 210 andtubular member 225 off of the conical face of themandrel 215. The extrusion of themandrel launcher 210 andtubular member 225 off of the conical face of themandrel 215 causes themandrel launcher 210 andtubular member 225 to expand in the radial direction. Continued pumping of thefluidic material 290 preferably causes the entire length of thetubular member 225 to expand in the radial direction. - In a preferred embodiment, the pumping rate and pressure of the
fluidic material 290 is reduced during the latter stages of the extrusion process in order to minimize shock to theapparatus 200. In a preferred embodiment, theapparatus 200 includes shock absorbers for absorbing the shock caused by the completion of the extrusion process. In a preferred embodiment, the extrusion process causes themandrel 215 to move in anaxial direction 295. - As illustrated in
FIG. 2 e, in a preferred embodiment, upon the completion of the extrusion process, thesupport member 205,packer 210, firstfluid conduit 215,annular seal 230, secondfluid conduit 235,mandrel 245, and mandrel launcher 250 are removed from thewellbore 280, In a preferred embodiment, the resulting new section of wellbore casing includes the preexistingwellbore casing 275, the expandedtubular member 225, theslips 230, theseals 235, theshoe 240, and an outer annular layer 4000 of hardened fluidic material. - In an alternative embodiment, the
apparatus 200 is used to repair a preexisting wellbore casing or pipeline. In this alternative embodiment, both ends of the tubular member 255 preferably includeslips 260 and seals 265. - In an alternative embodiment, the
apparatus 200 is used to form a tubular structural support for a building or offshore structure. - In a preferred embodiment, the
tubular members shoes 240;expansion cone launchers expansion cones - Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
Claims (41)
1. An apparatus for radially expanding a tubular member, comprising:
a first tubular member;
a second tubular member positioned within the first tubular member;
a third tubular member movably coupled to and positioned within the second tubular member;
a first annular sealing member for sealing an interface between the first and second tubular members;
a second annular sealing member for sealing an interface between the second and third tubular members; and
a mandrel positioned within the first tubular member and coupled to an end of the third tubular member.
2. The apparatus of claim 1 , further including an annular chamber defined by the first tubular member, the second tubular member, the third tubular member, the first annular sealing member, the second annular sealing member, and the mandrel.
3. The apparatus of claim 1 , further including an annular passage defined by the second tubular member and the third tubular member.
4. The apparatus of claim 1 , further including a fluid passage contained within the third tubular member and the mandrel.
5. The apparatus of claim 1 , further including one or more sealing members coupled to an exterior surface of the first tubular member.
6. The apparatus of claim 1 , further including:
an annular chamber defined by the first tubular member, the second tubular member, the third tubular member, the first annular sealing member, the second annular sealing member, and the mandrel; and
an annular passage defined by the second tubular member and the third tubular member.
7. The apparatus of claim 6 , wherein the annular chamber and the annular passage are fluidicly coupled.
8. The apparatus of claim 1 , further including one or more slips coupled to the exterior surface of the first tubular member.
9. The apparatus of claim 1 , wherein the mandrel includes a conical surface.
10. The apparatus of claim 9 , wherein the angle of attack of the conical surface ranges from about 0 to 30 degrees.
11. The apparatus of claim 9 , wherein the conical surface has a surface hardness ranging from about 58 to 62 Rockwell C.
12. An apparatus, comprising:
a tubular member;
a piston adapted to expand the diameter of the tubular member positioned within the tubular member, the piston including a passage for conveying fluids out of the tubular member; and
an annular chamber defined by the piston and tubular member.
13. The apparatus of claim 12 , wherein the piston includes a conical surface.
14. The apparatus of claim 13 , wherein the angle of attack of the conical surface ranges from about 0 to 30 degrees.
15. The apparatus of claim 14 , wherein the conical surface has a surface hardness ranging from about 58 to 62 Rockwell C.
16. The apparatus of claim 14 , wherein the tubular member includes one or more sealing members coupled to the exterior surface of the tubular member.
17. An apparatus, comprising:
a first tubular member, and
a second tubular member coupled to the first tubular member by the process of:
positioning the second tubular member in an overlapping relationship to the first tubular member
placing a mandrel within the second tubular member;
pressurizing an annular region within the second tubular member above the mandrel; and
displacing the mandrel with respect to the second tubular member.
18. The apparatus of claim 17 , wherein the process for coupling the second tubular member to the first tubular member further comprises:
removing fluids within the second tubular member that are displaced by the displacement of the mandrel.
19. The apparatus of claim 18 , wherein the removed fluids pass inside the annular region.
20. The apparatus of claim 17 , wherein the volume of the annular region increases.
21. The apparatus of claim 17 , wherein the process for coupling the second tubular member to the first tubular member further comprises sealing off the annular region.
22. The apparatus of claim 31 , wherein sealing off the annular region includes sealing a stationary member and sealing a non-stationary member.
23. The apparatus of claim 17 , wherein the process for coupling the second tubular member to the first tubular member further comprises conveying fluids in opposite directions.
24. The apparatus of claim 17 , wherein the process for coupling the second tubular member to the first tubular member further comprises conveying a pressurized fluid and a non-pressurized fluid in opposite directions.
25. The apparatus of claim 17 , wherein the pressurizing is provided at operating pressures ranging from about 0 to 9,000 psi.
26. The apparatus of claim 17 , wherein the pressuring is provided at flow rates ranging from about 0 to 3,000 gallons/minute.
27. The apparatus of claim 17 , wherein the first tubular member includes a defective portion, and wherein the second tubular member is positioned in opposing relation to the defective portion.
28. An apparatus for radially expanding a tubular member, comprising:
a first tubular member;
a second tubular member coupled to the first tubular member;
a third tubular member coupled to the second tubular member; and
a mandrel positioned within the second tubular member and coupled to an end portion of the third tubular member;
wherein the inside diameter of the second tubular member is greater than the inside diameters of the first and third tubular members.
29. The apparatus of claim 28 , wherein the mandrel includes a fluid passage having an inlet adapted to receive fluid stop member.
30. The apparatus of claim 28 , further including one or more slips coupled to the exterior surface of the third tubular member.
31. The apparatus of claim 28 , wherein the mandrel includes a conical surface.
32. The apparatus of claim 31 , wherein the angle of attack of the conical surface ranges from about 0 to 30 degrees.
33. The apparatus of claim 31 , wherein the conical surface has a surface hardness ranging from about 58 to 62 Rockwell C.
34. An apparatus, comprising:
a tubular member having a first portion, a second portion, and a third portion; and
a piston adapted to expand the diameter of the tubular member positioned within the second portion of the tubular member, the piston including a passage for conveying fluids out of the tubular member;
wherein the inside diameter of the second portion of the tubular member is greater than the inside diameters of the first and third portions of the tubular member.
35. The apparatus of claim 34 , wherein the piston includes a conical surface.
36. The apparatus of claim 35 , wherein the angle of attack of the conical surface ranges from about 0 to 30 degrees.
37. The apparatus of claim 35 , wherein the conical surface has a surface hardness ranging from about 58 to 62 Rockwell C.
38. The apparatus of claim 34 , wherein the tubular member includes one or more sealing members coupled to the exterior surface of the tubular member.
39. An apparatus for radially expanding a tubular member, comprising:
a first tubular member;
a second tubular member positioned within the first tubular member;
a third tubular member movably coupled to and positioned within the second tubular member;
a first annular sealing member for sealing an interface between the first and second tubular members;
a second annular sealing member for sealing an interface between the second and third tubular members;
a mandrel positioned within the first tubular member and coupled to an end of the third tubular member;
an annular chamber defined by the first tubular member, the second tubular member, the third tubular member, the first annular sealing member, the second annular sealing member, and the mandrel;
a fluid passage defined by the third tubular member and the mandrel fluidicly coupled to an interior region of the first tubular member below the mandrel; and
an annular passage defined by the second tubular member and the third tubular member fluidicly coupled to the annular chamber.
40. An apparatus, comprising:
a first tubular member; and
a second tubular member coupled to the first tubular member by the process of:
positioning the second tubular member in an overlapping relationship to the first tubular member;
placing a mandrel within the second tubular member;
sealing off an annular region within the second tubular member above the mandrel by sealing a stationary member and sealing a non-stationary member;
pressurizing the annular region;
displacing the mandrel with respect to the second tubular member; and
removing fluids within the second tubular member that are displaced by the displacement of the mandrel by passing the removed fluids inside of the annular region.
41. An apparatus for radially expanding a tubular member, comprising:
a first tubular member;
a second tubular member coupled to the first tubular member;
a third tubular member coupled to the second tubular member;
one or more slips coupled to the exterior surface of the third tubular member; and
a mandrel having a conical outer surface including an angle of attack between about 0 to 30 degrees and a surface hardness ranging from about 58 to 62 Rockwell C positioned within the second tubular member and coupled to an end portion of the third tubular member;
wherein the inside diameter of the second tubular member is greater than the inside diameters of the first and third tubular members;
wherein the mandrel includes a fluid passage having an inlet adapted to receive fluid stop member.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/553,240 US20070151725A1 (en) | 1998-12-07 | 2006-10-26 | Expanding a tubular member |
Applications Claiming Priority (14)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11129398P | 1998-12-07 | 1998-12-07 | |
US11961199P | 1999-02-11 | 1999-02-11 | |
US12170299P | 1999-02-25 | 1999-02-25 | |
US12404299P | 1999-03-11 | 1999-03-11 | |
US13110699P | 1999-04-26 | 1999-04-26 | |
US09/454,139 US6497289B1 (en) | 1998-12-07 | 1999-12-03 | Method of creating a casing in a borehole |
US09/502,350 US6823937B1 (en) | 1998-12-07 | 2000-02-10 | Wellhead |
US18354600P | 2000-02-18 | 2000-02-18 | |
US09/510,913 US7357188B1 (en) | 1998-12-07 | 2000-02-23 | Mono-diameter wellbore casing |
US09/523,468 US6640903B1 (en) | 1998-12-07 | 2000-03-10 | Forming a wellbore casing while simultaneously drilling a wellbore |
US09/559,122 US6604763B1 (en) | 1998-12-07 | 2000-04-26 | Expandable connector |
US10/169,434 US7603758B2 (en) | 1998-12-07 | 2001-02-14 | Method of coupling a tubular member |
PCT/US2001/004753 WO2001060545A1 (en) | 2000-02-18 | 2001-02-14 | Expanding a tubular member |
US11/553,240 US20070151725A1 (en) | 1998-12-07 | 2006-10-26 | Expanding a tubular member |
Related Parent Applications (7)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/454,139 Continuation-In-Part US6497289B1 (en) | 1998-11-16 | 1999-12-03 | Method of creating a casing in a borehole |
US09/502,350 Continuation-In-Part US6823937B1 (en) | 1998-11-16 | 2000-02-10 | Wellhead |
US09/510,913 Continuation-In-Part US7357188B1 (en) | 1998-11-16 | 2000-02-23 | Mono-diameter wellbore casing |
US52346000A Continuation-In-Part | 1998-12-07 | 2000-03-10 | |
US09/559,122 Continuation-In-Part US6604763B1 (en) | 1998-11-16 | 2000-04-26 | Expandable connector |
US10/169,434 Division US7603758B2 (en) | 1998-11-16 | 2001-02-14 | Method of coupling a tubular member |
PCT/US2001/004753 Division WO2001060545A1 (en) | 1998-12-07 | 2001-02-14 | Expanding a tubular member |
Publications (1)
Publication Number | Publication Date |
---|---|
US20070151725A1 true US20070151725A1 (en) | 2007-07-05 |
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ID=33492677
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/553,240 Abandoned US20070151725A1 (en) | 1998-12-07 | 2006-10-26 | Expanding a tubular member |
Country Status (1)
Country | Link |
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US (1) | US20070151725A1 (en) |
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US7793721B2 (en) | 2003-03-11 | 2010-09-14 | Eventure Global Technology, Llc | Apparatus for radially expanding and plastically deforming a tubular member |
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US20120205091A1 (en) * | 2011-02-16 | 2012-08-16 | Turley Rocky A | Stage tool |
US20130000924A1 (en) * | 2011-06-29 | 2013-01-03 | Enventure Global Technology, L.L.C. | Expandable liner system |
US8573293B1 (en) | 2008-02-29 | 2013-11-05 | Pruitt Tool & Supply Co. | Dual rubber cartridge |
US8905150B1 (en) | 2011-08-22 | 2014-12-09 | Pruitt Tool & Supply Co. | Casing stripper attachment |
US8973652B1 (en) | 2011-08-22 | 2015-03-10 | Pruitt Tool & Supply Co. | Pipe wiper box |
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US9810037B2 (en) | 2014-10-29 | 2017-11-07 | Weatherford Technology Holdings, Llc | Shear thickening fluid controlled tool |
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US7793721B2 (en) | 2003-03-11 | 2010-09-14 | Eventure Global Technology, Llc | Apparatus for radially expanding and plastically deforming a tubular member |
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US8573293B1 (en) | 2008-02-29 | 2013-11-05 | Pruitt Tool & Supply Co. | Dual rubber cartridge |
US9243730B1 (en) | 2010-09-28 | 2016-01-26 | Pruitt Tool & Supply Co. | Adapter assembly |
US9163468B2 (en) | 2010-10-22 | 2015-10-20 | Enventure Global Technology, Llc | Expandable casing patch |
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US11215021B2 (en) | 2011-02-16 | 2022-01-04 | Weatherford Technology Holdings, Llc | Anchoring and sealing tool |
US9920588B2 (en) | 2011-02-16 | 2018-03-20 | Weatherford Technology Holdings, Llc | Anchoring seal |
US10174579B2 (en) | 2011-02-16 | 2019-01-08 | Weatherford Technology Holdings, Llc | Extrusion-resistant seals for expandable tubular assembly |
US9528352B2 (en) | 2011-02-16 | 2016-12-27 | Weatherford Technology Holdings, Llc | Extrusion-resistant seals for expandable tubular assembly |
US9567823B2 (en) | 2011-02-16 | 2017-02-14 | Weatherford Technology Holdings, Llc | Anchoring seal |
US20130000924A1 (en) * | 2011-06-29 | 2013-01-03 | Enventure Global Technology, L.L.C. | Expandable liner system |
US8973652B1 (en) | 2011-08-22 | 2015-03-10 | Pruitt Tool & Supply Co. | Pipe wiper box |
US8905150B1 (en) | 2011-08-22 | 2014-12-09 | Pruitt Tool & Supply Co. | Casing stripper attachment |
US9260926B2 (en) | 2012-05-03 | 2016-02-16 | Weatherford Technology Holdings, Llc | Seal stem |
US9810037B2 (en) | 2014-10-29 | 2017-11-07 | Weatherford Technology Holdings, Llc | Shear thickening fluid controlled tool |
US10180038B2 (en) | 2015-05-06 | 2019-01-15 | Weatherford Technology Holdings, Llc | Force transferring member for use in a tool |
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Legal Events
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AS | Assignment |
Owner name: SHELL OIL COMPANY, TEXAS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:COOK, ROBERT LANCE;BRISCO, DAVID PAUL;STEWART, R. BRUCE;AND OTHERS;REEL/FRAME:019033/0302;SIGNING DATES FROM 20061217 TO 20070119 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |