U.S. patent application number 10/174699 was filed with the patent office on 2003-12-25 for internal support apparatus for downhole tubular structures and method of use.
Invention is credited to Echols, Ralph H., Freeman, Tommie Austin, Hailey,, Travis T. JR., Rice, Patrick W., Yonker, John H..
Application Number | 20030234111 10/174699 |
Document ID | / |
Family ID | 29733658 |
Filed Date | 2003-12-25 |
United States Patent
Application |
20030234111 |
Kind Code |
A1 |
Echols, Ralph H. ; et
al. |
December 25, 2003 |
Internal support apparatus for downhole tubular structures and
method of use
Abstract
An internal support apparatus and method for providing support
to a tubular structure that is positioned in a wellbore. The
apparatus is insertable into the tubular structure to reside in
close proximity with an interior surface of the tubular structure,
make light contact with an interior surface of the tubular
structure, or expand the tubular structure. Thereafter, the support
apparatus can remain in the tubular structure indefinitely to
provide support against collapse or further collapse and allow the
tubular structure to remain in operation.
Inventors: |
Echols, Ralph H.; (Dallas,
TX) ; Freeman, Tommie Austin; (Flower Mound, TX)
; Rice, Patrick W.; (Plano, TX) ; Hailey,, Travis
T. JR.; (Sugar Land, TX) ; Yonker, John H.;
(Carrollton, TX) |
Correspondence
Address: |
HALLIBURTON ENERGY SERVICES, INC.
2601 BELTLINE ROAD
BUILDING 1-B
CARROLLTON
TX
75006
US
|
Family ID: |
29733658 |
Appl. No.: |
10/174699 |
Filed: |
June 19, 2002 |
Current U.S.
Class: |
166/382 ;
166/207; 166/230 |
Current CPC
Class: |
E21B 29/10 20130101;
E21B 43/108 20130101; E21B 43/088 20130101; E21B 43/103 20130101;
E21B 17/1014 20130101 |
Class at
Publication: |
166/382 ;
166/207; 166/230 |
International
Class: |
E21B 023/01 |
Claims
We claim:
1. An internal support apparatus for fixed installation in a
tubular structure that is residing in a wellbore, comprising: an
elongate body; at least one support member along a length of the
elongate body and projecting outward therefrom, wherein the at
least one support member projects at least into close proximity
with an interior surface of the tubular structure when the
apparatus is inserted into the tubular structure.
2. The apparatus of claim 1 wherein the elongate body is tubular,
and further comprising at least one aperture in the elongate body
for passage of fluids between an interior and an exterior of the
elongate body.
3. The apparatus of claim 1 wherein the at least one support member
is at least one ridge running longitudinally on the elongate
body.
4. The apparatus of claim 1 wherein the at least one support member
is a plurality of ridges running longitudinally on the elongate
body and substantially equally spaced about the circumference of
the elongate body.
5. The apparatus of claim 1 wherein the at least one support member
is wire wrapped around the elongate body.
6. The apparatus of claim 5 wherein the wire is wrapped in a
pattern to act as a filter.
7. The apparatus of claim 1 wherein the at least one support member
is residing in substantially perpendicular relation to the axis of
the elongate body.
8. The apparatus of claim 7 wherein the at least one support member
is changeable from a first position residing in substantially
perpendicular relation to the axis of the elongate body to a second
position residing at an acute angle to the axis of the elongate
body; and wherein in the first position, a longest distance between
the at least one support member and the axis of the elongate body
is greater than a longest distance between the at least one support
member and the axis of the elongate body in the second
position.
9. The apparatus of claim 7 wherein the at least one support member
tilts about a tilt axis perpendicular to a longitudinal axis of the
elongate body from a first position residing in substantially
perpendicular relation to the longitudinal axis of the elongate
body to a second position residing at an acute angle to the
longitudinal axis of the elongate body; and wherein a dimension of
the at least one support member measured along the tilt axis is
smaller than a dimension of the at least one support member
measured perpendicular to the tilt axis.
10. The apparatus of claim 1 wherein the at least one support
member has a sloping surface on one end adapted to expand the
tubular structure about the internal support apparatus as the
internal support apparatus is inserted into the tubular
structure.
11. The apparatus of claim 1 wherein the elongate body has a
sloping surface on one end adapted to expand the tubular structure
about the internal support apparatus as the internal support
apparatus is inserted into the tubular structure.
12. The apparatus of claim 1 further comprising at least one seal
for substantially sealing the elongate body to the tubular
structure.
13. The apparatus of claim 12 wherein the at least one seal is at
least two seals spaced apart to seal an interval of the tubular
structure.
14. The apparatus of claim 1 wherein the tubular structure is at
least partially collapsed, and wherein the at least one support
member projects at least into light contact with an interior
surface of a collapsed portion of the tubular structure.
15. The apparatus of claim 1 wherein the tubular structure is at
least partially collapsed, and wherein the at least one support
member projects radially past an interior surface of a collapsed
portion of the tubular structure such that the collapsed portion
must expand to receive the support apparatus.
16. The apparatus of claim 1 wherein the at least one support
member projects at least into light contact with an interior
surface of the tubular structure.
17. The apparatus of claim 1 wherein the tubular structure is
affixed to the wellbore.
18. The apparatus of claim 1 wherein the at least one support
member is movable parallel to a radius of the tubular body, and
wherein the at least one support member is biased radially
outward.
19. An apparatus for insertion into a tubular structure that is
residing in a wellbore, comprising: a tubular body having at least
one slot running in a helical pattern about the body, wherein the
slot is adapted to allow the tubular body to be extended axially,
and extending the tubular body axially from a first position to a
second position contracts the tubular body radially.
20. The apparatus of claim 19 wherein in a second position, a
largest dimension of the body measured perpendicular to the axis of
the body is less than a smallest internal dimension of the tubular
structure measured perpendicular to the axis of the tubular
structure.
21. The apparatus of claim 19 wherein the body has apertures
allowing fluid flow between an exterior of the body and an interior
of the body.
22. The apparatus of claim 19 wherein the body is configured such
that when residing in the tubular structure, the body in a first
position makes light contact with an interior surface of the
tubular structure.
23. The apparatus of claim 19 wherein the body is configured such
that when residing in the tubular structure, the body in a first
position expands the tubular structure.
24. The apparatus of claim 19 wherein the body is configured such
that when residing in a collapsed portion of the tubular structure,
the body in a first position expands the collapsed portion of the
tubular structure.
25. The apparatus of claim 19 wherein the body is configured such
that in a second position the body passes freely through the
tubular structure.
26. The apparatus of claim 19 wherein the body is configured such
that when residing in the tubular structure, the body in a first
position is inset from an interior surface of the tubular
structure.
27. The apparatus of claim 19 further comprising slips at an end of
the body configured to engage an interior surface of the tubular
structure when the body is in a first position.
28. A device for internally supporting a tubular structure
positioned in a well bore, comprising: an elongate tubular body
having apertures that allow fluid communication between an exterior
of the tubular body and an interior of the tubular body; and a wire
wrapped mesh about the exterior of the elongate tubular body;
wherein the device is configured such that when residing in the
tubular structure, the device is positioned at least in close
proximity with an interior surface of the tubular structure.
29. The device of claim 28 wherein the wire wrapped mesh comprises
a wire wrapped circumferentially about the exterior of the elongate
tubular body.
30. The device of claim 28 wherein the wire wrapped mesh is
configured to filter against passage of sand into the interior of
the elongate tubular body.
31. The device of claim 28 wherein the elongate tubular body has at
least one seal adapted to substantially seal against the tubular
structure.
32. The device of claim 28 wherein the elongate tubular body has at
least two seals residing in spaced relation and adapted to
substantially seal against the tubular structure.
33. The device of claim 28 wherein an end of the elongate tubular
body has an inwardly sloping surface configured to act as a
mandrel.
34. The device of claim 28 wherein the device makes light contact
with an interior surface of the tubular structure.
35. A device for internal support of a tubular structure,
comprising: an elongate body; and at least one support member
changeable from a first position residing in substantially
perpendicular relation to the axis of the elongate body to a second
position residing at an acute angle to the axis of the elongate
body; and wherein in the first position, a longest distance
measured perpendicular to the axis of the elongate body and between
the at least one support member and the axis of the elongate body
is greater than in the second position.
36. The device of claim 35 wherein in the second position the
longest distance is less than a smallest internal dimension of the
tubular structure.
37. The device of claim 35 wherein a height of the at least one
support member is greater than a width of the at least one support
member.
38. The device of claim 35 wherein the at least one support member
is configured to make light contact with an interior surface of the
tubular structure when in the first position.
39. The device of claim 35 wherein the at least one support member
is configured to pass freely through the interior of the tubular
structure when in the second position.
40. An internal support apparatus insertable into a tubular
structure that is residing in a wellbore, the support apparatus
comprising: an elongate body; and at least one support member
movable between a radially retracted position and a radially
extended position; wherein the at least one support member is
biased to the radially extended position.
41. The apparatus of claim 40 wherein the at least one support
member is a semi-elliptic spring.
42. The apparatus of claim 40 wherein the at least one support
member is biased to the radially extended position by at least one
spring.
43. The apparatus of claim 40 configured such that when residing in
the tubular structure the at least one support member in a radially
extended position makes light contact with an interior surface of
the tubular structure.
44. The apparatus of claim 40 wherein when residing in a tubular
structure with at least a portion of the tubular structure
collapsed, the at least one support member in a radially extended
position makes light contact with a substantially uncollapsed
portion of the tubular structure.
45. The apparatus of claim 44 wherein the at least one support
member in a radially retracted position makes light contact with
the collapsed portion of the tubular structure.
46. A method of providing support to a tubular structure that is
residing in a wellbore, the method comprising: inserting a tubular
body having a plurality of apertures spaced thereabout into the
tubular structure; fixing the tubular body in the borehole; and
moving a mandrel through the tubular body thereby expanding the
tubular body into light contact with a interior surface of the
tubular structure.
47. The method of claim 46 wherein the tubular structure is at
least partially collapsed, and wherein the step of moving a mandrel
through the tubular body further comprises expanding at least the
collapsed portion of the tubular structure.
48. The method of claim 46 wherein the apertures are slots.
49. A method for providing support to a tubular structure that is
residing in a well, the method comprising: inserting an elongate
body having at least one support member into the tubular structure
such that the at least one support member resides at least in close
proximity with an interior surface of the tubular structure; and
producing fluids from the well through the tubular structure.
50. The method of claim 49 wherein the tubular structure is at
least partially collapsed and wherein inserting an elongate body
into the tubular structure comprises expanding the collapsed
portion of the tubular structure.
51. The method of claim 49 wherein the support member resides in
light contact with an interior surface of the tubular
structure.
52. The method of claim 49 further comprising anchoring the
elongate body in the wellbore.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field of the Invention
[0002] The present invention relates in general to providing
internal support to tubular structures in a wellbore, and more
particularly to an apparatus for providing support to such tubular
structures to compensate for physical weakness or damage.
[0003] 2. Description of Related Art
[0004] In a well, such as an oil and gas well, utilizing
sand-control screens, the annulus between the wellbore and the
sand-control screens is generally packed within a layer of gravel
commonly referred to in the industry as "gravel packing" or "gravel
pack." The gravel layer (gravel pack) acts as a filter to prevent
passage of formation fines (ex. sand) and other particulate into
the production string. The sand-control screen provides a secondary
filter to filter additional particulate and to prevent entry of the
gravel pack into the production tubing. Over time, the gravel and
the sand-control screens can become filled or clogged with
particulate. The clogs increase resistance to fluid flow thereby
creating an increasing pressure differential between the interior
and exterior of the screen. This pressure differential causes
increased loading on the screen that can cause it to collapse.
Expanded screens, those that are inserted into position and then
expanded to form the screen, are especially susceptible to collapse
because of their inherent structural design. If the screen
collapses, its permeability can be decreased, dramatically reducing
the flow capacity of the screen. Also, the decrease in flow area
caused by clogging or collapsed portions cause localized increased
flow velocities. The increased flow velocity in localized regions
of the screen promotes erosion and premature failure. In order to
restore a well to its full production capability a collapsed screen
must be removed and replaced. This requires removal and
reinstallation of the entire production string in the wellbore, a
time consuming and costly procedure.
[0005] In a related problem, portions of the production string, for
example the production tubing, sand-control screens, or other
components in the string, can be damaged when the formation shifts
or sluffs into the wellbore. The damage can restrict flow through
the production string and cause localized increased flow speeds
that promote erosion. As above, repair of a damaged portion of the
production string requires removal and reinstallation of the entire
production string.
[0006] In a worse case scenario, the production string and/or
sand-control screens can become stuck in the formation and cannot
be removed. Such a scenario may necessitate premature abandonment
of the well.
[0007] Therefore, there is a need to provide internal support to
the damaged or weak tubular structures in the well bore, such as
sand-control screens, production tubing, or other like structures.
Such support should both prevent collapse of the tubular structure,
and remedy collapsed tubular structures, without requiring removal
and reinstallation of the tubular structure.
SUMMARY OF THE INVENTION
[0008] The invention provides an internal support apparatus and a
method of supporting tubular structures in a wellbore. Such support
may eliminate the need to replace the tubular structure and allow
the tubular structure to remain in operation.
[0009] In one embodiment, the invention encompasses an internal
support apparatus for fixed installation in a tubular structure
that is residing in a wellbore. The support apparatus includes an
elongate body. At least one support member projects outwardly from
the elongate body at least into close proximity with an interior
surface of the tubular structure when the apparatus is inserted
into the tubular structure. The elongate body can be tubular and
can have at least one aperture for passage of fluids between an
interior and an exterior of the elongate body. The support member
can be at least one ridge running longitudinally on the exterior
surface of the elongate tubular body. The support member can be a
plurality of ridges running longitudinally on the elongate body and
substantially equally spaced about the circumference of the
elongate body. The support member can be wire wrapped around the
elongate body, and the wire can be wrapped in a pattern to act as a
filter. The support member can reside in substantially
perpendicular relation to the axis of the elongate body.
[0010] In another embodiment the support apparatus has an elongate
body and at least one support member changeable from a first
position residing in substantially perpendicular relation to the
axis of the elongate body to a second position residing at an acute
angle to the axis of the elongate body. In the first position, a
longest distance between the at least one support member and the
axis of the elongate body is greater than a longest distance
between the at least one support member and the axis of the
elongate body in the second position.
[0011] In another embodiment the support apparatus has a tubular
body with at least one slot running in a helical pattern about the
body. The slot enables the tubular body to be extend.
[0012] An advantage of the invention is that physically weak or
damaged tubular structures that are residing in the wellbore can be
supported rather than requiring costly replacement or other
remedial actions.
[0013] Another advantage of the invention is that, in some
situations, the support device can be installed without requiring
removal of the production string.
[0014] Another advantage of the invention is that after
installation of the support apparatus, the tubular structure can be
operated as normal. For example, if in normal operation the tubular
structure is a conduit for fluids, fluids may continued to be
flowed through the tubular structure after installation of the
support apparatus.
[0015] Another advantage of the invention is that the devices are
simple, and thus inexpensive to manufacture.
[0016] These and other advantages will be apparent from the
accompanying drawings and detailed disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Various objects and advantages of the invention will become
apparent and more readily appreciated from the following
description of the exemplary embodiments, taken in conjunction with
the accompanying drawings of which:
[0018] FIGS. 1A and 1B are cross-sectional views of an exemplary
support apparatus supporting a tubular structure in accordance with
the present invention, the support apparatus having support
ridges;
[0019] FIGS. 2A and 2B are cross-sectional views of another
exemplary support apparatus supporting a tubular structure in
accordance with the invention, the support apparatus having support
ridges;
[0020] FIGS. 3A and 3B are cross-sectional views of another
exemplary support apparatus supporting a tubular structure in
accordance with the invention, the support apparatus having support
bows;
[0021] FIGS. 4A and 4B are cross-sectional views of another
exemplary support apparatus supporting a tubular structure in
accordance with the invention, the support apparatus having
outwardly biased support blocks;
[0022] FIGS. 5A and 5B are cross-sectional views of another
exemplary support apparatus supporting a tubular structure in
accordance with the invention, the support apparatus having a
wire-wrapped support structure;
[0023] FIGS. 6A and 6B are partial cross-sectional side views of
another exemplary support apparatus in accordance with the present
invention, being inserted into a tubular structure (FIG. 6A) and
expanded to support the tubular structure (FIG. 6B);
[0024] FIGS. 7A, 7B, and 7C are cross-sectional views in sequence
depicting use of another exemplary support apparatus in accordance
with the present invention, wherein FIG. 7A depicts the support
apparatus being inserted into the tubular structure, FIG. 7B
depicts the support apparatus is being expanded by inserting a
mandrel through the support apparatus located inside of the tubular
structure, and FIG. 7C depicts the support apparatus expanded to
support the tubular structure;
[0025] FIGS. 8A and 8B and 8C are cross-sectional views in sequence
depicting another exemplary internal support apparatus in
accordance with the present invention, wherein FIG. 8A illustrates
the support apparatus before activation and FIG. 8B illustrates the
support apparatus after actuation; and 8C illustrates a selective
injection tool actuating the support apparatus; and
[0026] FIGS. 9A and 9B are elevational views of two exemplary
support plates for use with the exemplary embodiment depicted in
FIGS. 8A and 8B.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS OF THE
INVENTION
[0027] Reference is now made to the drawings wherein like reference
numerals denote like or similar parts throughout the Figures.
[0028] Referring first to FIGS. 1A and 1B, a wellbore 10 of a
subterranean well has a tubular structure 12 residing therein for
which internal support is desired. The term tubular structure is
used herein to encompass virtually any type of device within the
wellbore 10 that has a tubular or substantially tubular
cross-section for at least a portion of its length. The tubular
structure 12 can be, for example, a fluid permeable screen for
preventing intrusion of particulate into the production tubing
(including an expanded screen of the same type), a portion of flow
tubing (such as the production tubing), or a portion of the
wellbore casing. One of ordinary skill in the art will appreciate
the applicability of the apparatus and methods described herein to
many other various tubular structures 12 within the wellbore 10. An
internal support apparatus 14 resides in the tubular structure 12,
and has been fixedly installed such that there is substantially no
movement of the support apparatus 14 in relation to the tubular
structure 12. Thereafter, the support apparatus 14 remains in the
tubular structure 12 indefinitely to provide support against
collapse or further collapse and allow the tubular structure 12 to
remain in operation. Thus, for example, if the tubular structure 12
is a sand screen, fluids are produced from the well as normal (i.e.
from the formation through the sand screen).
[0029] One exemplary internal support apparatus 14 has an elongate
tubular body 16 with one or more radially outwardly projecting
support ridges 20 on its exterior. The tubular body 16 can be
continuous (FIGS. 1A and 1B) or can have one or more apertures 18
to allow fluid flow therethrough (FIGS. 2A and 2B). The support
ridges 20 run longitudinally along at least a portion of the length
of the tubular body 16. While depicted in the figures as
cylindrical tubing, the tubular body 16 can be of any profile and
any cross-section. Thus, for example, the cylindrical cross-section
tube can be substituted by a rectangular, square, triangular,
hexagonal, or other cross-section tube.
[0030] The number of support ridges 20 depends on the particular
application and the manner of support required by the tubular
structure 12, and can be a single ridge or a plurality of ridges.
For example, two support ridges 20 in opposing relation on the
surface of the tubular body 16 will provide support primarily to
opposing portions of the tubular structure 12. Multiple ridges 20
distributed about the tubular body 16 (see FIG. 1B) will provide
more even support, because the ridges will bear more evenly on the
interior surface of the tubular structure 12. If more than one
ridge 20 is provided, the ridges 20 can be equally spaced about the
tubular body, or spaced in an irregular configuration depending the
manner of support required by the tubular structure 12. Ridges 20
need not be continuous along the entire length of the tubular body
16. Also, ridges 20 need not be of rectangular section as depicted
in the figures, but can be of other shapes, for example but in no
means by limitation, domed, triangular, trapezoidal or
otherwise.
[0031] In use, the internal support apparatus 14 is positioned in
the interior of the tubular structure 12 to which it is providing
support, and remains in place during operation of the tubular
structure 12. In one exemplary embodiment, the support apparatus 14
is configured such that the ridges 20 reside in light contact with
or slightly inset from the interior surface of the (undamaged)
tubular structure 12. The term "light contact" is used herein to
describe that the support apparatus 14 continuously or
intermittently contacts the tubular structure 12 without
substantially expanding the tubular structure 12. The term "slight
inset" is used herein to describe that the support apparatus 14
resides in close proximity with the inner surface of the tubular
structure 12, but does not make contact with the tubular structure
12. When in close proximity, the tubular structure 12 can flex
inward into contact with the support apparatus 14, but does not
flex enough that the tubular structure 12 is substantial damaged
(ex. bend, tear or break).
[0032] The distance between the outermost surface of opposing
ridges 20 can be equal to or slightly smaller than an interior
dimension of the undamaged tubular structure 20. Thus, if the
support apparatus 14 is inserted into an undamaged tubular
structure 12, the ridges 20 will support against collapse of the
tubular structure 12. If inserted into a collapsed or otherwise
damaged tubular structure 12, the ridges 20 will expand the
collapsed portion of the tubular structure 12 to approximately its
original interior dimensions. The same effect can be accomplished
by configuring the support apparatus 14 such that the ridges 20
reside slightly inset and not touching the inner surface of the
tubular structure 12. However, if the ridges are slightly inset,
the support apparatus 14 will be easier to pass into and out of the
tubular structure 12. Alternately, in a collapsed or otherwise
damaged tubular structure 12, the ridges 20 can be configured to
lightly contact the inner surface of the damaged portion of the
tubular structure 12 to support against further collapse while not
substantially expanding the collapsed portion. As above, the same
effect can be accomplished by configuring the support apparatus 14
such that the ridges 20 are slightly inset from the inner surface
of the damaged portion. For example, the distance between the
outermost surface of opposing ridges 20 is equal to or slightly
smaller than an interior dimension of the damaged portion of the
tubular structure 20. It may also be desirable to configure the
support apparatus 14 such that the ridges 20 would partially expand
a damaged portion of the tubular structure 12, but not fully expand
the damaged portion to its original dimension. For example, the
distance between the outermost surface of opposing ridges 20 is
greater than an interior dimension of the damaged portion, but
smaller than the interior dimension of an undamaged portion of the
tubular structure. The distance between the outermost surfaces of
opposing ridges 20 can be different between different pairs of
opposing ridges 20 on the same support apparatus 14 to accommodate
various internal dimensions (damaged or undamaged) of the tubular
structure 12.
[0033] The longitudinal length of internal support apparatus 14 is
preferably sized to span the portion of the tubular structure 12
requiring support. However, multiple support apparatus 14 can be
joined together to span the portion of the tubular structure 12
requiring support, as is shown in FIG. 2A.
[0034] The leading edge of the ridges 20 can have a mandrel surface
22 sloping inward and forward towards the center line of the
support apparatus 14. The mandrel surface 22 acts as a mandrel or a
wedge to force the tubular structure 12 over the ridges 20 as the
support apparatus 14 is inserted into the tubular structure 12.
Thus, if the support apparatus 14 is configured to expand the
tubular structure 12, the support apparatus 14 will more easily and
smoothly pass into and expand the tubular structure 12, reducing
the risk of the support apparatus 14 hanging on tubular structure
12 or causing further damage.
[0035] Referring now to FIGS. 3A and 3B, rather than having fixed
ridges 20 as discussed with respect to the support apparatus 14 of
FIGS. 1 and 2, an alternate support apparatus 70 can have radially
resilient support bows 72. One end of each support bow 72 is
secured to the tubular body 16, for example with a weld or fastener
74, such as a screw or bolt. The support bows 72 are semi-elliptic
springs that arch radially outward from the tubular body 16,
resisting but allowing radial compression inward towards the
tubular body 16. As above, one or multiple bows can be arranged
about the exterior tubular body 16. The number and orientation will
depend on the particular support required by the tubular structure
12, as discussed above. The support apparatus 14 can be configured
such that the resilient support bows 72 make light contact with the
inner surface of an undamaged tubular structure 12. As can be seen
in FIG. 3A, when inserted into the tubular structure 12, the
resilient support bows 72 will then flex inward to accommodate and
provide support to a collapsed or damaged portion of the tubular
structure 12. Thus, the support apparatus 70 can be fixably
installed in a damaged or undamaged tubular structure 12 and
provide support during the operation of the tubular structure 12.
As above, apertures 18 can be optionally be provided in the tubular
body 16 to allow passage of fluid from the exterior of the tubular
body 16 into the interior of the tubular body 16.
[0036] Referring to FIGS. 4A and 4B, an alternate embodiment of the
support apparatus 76 incorporates radially movable support blocks
78 biased outward from the tubular body 16. As above, apertures 18
can optionally be provided in the tubular support body 16 to allow
for flow therethrough. The support apparatus 76 has an exterior
housing 80 concentric about the tubular body 16. The support blocks
78 reside between the exterior housing 80 and the tubular body 16,
and extend partially out from the exterior housing 80. Springs 84
are positioned between the support blocks 78 and the tubular body
16 to bias the support blocks 78 radially outwardly. The support
blocks 78 are configured to be moveable between a retracted
position, with the springs 84 compressed and the support block 78
adjacent the tubular body 16, and an extended position, with the
springs 84 expanded and the support block 78 radially offset from
the tubular body 16. Each of the support blocks 78 has a stop
flange 82 about its perimeter that is configured to abut the inner
surface of the housing 80 when the support block 78 is fully
extended to retain the block 78 in the housing 80. The support
apparatus 12 can be configured such that the support blocks 78 bear
lightly against the inner surface of the undamaged tubular
structure 12. However, when the support apparatus 76 is inserted
into a tubular structure 12 that has collapsed or partially
collapsed, the support blocks 78 in the portion of the collapsed
tubular structure 12 will be pushed radially in towards the tubular
body 16, and conform to the interior shape of the collapsed tubular
structure 12. The radially outward bias of the support blocks 78
then provides radial support to the collapsed or partially
collapsed portion of the tubular structure 12. Thus, the support
apparatus 76 can be fixably installed in a damaged or undamaged
tubular structure 12 and provide support during the operation of
the tubular structure 12.
[0037] Referring to FIGS. 5A and 5B, in another embodiment, the
tubular body 16 can have a screen-type support structure 24 that
functions similarly to the ridges 20 described above. The
screen-type support structure can be built-up in a wire-wrapping
process and with wire circumferentially or spirally wrapped along
the longitudinal length of the tubular body 16 to form the support
structure 24. Additionally, wire laid longitudinally beneath the
circumferential or spiral wire can be used to build up the screen
structure 24. The screen-type support structure 24 can be
constructed to operate as a screen or filter, for example by
deliberate spacing of the wire-wrap to reduce entry of particulate
(such as sand and gravel) into the interior of the support
apparatus 14. As above, the tubular body 16 can have apertures 18
to allow fluid passage therethrough. Also, as above, the support
apparatus 14 can have a sloped mandrel surface 26 on its leading
edge. However, as seen in FIG. 5A, the mandrel surface 26 need not
be part of the ridges 20 (as in FIG. 1A) and can be provided on the
tubular body 16 itself. A mandrel surface 26 integrated into the
tubular body 16 can be used with any of the embodiments disclosed
herein. The support apparatus 14 can be configured to reside in
light contact with the undamaged tubular structure 12, in light
contact with a damaged portion of the tubular structure 12,
slightly inset from the undamaged or damaged portion of the tubular
structure 12, or to expand a damaged portion of the tubular
structure 12.
[0038] The internal support apparatus 14 can be configured to seal
or substantially seal with the tubular structure 12 at one or more
points along its length. As can be seen in FIG. 5A, support
apparatus 14 can be provided with a seal 28 positioned to
substantially continuously abut the inner diameter of the tubular
structure 12 and seal or substantially seal against passage of
fluid or particulate from below the seal 28 into the annular space
between the support apparatus 14 and the interior surface of
tubular support structure 12. Seal 28 is provided in the rear
portion of mandrel 24, but can be provided at any point along the
support apparatus 14 that would place the seal in a position to
seal against the interior surface of tubular structure 12. An
additional seal 30 can be provided on the support apparatus 14 to
abut and seal or substantially seal against another portion of the
interior of the tubular structure 12. Provided that flow from below
seal 28 and above seal 30 is prevented, the support apparatus 14
will isolate an interval of the tubular structure 12 between the
seals, so that only flow from between the seals can pass through
the internal support apparatus 14. The support apparatus 14 may,
for example, be configured to filter particulate, as described
above, and to use seals to isolate a portion of a ruptured tubular
structure 12 so that flow entering the rupture will be filtered
through the support apparatus 14. In another example, the internal
support apparatus 14 may be configured without apertures, thus
isolating a damaged portion of the tubular structure 12 with seals
will minimize intrusion of fluid from a damaged portion. Although
such seals 28 and 30 are only discussed with respect to support
apparatus 14 having a screen-type support structure 24, similar
seals can be provided on any of the exemplary embodiments described
herein.
[0039] While each of the embodiments described herein can be fixed
relative to the tubular structure 12 frictionally, FIG. 5A depicts
the support apparatus 14 supported from a tubing hanger 32 that
engages the wellbore, directly or indirectly, to fix the support
apparatus 14 relative to the tubular structure. The tubing hanger
32 can be configured to seal against the inner diameter of the
wellbore 10 or casing in the wellbore 10. Support apparatus 14 can
join to the hanger 32 to secure the position of the support
apparatus 14 relative to the tubular structure 12. Each of the
exemplary embodiments described herein can be supported from a
tubing hanger 32 in a similar manner.
[0040] FIGS. 6A and 6B depict another exemplary internal support
apparatus 34 in axially extended and radially contracted mode
respectively. The support apparatus 34 is tubular and has a helical
slot 36 along at least a portion of its length. The helical slot 36
allows the support apparatus 34 to be extended axially, and as it
extends axially, to contract radially in a manner similar to
axially stretching a coil spring. Thus, unextended (FIG. 6B) the
support apparatus 34 can be configured to provide support to the
tubular structure 12, but when extended axially, the support
apparatus 34 can pass easily into and out of the tubular structure
12. Also, when axially extended, the reduced outer dimension of the
radially contacted support apparatus 34 aids in navigating bends
and other restricted diameter portions of the wellbore 10. Also as
above, apertures 18 can optionally be provided in the support
apparatus 34 to allow fluid to flow through therethrough. An
anchoring mechanism 38, for example slips or a dog-type anchoring
mechanism, can be provided at one or both ends of the support
apparatus 34 to engage the interior of the tubular structure 12 or
other element in the wellbore 10.
[0041] In use, the internal support apparatus 34 is contracted
radially by axially extending the apparatus 34 with a setting tool
40 (FIG. 6A). Setting tool 40 is a tool that grips the support
apparatus 34 about the portion having helical slots 36 and that is
actuable to extend, thus extending the portion of the support
apparatus 34 having helical slots 36. The setting tool 40 can also
be actuable to retract. For example, a hydraulic setting tool 40
can incorporate a piston and rod assembly, wherein hydraulic fluid
supplied from a reservoir and electric pumps contained in or about
the setting tool 40 or from the surface, is used to extend and/or
retract the rod. An electric setting tool 40 can use electric
motors together with a screw mechanism or gear train to extend and
retract the rod. An example of a tool that can be used as the
setting tool 40 is the Downhole Power Unit available from
Halliburton Energy Services, Inc.
[0042] The setting tool 40 is operated to engage the support
apparatus 34 about the portion having helical slots 36, and
extended to axially extend and radially contract the support
apparatus 34. Once axially extended, the support apparatus 34 can
then be tripped into the well and positioned in the tubular
structure 12 at the area for which support is desired. Thereafter,
the setting tool 40 is contracted and removed (FIG. 6B), thereby
axially contracting and radially expanding the support apparatus 34
until the support apparatus 34 reaches its unextended position or
contacts the interior of the tubular structure 12. The anchoring
mechanism 38 can be set to engage the tubular structure 12 and
secure the position of the support apparatus 34 in a manner known
in the art, for example through manipulation of the tubing string
or hydraulically. In an exemplary embodiment where the anchoring
mechanism 38 is slips, the slips are configured to engage the
tubular structure 12 when the support apparatus 34 is expanded. The
slips at each end of the support apparatus 34 are oppositely
oriented such that when the support apparatus 34 is expanded and
the slips contact with the tubular structure 12, the slips at a
forward end of the support apparatus 34 will engage the tubular
structure 12 and prevent forward movement of the support apparatus
34, and slips at a rearward end of the support apparatus 34 will
engage the tubular structure 12 and prevent rearward movement of
the support apparatus 34.
[0043] The support apparatus 34 can be configured to make light
contact with the inner surface of the undamaged tubular structure
12 or be slightly inset from the inner surface of the undamaged
tubular structure 12 when fully expanded (i.e. axially contracted).
Thus, if the tubular structure 12 is collapsed or otherwise
damaged, the support apparatus 34 can be fully expanded to expand
the damaged portion of the tubular structure 12 back to
substantially its original interior dimensions. The support
apparatus 34 can also be partially expanded to partially expand the
damaged tubular structure 12. It is important to note here that, if
not substantially plastically deformed when axially extended, the
support apparatus 34 will tend to spring back from an extended,
radially contracted state to its original retracted, radially
expanded state without assistance from the setting tool 40.
However, if a portion of the tubular structure 12 is collapsed the
support apparatus 34 may not be able to overcome and expand the
damaged portion of the tubular structure 12 on its own. In such a
case, the support apparatus 34 may, by its own tendency to retract
and radially expand, fully expand into contact with undamaged areas
of the tubular structure 12 and partially expand into contact with
the damaged areas of the tubular structure 12, thereby conforming
to the inner contours of the tubular structure 12. Alternately, the
setting tool 40 can be powered to retract and radially expand the
support apparatus 34 to overcome and expand the damaged portion of
the tubular structure 12. If the support apparatus 34 is axially
extended enough to plastically deform, it will not completely
spring back to its original retracted state, and the setting tool
40 can be powered to retract and radially expand the support
apparatus 34.
[0044] Alternately, the support apparatus 34 can be configured to
make light contact with or be slightly inset from the inner surface
of a collapsed or damaged portion of the tubular structure 12 when
fully expanded to support against further collapse while not
substantially expanding the collapsed portion. It may also be
desirable to configure the support apparatus 34 such that when
expanded it would partially expand a damaged portion of the tubular
structure 12, but not fully expand the damaged portion to its
original dimensions.
[0045] In any configuration, whether inset, lightly contacting, or
expanding the tubular structure 12, the support apparatus 34 can be
fixably installed in a damaged or undamaged tubular structure 12
and provide support during the operation of the tubular structure
12.
[0046] FIGS. 7A, 7B and 7C depict another exemplary internal
support apparatus 42. The support apparatus 42 is a tubular body
having an outer diameter smaller than the inner diameter of the
tubular structure 12 (FIG. 7A). The support apparatus 42 has a
plurality of apertures 18. The apertures 18 can be slot-shaped,
longitudinally oriented, and arranged in an overlapping pattern
about the support apparatus 42, though other shapes may be used in
this invention. The apertures 18 expand thus enabling the support
apparatus 42 to be plastically deformed into an expanded state
(FIG. 7C) in a manner similar to expanding an expandable
sand-control screen. The number and size of apertures 18 and the
wall thickness of the support apparatus 42 can be optimized to
provide strength to the support apparatus 42 when expanded. Once
positioned in the tubular structure 12, the support apparatus 42
can be anchored at one or both ends to the borehole 10, for example
by joining with a tubing hanger 32, or to the tubular structure 12
itself. A mandrel expansion tool 44, similar to existing tools used
to expand expandable sand-control screens, can be forced through
the support apparatus 42 to expand the diameter of the support
apparatus 42 into light contact with or slightly inset from the
interior surface of the undamaged tubular structure 12. As such,
the support apparatus 42 will provide support the tubular structure
12. Additionally, if the tubular structure 12 is collapsed or
otherwise damaged, the mandrel expansion tool 44 will expand the
damaged portion of the tubular structure 12. Thus, the support
apparatus 42 can be fixably installed in a damaged or undamaged
tubular structure 12 and provide support during the operation of
the tubular structure 12.
[0047] FIGS. 8A and 8B depict another exemplary internal support
apparatus 46. The support apparatus 46 has a tubular body portion
48 carrying a plurality of support plates 50. As seen in FIG. 9A,
the support plates 50 can be elliptical and have an elliptical
opening 52 that receives the body portion 48. The minor axis A1 of
the elliptical opening 52 is sized to closely receive the body
portion 48, while the major axis A2 of the elliptical opening 52 is
sized to allow the support plates 50 to tilt on the body portion 48
about the minor axis A1 as shown in FIG. 8A. The outer dimension of
the support plates 50 is greatest along the major axis A2, and
smaller along the minor axis A1 such that with the support plates
50 in a tilted position a distance measured along the major axis A2
and perpendicular to the longitudinal axis of the tubular body 48
is less than the inner diameter of the undamaged tubular structure
12 and when support plates 50 are disposed substantially
perpendicular ("upright") to the axis of the body portion 48, the
support plates 50 will effectively increase the outside dimension
of support apparatus 46 to provide support to the tubular structure
12. The length of minor axis A1 of the support plates 50 is less
than the inner diameter of the undamaged tubular structure 12. The
major axis A2 of the support plates 50 may be slightly smaller than
the inner diameter of the tubular structure 12, so that when moved
from a tilted position to an upright position, the support plates
50 make light contact with the inner surface of the undamaged
tubular structure 12. Alternately, the major axis A2 of the support
plates 50 may be equal to or slightly larger than the inner
diameter of the tubular structure 12 to slightly expand the tubular
structure 12 when actuated from a tilted to an upright position.
The support plates 50 can be other shapes than the elliptical shape
shown in FIG. 9A, for example, a flat sided oval as in FIG. 9B,
rectangular, or other shape.
[0048] The support plates 50 are spaced on the body portion 48 by a
plurality of slide rings 54 sized to coaxially receive and slide on
the body portion 48. Slide rings 54 each accommodate a lock-ring 56
that is biased inward against the body portion 48, and body portion
48 has corresponding lock-ring grooves 58. With the support plates
50 in a tilted position (FIG. 8A), the slide rings 54 freely slide
on the body portion 48. However, the lock-ring grooves 58 are
spaced such that if the respective lock-ring 56 of two or more
slide rings 54 locks into adjacent lock-ring grooves 58, the slide
rings 54 will be spaced to support the support plates 50
substantially perpendicular to the longitudinal axis of the body
portion 48 (FIG. 8B).
[0049] The body portion 48 has a hydraulic chamber 60 that receives
and seals with the slide ring 54 at one end of the support plate 50
stack. A hydraulic passage 62 in body portion 48 feeds the
hydraulic chamber 60. The hydraulic passage 62 can receive
pressure, for example, from the interior of the support apparatus
12 with a selective injection tool 64 (FIG. 8C) that is insertable
into the inner diameter of the support apparatus 46, seals 66
around passage 62, and communicates pressurized hydraulic fluid
into the passage 62. An example of a device suitable for use as a
selective injection tool 64 is the Selective Injection Packer
available from Halliburton Energy Services, Inc.
[0050] The support plates 50 and slide rings 54 are bounded at one
end by the hydraulic chamber 60 and at the other by a stop member
68 affixed to the body portion 48. As pressure is supplied to the
hydraulic chamber 60, the end-most slide ring 54 is forced axially
towards the support plates 50 and other slide rings 54. The support
plate 50 adjacent the stop member 68, bears against the stop member
68, and the support plates 50 and slide rings 54 are forced
together forcing the support plates 50 into substantially
perpendicular relation with the body portion 48. The lock-rings 56
of the slide rings 54 snap into their respective lock-ring grooves
58 and lock the slide rings 54 into position on the body portion
48, thus locking the support plates 50 in substantially
perpendicular relation to the body portion 48.
[0051] In use, the support plates 50 are arranged in the tilted
position and tripped into the well and positioned in the tubular
structure 12. Once in position, the hydraulic chamber 60 is
pressurized (for example, with the selective injection tool 64),
forcing the slide rings 54 and support plates 50 to tightly stack
against the stop member 68 and forcing support plates 50 into
substantially perpendicular relation with the body portion 48. When
tightly stacked, the lock-rings 56 snap into corresponding
lock-ring grooves 58 and lock the slide rings 54 in place and the
support plates 50 in position to support the tubular structure 12.
Thus, the support apparatus 46 can be fixably installed in a
damaged or undamaged tubular structure 12 and provide support
during the operation of the tubular structure 12.
[0052] Although several exemplary embodiments of the methods and
systems of the invention have been illustrated in the accompanying
drawings and described in the foregoing description, it will be
understood by those skilled in the art that the invention is not
limited to the embodiments disclosed, but is capable of numerous
rearrangements, modifications and substations without departing
from the spirit and scope of the invention as defined in the
following claims.
* * * * *