U.S. patent application number 10/513614 was filed with the patent office on 2005-10-06 for mono diameter wellbore casing.
Invention is credited to Brisco, David Paul, Watson, Brock Wayne.
Application Number | 20050217866 10/513614 |
Document ID | / |
Family ID | 29401627 |
Filed Date | 2005-10-06 |
United States Patent
Application |
20050217866 |
Kind Code |
A1 |
Watson, Brock Wayne ; et
al. |
October 6, 2005 |
Mono diameter wellbore casing
Abstract
An apparatus and system is disclosed for radially expanding and
plastically deforming an expandable tubular member.
Inventors: |
Watson, Brock Wayne;
(Carrollton, TX) ; Brisco, David Paul; (Duncan,
OK) |
Correspondence
Address: |
HAYNES AND BOONE, LLP
1000 LOUISIANA
SUITE 4300
HOUSTON
TX
77002
US
|
Family ID: |
29401627 |
Appl. No.: |
10/513614 |
Filed: |
November 5, 2004 |
PCT Filed: |
May 6, 2003 |
PCT NO: |
PCT/US03/14153 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60380147 |
May 6, 2002 |
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Current U.S.
Class: |
166/384 ;
166/207 |
Current CPC
Class: |
E21B 43/105 20130101;
E21B 43/103 20130101 |
Class at
Publication: |
166/384 ;
166/207 |
International
Class: |
E21B 023/02 |
Claims
What is claimed is:
1. An apparatus for radially expanding and plastically deforming an
expandable tubular member, comprising: an anchoring mechanism
adapted to mate with an end of the expandable tubular member; a
tubular support member releasably coupled to the anchoring
mechanism, an adjustable expansion mandrel coupled to the tubular
support member adapted to be controllably expanded to a larger
outside dimension for radial expansion of the expandable tubular
member or collapsed to a smaller outside dimension; an actuator
coupled to the tubular support member and the adjustable expansion
mandrel adapted to controllably longitudinally displace the
adjustable expansion mandrel relative to the tubular support member
and the expandable tubular member; and a gripping device coupled to
the tubular support member adapted to controllably engage the
expandable tubular member.
2. The apparatus of claim 1 further comprising a locking device
coupled to the actuator adapted to controllably engage the
expandable tubular member.
3. The apparatus of claim 1 further comprising a sealing device for
sealingly engaging the expandable tubular member adapted to define
an annular pressure chamber above the adjustable expansion mandrel
during radial expansion of the expandable tubular member.
4. The apparatus of claim 1 wherein the gripping device comprises:
a tubular mandrel having a plurality of tapered grooves defined on
an exterior surface of the tubular mandrel, a retaining sleeve
coupled to the tubular mandrel and adapted to slidingly move
longitudinally with respect to the tubular mandrel, the retaining
sleeve having a plurality of openings, a plurality of gripping
elements positioned within the tapered grooves, wherein when the
retaining sleeve is in a first longitudinal configuration, portions
of the gripping elements protrude through the plurality of
openings, and when the retaining sleeve is in a second longitudinal
configuration, portions of the gripping elements do not protrude
through plurality of tapered openings.
5. The apparatus of claim 1 wherein the anchoring device is a float
shoe, comprising: an expandable sleeve adapted to mate with the
tubular member, wherein the tubular member is adapted to
controllably expand the expandable sleeve to a larger outside
dimension for radial expansion of the expandable sleeve to the
expandable tubular member.
6. The apparatus of claim 5 wherein the anchoring device comprises:
a first passage, a second passage, a seat within the first passage
adapted to receive a plug, a sliding valve disposed within the
first passage, adapted to direct flow from the first passage to the
second passage, and a one-way valve coupled to the first and second
passages.
7. The apparatus of claim 1 wherein the anchoring mechanism is a
packer.
8. The apparatus of claim 7 wherein the packer is hydraulically
actuated.
9. The apparatus of claim 7 wherein the packer comprises: a first
passage, a second passage, a first seat within the first passage
adapted to receive a plug, and a sliding valve disposed within the
first passage, adapted to direct flow from the first passage to the
second passage.
10. A method for radially expanding and plastically deforming an
expandable tubular member within a borehole, comprising:
positioning an adjustable expansion mandrel, an anchoring device,
and a coupling mechanism below the expandable tubular member such
that the anchoring device contacts a bottom of the borehole,
increasing the outside dimension of the adjustable expansion
mandrel; and displacing the adjustable expansion mandrel upwardly
relative to the expandable tubular member to radially expand and
plastically deform portions of the expandable tubular member,
displacing the anchoring device upwardly relative to the expandable
tubular member such that the anchoring device contacts the bottom
of the expandable tubular member, coupling the anchoring device to
the bottom of the casing, uncoupling the expansion mandrel from the
anchoring device, and displacing the adjustable expansion mandrel
upwardly relative to the expandable tubular member n times to
radially expand and plastically deform n portions of the expandable
tubular member.
11. The method of claim 10, further comprising: lowering the
adjustable expansion mandrel to couple the expansion mandrel to the
anchoring device, and cementing the borehole, wherein the cementing
flows through a flow path located in the anchoring device.
12. The method of claim 10 further comprising expanding an
expansion device coupled to the anchoring device such that the
anchoring device couples to the casing.
13. An apparatus for radially expanding and plastically deforming
an expandable tubular member, comprising: an anchoring mechanism
adapted to mate with an end of the expandable tubular member; a
tubular support member releasably coupled to the anchoring
mechanism, an adjustable expansion device coupled to the tubular
support member adapted to be controllably expanded to a larger
outside dimension for radial expansion of the expandable tubular
member or collapsed to a smaller outside dimension; an actuator
coupled to the tubular support member and the adjustable expansion
device adapted to controllably longitudinally displace the
adjustable expansion device relative to the tubular support member
and the expandable tubular member; and a gripping device coupled to
the tubular support member adapted to controllably engage the
expandable tubular member.
14. The apparatus of claim 13 further comprising a locking device
coupled to the actuator adapted to controllably engage the
expandable tubular member.
15. The apparatus of claim 13 further comprising a sealing device
for sealingly engaging the expandable tubular member adapted to
define an annular pressure chamber above the adjustable expansion
device during radial expansion of the expandable tubular
member.
16. The apparatus of claim 13 wherein the gripping device
comprises: a tubular member having a plurality of tapered grooves
defined on an exterior surface of the tubular member, a retaining
sleeve coupled to the tubular member and adapted to slidingly move
longitudinally with respect to the tubular member, the retaining
sleeve having a plurality of openings, a plurality of gripping
elements positioned within the tapered grooves, wherein when the
retaining sleeve is in a first longitudinal configuration, portions
of the gripping elements protrude through the plurality of
openings, and when the retaining sleeve is in a second longitudinal
configuration, portions of the gripping elements do not protrude
through plurality of tapered openings.
17. The apparatus of claim 13 wherein the anchoring device is a
float shoe, comprising: an expandable sleeve adapted to mate with
the tubular member, wherein the tubular member is adapted to
controllably expand the expandable sleeve to a larger outside
dimension for radial expansion of the expandable sleeve to the
expandable tubular member.
18. The apparatus of claim 17 wherein the anchoring device
comprises: a first passage, a second passage, a seat within the
first passage adapted to receive a plug, a sliding valve disposed
within the first passage, adapted to direct flow from the first
passage to the second passage, and a one-way valve coupled to the
first and second passages.
19. The apparatus of claim 13 wherein the anchoring mechanism is a
packer.
20. The apparatus of claim 19 wherein the packer is hydraulically
actuated.
21. The apparatus of claim 19 wherein the packer comprises: a first
passage, a second passage, a first seat within the first passage
adapted to receive a plug, and a sliding valve disposed within the
first passage, adapted to direct flow from the first passage to the
second passage.
22. A method for radially expanding and plastically deforming an
expandable tubular member within a borehole, comprising:
positioning an adjustable expansion device, an anchoring device,
and a coupling mechanism below the expandable tubular member such
that the anchoring device contacts a bottom of the borehole,
increasing the outside dimension of the adjustable expansion
device; and displacing the adjustable expansion device upwardly
relative to the expandable tubular member to radially expand and
plastically deform portions of the expandable tubular member,
displacing the anchoring device upwardly relative to the expandable
tubular member such that the anchoring device contacts the bottom
of the expandable tubular member, coupling the anchoring device to
the bottom of the casing, uncoupling the adjustable expansion
device from the anchoring device, and displacing the adjustable
expansion device upwardly relative to the expandable tubular member
n times to radially expand and plastically deform n portions of the
expandable tubular member.
23. The method of claim 22, further comprising: lowering the
adjustable expansion device to couple the expansion device to the
anchoring device, and cementing the borehole, wherein the cementing
flows through a flow path located in the anchoring device.
24. The method of claim 22 further comprising expanding an
expansion device coupled to the anchoring device such that the
anchoring device couples to the casing.
25. An apparatus for radially expanding and plastically deforming
an expandable tubular member, comprising: an anchoring mechanism
adapted to mate with an end of the expandable tubular member; a
tubular support member releasably coupled to the anchoring
mechanism, an expansion device coupled to the tubular support
member adapted to be controllably expanded to a larger outside
dimension for radial expansion of the expandable tubular member or
collapsed to a smaller outside dimension; an actuator coupled to
the tubular support member and the adjustable expansion device
adapted to controllably longitudinally displace the adjustable
expansion device relative to the tubular support member and the
expandable tubular member; and a gripping device coupled to the
tubular support member adapted to controllably engage the
expandable tubular member.
26. The apparatus of claim 25 further comprising a locking device
coupled to the actuator adapted to controllably engage the
expandable tubular member.
27. The apparatus of claim 25 further comprising a sealing device
for sealingly engaging the expandable tubular member adapted to
define an annular pressure chamber proximate the expansion device
during radial expansion of the expandable tubular member.
28. The apparatus of claim 25 wherein the gripping device
comprises: a tubular member having a plurality of tapered grooves
defined on an exterior surface of the tubular member, a retaining
sleeve coupled to the tubular member and adapted to slidingly move
longitudinally with respect to the tubular member, the retaining
sleeve having a plurality of openings, a plurality of gripping
elements positioned within the tapered grooves, wherein when the
retaining sleeve is in a first longitudinal configuration, portions
of the gripping elements protrude through the plurality of
openings, and when the retaining sleeve is in a second longitudinal
configuration, portions of the gripping elements do not protrude
through plurality of tapered openings.
29. The apparatus of claim 25 wherein the anchoring device is a
float shoe, comprising: an expandable sleeve adapted to mate with
the tubular member, wherein the tubular member is adapted to
controllably expand the expandable sleeve to a larger outside
dimension for radial expansion of the expandable sleeve to the
expandable tubular member.
30. The apparatus of claim 29 wherein the anchoring device
comprises: a first passage, a second passage, a seat within the
first passage adapted to receive a plug, a sliding valve disposed
within the first passage, adapted to direct flow from the first
passage to the second passage, and a one-way valve coupled to the
first and second passages.
31. The apparatus of claim 25 wherein the anchoring mechanism is a
packer.
32. The apparatus of claim 31 wherein the packer is hydraulically
actuated.
33. The apparatus of claim 31 wherein the packer comprises: a first
passage, a second passage, a first seat within the first passage
adapted to receive a plug, and a sliding valve disposed within the
first passage, adapted to direct flow from the first passage to the
second passage.
34. A method for radially expanding and plastically deforming an
expandable tubular member within a borehole, comprising:
positioning an expansion device, an anchoring device, and a
coupling mechanism below the expandable tubular member; displacing
the expansion device upwardly relative to the expandable tubular
member to radially expand and plastically deform portions of the
expandable tubular member, displacing the anchoring device upwardly
relative to the expandable tubular member, coupling the anchoring
device to the bottom of the casing, uncoupling the expansion device
from the anchoring device, and displacing the expansion device
upwardly relative to the expandable tubular member n times to
radially expand and plastically deform n portions of the expandable
tubular member.
35. The method of claim 34, further comprising: lowering the
expansion device to couple the expansion device to the anchoring
device, and cementing the borehole, wherein the cementing flows
through a flow path defined in the anchoring device.
36. The method of claim 34 further comprising expanding an
expansion device coupled to the anchoring device such that the
anchoring device couples to the casing.
37. A gripping device for gripping a wellbore casing, comprising: a
tubular member having a plurality of tapered grooves defined on an
exterior surface of the tubular member, a retaining sleeve coupled
to the tubular member and adapted to slidingly move longitudinally
with respect to the tubular member, the retaining sleeve having a
plurality of openings, a plurality of gripping elements positioned
within the tapered grooves, wherein when the retaining sleeve is in
a first longitudinal configuration, portions of the gripping
elements protrude through the plurality of openings, and when the
retaining sleeve is in a second longitudinal configuration,
portions of the gripping elements do not protrude through plurality
of tapered openings.
38. An anchoring device for anchoring the position of a wellbore
casing, comprising: an expandable sleeve adapted to mate with the
wellbore casing.
39. An anchoring device for anchoring the position of a wellbore
casing, comprising: a housing, a first passage defined within the
housing, a second passage defined within the housing, a seat within
the first passage adapted to receive a plug, a sliding valve
disposed within the first passage, adapted to direct flow from the
first passage to the second passage, and a one-way valve coupled to
the first and second passages.
40. A system for radially expanding and plastically deforming an
expandable tubular member within a borehole, comprising: means for
positioning an adjustable expansion mandrel, an anchoring device,
and a coupling mechanism below the expandable tubular member such
that the anchoring device contacts a bottom of the borehole, means
for increasing the outside dimension of the adjustable expansion
mandrel; means for displacing the adjustable expansion mandrel
upwardly relative to the expandable tubular member to radially
expand and plastically deform portions of the expandable tubular
member, means for displacing the anchoring device upwardly relative
to the expandable tubular member such that the anchoring device
contacts the bottom of the expandable tubular member, means for
coupling the anchoring device to the bottom of the casing, means
for uncoupling the expansion mandrel from the anchoring device, and
means for displacing the adjustable expansion mandrel upwardly
relative to the expandable tubular member n times to radially
expand and plastically deform n portions of the expandable tubular
member.
41. The system of claim 40, further comprising: means for lowering
the adjustable expansion mandrel to couple the expansion mandrel to
the anchoring device, and means for cementing the borehole, wherein
the cementing flows through a flow path located in the anchoring
device.
42. The system of claim 40 further comprising means for expanding
an expansion device coupled to the anchoring device such that the
anchoring device couples to the casing.
43. A method for radially expanding and plastically deforming an
expandable tubular member within a borehole, comprising: means for
positioning an adjustable expansion device, an anchoring device,
and a coupling mechanism below the expandable tubular member such
that the anchoring device contacts a bottom of the borehole, means
for increasing the outside dimension of the adjustable expansion
device; means for displacing the adjustable expansion device
upwardly relative to the expandable tubular member to radially
expand and plastically deform portions of the expandable tubular
member, means for displacing the anchoring device upwardly relative
to the expandable tubular member such that the anchoring device
contacts the bottom of the expandable tubular member, means for
coupling the anchoring device to the bottom of the casing, means
for uncoupling the adjustable expansion device from the anchoring
device, and means for displacing the adjustable expansion device
upwardly relative to the expandable tubular member n times to
radially expand and plastically deform n portions of the expandable
tubular member.
44. The system of claim 43, further comprising: means for lowering
the adjustable expansion device to couple the expansion device to
the anchoring device, and means for cementing the borehole, wherein
the cementing flows through a flow path located in the anchoring
device.
45. The system of claim 43 further comprising means for expanding
an expansion device coupled to the anchoring device such that the
anchoring device couples to the casing.
46. A system for radially expanding and plastically deforming an
expandable tubular member within a borehole, comprising: means for
positioning an expansion device, an anchoring device, and a
coupling mechanism below the expandable tubular member; means for
displacing the expansion device upwardly relative to the expandable
tubular member to radially expand and plastically deform portions
of the expandable tubular member, means for displacing the
anchoring device upwardly relative to the expandable tubular
member, means for coupling the anchoring device to the bottom of
the casing, means for uncoupling the expansion device from the
anchoring device, and means for displacing the expansion device
upwardly relative to the expandable tubular member n times to
radially expand and plastically deform n portions of the expandable
tubular member.
47. The system of claim 46, further comprising: means for lowering
the expansion device to couple the expansion device to the
anchoring device, and means for cementing the borehole, wherein the
cementing flows through a flow path defined in the anchoring
device.
48. The method of claim 46 further comprising means for expanding
an expansion device coupled to the anchoring device such that the
anchoring device couples to the casing.
49. A method of gripping a wellbore casing, comprising: gripping
the interior surface of the wellbore casing at a plurality of
discrete spaced apart locations.
50. A method of anchoring the position of a wellbore casing,
comprising: radially expanding and plastically deforming a sleeve
within the wellbore casing into contact with the interior surface
of the wellbore casing.
51. A system for gripping a wellbore casing, comprising: means for
gripping the interior surface of the wellbore casing at a plurality
of discrete spaced apart locations; and means for actuating the
means for gripping.
52. A system for anchoring the position of a wellbore casing,
comprising: means for radially expanding and plastically deforming
a sleeve within the wellbore casing into contact with the interior
surface of the wellbore casing; and means for controlling the means
for radially expanding and plastically deforming the sleeve.
53. A method of radially expanding and plastically deforming a
tubular member, comprising: pressurizing an interior portion of the
tubular member; and displacing an expansion device through the
pressurized interior portion of the tubular member.
54. The method of claim 53, wherein pressurizing an interior
portion of the tubular member comprises pressurizing an annular
interior portion of the tubular member.
55. The method of claim 53, wherein displacing an expansion device
through the pressurized interior portion of the tubular member
comprises pulling the expansion device through the pressurized
interior portion of the tubular member.
56. The method of claim 53, wherein pulling the expansion device
through the pressurized interior portion of the tubular member
comprises using the operating pressure of the pressurized interior
portion of the tubular member to pull the expansion device through
the pressurized interior portion of the tubular member.
57. A system for radially expanding and plastically deforming a
tubular member, comprising: means for pressurizing an interior
portion of the tubular member; and means for displacing an
expansion device through the pressurized interior portion of the
tubular member.
58. The system of claim 57, wherein means for pressurizing an
interior portion of the tubular member comprises means for
pressurizing an annular interior portion of the tubular member.
59. The system of claim 57, wherein means for displacing an
expansion device through the pressurized interior portion of the
tubular member comprises means for pulling the expansion device
through the pressurized interior portion of the tubular member.
60. The system of claim 57, wherein means for pulling the expansion
device through the pressurized interior portion of the tubular
member comprises means for using the operating pressure of the
pressurized interior portion of the tubular member to pull the
expansion device through the pressurized interior portion of the
tubular member.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is the National Stage application
corresponding to PCT application serial number PCT/US2003/014153,
attorney docket number 25791.104.02, filed on May 6, 2003, which
claimed the benefit of the filing date of U.S. provisional patent
application Ser. No. 60/380,147, attorney docket no 25791.104,
filed on May 6, 2002, the disclosures of which are incorporated
herein by reference.
[0002] The present application is a continuation-in-part of U.S.
utility patent application Ser. No. 10/507,567, attorney docket
number 25791.95.03, filed on Sep. 13, 2004, which was the National
Stage application for PCT application serial number
PCT/US2003/004837, attorney docket number 25791.95.02, filed on
Feb. 19, 2003, which claimed the benefit of the filing date of U.S.
provisional patent application Ser. No. 60/363829, attorney docket
number 25791.95, filed on Mar. 13, 2002, which was a
continuation-in-part of both of: (1) U.S. utility patent
application Ser. No. 10/495,347, attorney docket number
25791.87.05, filed on May 12, 2004, which was filed as the National
Stage application for PCT application serial number
PCT/US2002/036157, attorney docket number 25791.87.02, filed on
Nov. 12, 2002, which claimed the benefit of the filing date of U.S.
provisional application Ser. No. 60/338996, attorney docket number
25791.87, filed on Nov. 12, 2001; and (2) U.S. utility patent
application Ser. No. 10/495,344, attorney docket number
25791.88.05, filed on May 12, 2004, which was filed as the National
Stage application for PCT application serial number
PCT/US2002/036267, attorney docket number 25791.88.02, filed on
Nov. 12, 2002, which claimed the benefit of the filing date of U.S.
provisional application Ser. No. 60/339013, attorney docket number
25791.88, filed on Nov. 12, 2001, the disclosures of which are
incorporated herein by reference.
[0003] The present application is related to the following: (1)
U.S. patent application Ser. No. 09/454,139, attorney docket no.
25791.03.02, filed on Dec. 3, 1999, (2) U.S. patent application
Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb.
23, 2000, (3) U.S. patent application Ser. No. 09/502,350, attorney
docket no. 25791.8.02, filed on Feb. 10, 2000, (4) U.S. patent
application Ser. No. 09/440,338, attorney docket no. 25791.9.02,
filed on Nov. 15, 1999, (5) U.S. patent application Ser. No.
09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10,
2000, (6) U.S. patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, (7) U.S. patent
application Ser. No. 09/511,941, attorney docket no. 25791.16.02,
filed on Feb. 24, 2000, (8) U.S. patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
(9) U.S. patent application Ser. No. 09/559,122, attorney docket
no. 25791.23.02, filed on Apr. 26, 2000, (10) PCT patent
application serial no. PCT/US00/18635, attorney docket no.
25791.25.02, filed on Jul. 9, 2000, (11) U.S. provisional patent
application Ser. No. 60/162,671, attorney docket no. 25791.27,
filed on Nov. 1, 1999, (12) U.S. provisional patent application
Ser. No. 60/154,047, attorney docket no. 25791.29, filed on Sep.
16, 1999, (13) U.S. provisional patent application Ser. No.
60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999,
(14) U.S. provisional patent application Ser. No. 60/159,039,
attorney docket no. 25791.36, filed on Oct. 12, 1999, (15) U.S.
provisional patent application Ser. No. 60/159,033, attorney docket
no. 25791.37, filed on Oct. 12, 1999, (16) U.S. provisional patent
application Ser. No. 60/212,359, attorney docket no. 25791.38,
filed on Jun. 19, 2000, (17) U.S. provisional patent application
Ser. No. 60/165,228, attorney docket no. 25791.39, filed on Nov.
12, 1999, (18) U.S. provisional patent application Ser. No.
60/221,443, attorney docket no. 25791.45, filed on Jul. 28, 2000,
(19) U.S. provisional patent application Ser. No. 60/221,645,
attorney docket no. 25791.46, filed on Jul. 28, 2000, (20) U.S.
provisional patent application Ser. No. 60/233,638, attorney docket
no. 25791.47, filed on Sep. 18, 2000, (21) U.S. provisional patent
application Ser. No. 60/237,334, attorney docket no. 25791.48,
filed on Oct. 2, 2000, (22) U.S. provisional patent application
Ser. No. 60/270,007, attorney docket no. 25791.50, filed on Feb.
20, 2001, (23) U.S. provisional patent application Ser. No.
60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001,
(24) U.S. provisional patent application Ser. No. 60/259,486,
attorney docket no. 25791.52, filed on Jan. 3, 2001, (25) U.S.
provisional patent application Ser. No. 60/303,740, attorney docket
no. 25791.61, filed on Jul. 6, 2001, (26) U.S. provisional patent
application Ser. No. 60/313,453, attorney docket no. 25791.59,
filed on Aug. 20, 2001, (27) U.S. provisional patent application
Ser. No. 60/317,985, attorney docket no. 25791.67, filed on Sep. 6,
2001, (28) U.S. provisional patent application Ser. No.
60/3318,386, attorney docket no. 25791.67.02, filed on Sep. 10,
2001, (29) U.S. utility patent application Ser. No. 09/969,922,
attorney docket no. 25791.69, filed on Oct. 3, 2001, (30) U.S.
utility patent application Ser. No. 10/016,467, attorney docket no.
25791.70, filed on Dec. 10, 2001; (31) U.S. provisional patent
application Ser. No. 60/343,674, attorney docket no. 25791.68,
filed on Dec. 27, 2001; (32) U.S. provisional patent application
Ser. No. 60/346,309, attorney docket no 25791.92, filed on Jan. 7,
2002; (33) U.S. provisional patent application Ser. No. 60/372,048,
attorney docket no. 25791.93, filed on Apr. 12, 2002; and (34) U.S.
provisional patent application Ser. No. 60/372,632, attorney docket
no. 25791.101, filed on Apr. 15, 2002, the disclosures of which are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0004] This invention relates generally to oil and gas exploration,
and in particular to forming and repairing wellbore casings to
facilitate oil and gas exploration and production.
[0005] Conventionally, when a wellbore is created, a number of
casings are installed in the borehole to prevent collapse of the
borehole wall and to prevent undesired outflow of drilling fluid
into the formation or inflow of fluid from the formation into the
borehole. The borehole is drilled in intervals whereby a casing
which is to be installed in a lower borehole interval is lowered
through a previously installed casing of an upper borehole
interval. As a consequence of this procedure the casing of the
lower interval is of smaller diameter than the casing of the upper
interval. Thus, the casings are in a nested arrangement with casing
diameters decreasing in downward direction. Cement annuli are
provided between the outer surfaces of the casings and the borehole
wall to seal the casings from the borehole wall. As a consequence
of this nested arrangement a relatively large borehole diameter is
required at the upper part of the wellbore. Such a large borehole
diameter involves increased costs due to heavy casing handling
equipment, large drill bits and increased volumes of drilling fluid
and drill cuttings. Moreover, increased drilling rig time is
involved due to required cement pumping, cement hardening, required
equipment changes due to large variations in hole diameters drilled
in the course of the well, and the large volume of cuttings drilled
and removed.
[0006] The present invention is directed to overcoming one or more
of the limitations of the existing processes for forming and
repairing wellbore casings.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the present invention, an
apparatus and method for forming a mono diameter wellbore casing is
provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIGS. 1a-1f are conceptual illustrations of one aspect of
the present invention.
[0009] FIGS. 2a-2f are fragmentary cross-sectional illustrations of
the placement of an exemplary embodiment of an apparatus for
forming a mono diameter wellbore casing within a wellbore that
traverses a subterranean formation.
[0010] FIGS. 3a-3f are fragmentary cross-sectional illustrations of
the apparatus of FIGS. 2a-2f after placement on the bottom of the
wellbore.
[0011] FIGS. 4a-4f are fragmentary cross-sectional illustrations of
the apparatus of FIGS. 3a-3f after placing a ball or dart within
the ball or dart seat to initiate the radial expansion and plastic
deformation of the expandable tubular member.
[0012] FIGS. 5a-5f are fragmentary cross-sectional illustrations of
the apparatus of FIGS. 4a-4f after the initiation of the radial
expansion and plastic deformation of the aluminum sleeve within the
shoe.
[0013] FIG. 6a-6f are fragmentary cross sectional illustrations of
the apparatus of FIGS. 5a-5f after the completion of the radial
expansion and plastic deformation of the aluminum sleeve within the
shoe.
[0014] FIGS. 7a-7f are fragmentary cross-sectional illustrations of
the apparatus of FIGS. 6a-6f after displacing the sliding sleeve
valve within the shoe to permit circulation around the ball or
dart.
[0015] FIGS. 8a-8f are fragmentary cross-sectional illustrations of
an alternative embodiment of a bottom anchoring apparatus.
[0016] FIGS. 9a-9g are fragmentary cross sectional illustrations of
certain aspects of the operation of the apparatus of FIGS.
8a-8f.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0017] Referring initially to FIG. 1a, an embodiment of an
apparatus and method for radially expanding a tubular member will
now be described. As illustrated in FIG. 1a, a wellbore 100 is
positioned in a subterranean formation 105. In an exemplary
embodiment, the wellbore 100 may include a casing 110. The wellbore
100 may be positioned in any orientation from vertical to
horizontal. Thus, in this application the direction "up", "upper"
or "upward" refers to the direction towards the surface termination
of the wellbore and the direction "down", "lower" or "downward"
refers to the direction towards the bottom or end of the
wellbore.
[0018] In order to extend the wellbore 100 into the subterranean
formation 105, a drill string (not shown) is used in a well known
manner to drill out material from the subterranean formation 105 to
form the wellbore 100. The inside diameter of the wellbore 100 is
greater than or equal to the outside diameter of the casing
110.
[0019] In an exemplary embodiment, a tubular apparatus 120 having
an opening 122 may then be positioned within the wellbore 100 with
an upper end 124a of the apparatus 120 initially coupled to a well
string 125. The apparatus 120 is adapted to allow fluidic materials
to enter the upper end 124a of the tool and exit through the
opening 122 positioned at the lower end 124b of the tool, thereby
creating a passage (not shown) or fluid flow path 126. The
apparatus 120 may include, among other components, a casing lock
130, a gripping device 132, a tension actuator 134, a sealing
mechanism 136, an expansion cone 140, a cementing probe 144, and a
casing anchor 148.
[0020] The apparatus 120 as illustrated in FIG. 1a is in a
"running" or positioning configuration. In other words, the tool is
running or traveling down the wellbore. In several exemplary
embodiments, in the running configuration, the lower end 124b of
the apparatus 120 extends past the casing 110 into the wellbore.
The casing lock 130 may be used to support or couple the apparatus
120 to the casing 110 which may keep the casing 110 positioned
above the lower end 124b of the tool when the apparatus 120 is in
the running configuration. Alternatively, the expansion cone 140
may be used to support the casing 110 during the running or
positioning of the apparatus 120.
[0021] In one embodiment, the gripping device 132 may be positioned
close to the upper end 124a of the apparatus 120. In the
illustrative embodiment, the gripping device 132 is positioned
above the casing lock 130. As will be explained in detail below,
the gripping device 132 may be used to keep the casing 110
stationary during the operation of the apparatus 120. A force
multiplier or tension actuator 134 may be positioned below the
casing lock 130. The tension actuator 134 may be used to "pull" the
expansion cone 140 and the lower end 124b of the apparatus 120
inside the casing 110. In the illustrative embodiment, an
alternative sealing mechanism 136 may be positioned below the
tension actuator 134.
[0022] As illustrated in FIG. 1a, an apparatus for radially
expanding a tubular member, such as an expansion cone 140 may then
be positioned outside of the casing 110. A tubular member, such as
a cementing probe 144, may be positioned below the expansion cone
140. A casing anchor 148, such as a packer or drillable shoe, may
be positioned at the lower end 124b of the apparatus 120.
[0023] Turning now to FIG. 1b, there is illustrated the apparatus
120 positioned at the bottom of the wellbore 100. As will be
explained in detail below, when the apparatus 120 contacts with the
bottom of the wellbore 100, an expansion mechanism 150, coupled to
the casing anchor 148, expands radially outward such that the
casing 110 cannot move past the expansion mechanism. In one
embodiment, the expansion cone 140 may also expand upon impact with
the bottom of the well. The expansion cone may expand to a diameter
that is greater than the interior diameter of the casing 110.
[0024] In an exemplary embodiment, as illustrated in FIG. 1c, an
actuating event may occur to cause the gripping device 132 to grip
the casing 110. Such an actuating event may be placing a plug, such
as a ball or dart into the apparatus 120 to block the flow path 126
and prevent fluids from exiting through opening 122. Injecting a
fluidic material into the apparatus when the flow path 126 is
blocked causes an increase in pressure within the tool. The
increase pressure may actuate gripping elements of the gripping
device 132 thereby locking the top end of the apparatus 120 to the
expandable tubular member. In some alternative embodiments, the
continued injection of the fluidic material furthermore increases
the operating pressure within the tool which causes the expansion
cone to expand. The increase operating pressure may also cause the
tension actuator 134 to pull the expansion cone 140 into the
expandable tubular member. As a result, the casing or expandable
casing 110 is radially expanded as the expansion cone 140 travels
up the casing 110.
[0025] Turning now to FIG. 1d, the continued upward movement of the
expansion cone 140 pulls the casing anchor 148 into the end of the
radially expanded casing 110. As a result, the end of the radially
expanded casing 110 will impact the expansion mechanism 150,
thereby preventing the casing anchor 148 from moving further in the
upward direction. In some embodiments, the continued upward force
on the casing anchor 148 may cause the casing anchor to radially
expand within the casing to firmly couple the end of the tubular
member to the casing anchor 148. In alternative embodiments, this
anchoring may also hydraulically seal the anchor 148 to the casing
110.
[0026] The continued upward force on the apparatus 120 may cause
the cementing probe 144 to separate from the casing anchor 148, as
illustrated in FIG. 1e. At the top of the stroke, the casing lock
130 (not shown) may be released. After separation, the apparatus
120 is free to continue to advance up causing the casing 110 to
expand as necessary. If a hydraulic seal is created between the
anchor 148 and the casing 110, the region between the anchor and
the sealing mechanism 136 may be pressurized. This pressurized
region forces the expansion cone upwardly, thereby causing a radial
expansion and plastic deformation of the expandable casing 110. In
this manner, in the alternative embodiment, the fluid pressure
below the sealing mechanism 136 pulls the expansion cone 140
upwardly through the expandable casing 110. Thus, the use of the
tension actuator 134 to pull the expansion cone upwards is no
longer necessary.
[0027] At some point (e.g., at the top of the liner), it may become
desirable to stop expanding and to inject a hardenable fluidic
sealing material such as, for example, cement into the well
annulus. To begin the cementing operation, the apparatus 120 may be
lowered into the wellbore 100 until the cementing probe 144 couples
to the casing anchor 148 as illustrated in FIG. 1f. This coupling
opens a bypass flowpath 154 to permit fluidic materials to bypass
around the blockage in flow path 126. As a result, the bypass flow
path 154 allows for cement or other fluidic materials to flow
around the blockage of flow path 126.
[0028] Thus, the cement flows through the interior of the apparatus
120, through the bypass flow path 154, and out through a one-way
valve (not shown) into the annulus between the radially expanded
tubular member and the wellbore. After the cement has been injected
into the annulus, the one way valve may prevent the cement from
flowing backwards into the apparatus 120.
[0029] After completing the injection of the cement into the
annulus, the drilling pipe may then pulled upwardly out of the
wellbore. The radial expansion and plastic deformation of the
expandable tubular member may then be continued by the resumed
injection of fluidic material into the apparatus. After the cement
has cured, the anchor 148 may be drilled out and another expandable
tubular member may then be radially expanded and plastically
deformed within the wellbore with the upper end of the other
tubular member overlapping with the lower end of the earlier
expanded tubular member. In this manner, a mono diameter wellbore
casing may be formed that includes a plurality of radially expanded
tubular members.
[0030] Turning now to FIGS. 2a-2f, there is illustrated an
exemplary embodiment of an apparatus 200, which illustrates certain
aspects of the apparatus 120 discussed above. At the upper end of
the apparatus 200, there is the gripping device 132. In several
exemplary embodiments, the gripping device 132 may be any device
capable of engaging the inside surface of the tubular member or
casing 110 in a conventional manner and/or using one or more of the
methods and apparatus disclosed in one or more of the following:
(1) PCT application no. serial no. PCT/US02/36267, attorney docket
no. 25791.88, filed on Nov. 12, 2002, (2) U.S. provisional patent
application Ser. No. 60/338,996, attorney docket no. 25791.87,
filed on Nov. 12, 2001, (3) U.S. provisional patent application
Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar.
13, 2002, and (4) U.S. provisional patent application Ser. No.
60/339,013, attorney number attorney docket no. 25791.88, filed on
Nov. 12, 2001, the disclosures of which are incorporated herein by
reference. In the embodiment as illustrated in FIGS. 2a-2f, the
gripping device 132 comprises a tubular central mandrel 202 which
defines a central passage 203. The central mandrel 202 has an upper
end 204a adapted to threadably couple to and receive within an end
of the well string 125 in a conventional manner. A tubular
retaining sleeve 206 slidingly engages the central mandrel 202,
such that the retaining sleeve 206 may move longitudinally relative
to the central mandrel 202 between an external annular upper flange
205a and an external annular lower flange 205b projecting from the
central mandrel 202. A pair of concentric annular recesses in the
upper flange 205a form an annular guide flange 209 which fits
within the retaining sleeve 206. The retaining sleeve 206 has an
internal upper flange 207a and an internal lower flange 207b. The
upper flange 207a, the guide flange 209, the external surface of
the central mandrel 202 and the internal surface of the retaining
sleeve 206 defines an annular upper spring chamber 208a. Similarly,
the lower flange 205b, the lower flange 207b, the external surface
of the central mandrel 202 and the internal surface of the
retaining sleeve 206 defines an annular lower spring chamber 208b.
Helical springs 210a and 210b may be disposed within the upper and
lower retaining chambers 208a and 208b, respectively to
longitudinally position the retaining sleeve 206 relative to the
central mandrel 202.
[0031] A plurality of tapered recesses, for example recesses
212a-212d are defined in the external surface of the central
mandrel 202. Corresponding to each recess 212a-212d, there is a
tapered circular opening, for instance circular openings 214a-214d,
through the wall of the retaining sleeve 206. The tapered recesses
212a-212d, the interior surface of the retaining sleeve 206, and
the circular openings 214a-214d define retaining chambers
216a-216d, respectively. Hardened gripping elements, such as balls
218a-218d or sprag clutch elements, made from stainless steel or
another hardened material, may be positioned with the retaining
chambers 216a-216d. In the running configuration illustrated in
FIGS. 2a-2e, the springs 210a and 210b bias the sleeve 206 such
that the balls 218a-218d remain in the widest portion of the
tapered retaining chambers 216a-216d. In this configuration, the
balls do not engage the interior surface of the casing or casing
110.
[0032] An annular pressure chamber 222 may be defined between the
bottom of the internal flange 207a of the retaining sleeve 206 and
the top of an external annular flange 224. A sealing means, such as
an O-ring or sealing cartridge 211 may provide a seal between the
internal flange 207a and the exterior surface of the central
mandrel 202. Additionally, a sealing means, such as an O-ring or
sealing cartridge 213 may provide a seal between the side of the
flange 224 and the exterior of the central mandrel 202. A plurality
of radial passages, for instance passages 220a and 220b may be
defined with the central mandrel 202 which provides fluid
communication between the central passage 203 and the pressure
chamber 222. Thus, the pressure of the pressure chamber 222 remains
approximately the same as the pressure within the central passage
203. When the pressure of the central passage 203 is large enough
to overcome the biasing of the springs 208an and 208b, the pressure
chamber 222 expands by driving the upper flange 207 away from the
external flange 224. Thus, the upper flange 207 acts like a piston
pushing the retaining sleeve 206 in an upperwardly direction with
respect to the central mandrel 202.
[0033] When the retaining sleeve moves up, the steel balls
218a-218d are forced up into thinner regions of the retaining
chambers 216a-216d. A portion of the steels balls 218a-218d,
therefore, projects radially through the circular openings
214a-214d. As the steel balls 218a-218d project through the
circular openings 214a-214d, they engage the interior surface of
the casing 110. The balls 218a-218d grip the interior surface in
proportion to the pressure applied to the central passage 203. The
balls may create small concave indents that imparts a benign
compressive stress into the casing 110.
[0034] A lower end 204b of the central mandrel 202 may be adapted
to threadably couple to other components or tools, such as the
casing lock 130 or the tension actuator 134. In the illustrative
embodiment, the lower end 204 is coupled to the tension actuator
134.
[0035] In several exemplary embodiments, the tension actuator 134
may be any device capable of pulling the expansion cone 140 into
the casing 110 in a conventional manner and/or using one or more of
the methods and apparatus disclosed in one or more of the
following: (1) PCT application no. serial no. PCT/US02/36267,
attorney docket no. 25791.88, filed on Nov. 12, 2002, (2) U.S.
provisional patent application Ser. No. 60/338,996, attorney docket
no. 25791.87, filed on Nov. 12, 2001, (3) U.S. provisional patent
application Ser. No. 60/363,829, attorney docket no. 25791.95,
filed on Mar. 13, 2002, and (4) U.S. provisional patent application
Ser. No. 60/339,013, attorney number attorney docket no. 25791.88,
filed on Nov. 12, 2001, the disclosures of which are incorporated
herein by reference.
[0036] In the illustrative embodiment, the actuator 134 comprises
actuator barrel 250 having a top end 252 adapted to threadably
couple to the lower end 204b of the gripping device 132. The
actuator barrel 250 defines a longitudinal passage 250a having an
internal annular flange 250b at the lower end of the longitudinal
passage 250. The lower end of the actuator barrel 250 couples to a
connector barrel 254. The connector barrel 254 defines a
longitudinal passage 254a having an internal annular flange 254b at
the lower end of the longitudinal passage 254a. The lower end of
the connector barrel 254 couples to a connector barrel 256. The
connector barrel 256 defines a longitudinal passage 256a having an
internal annular flange 256b at the lower end of the longitudinal
passage 256a.
[0037] A piston tube 260 runs through the passages 250a, 254a, and
256a of the actuator barrel 250 and the connector barrels 254 and
256, respectively. The piston tube 260 may define a longitudinal
passage 261. An external annular flange 262a is defined at the top
end of the piston tube 260. The outside diameter of the annular
flange 262a is slightly smaller than the inside diameter of the
longitudinal passage 250a such that the annular flange 262a can
slide longitudinally within the longitudinal passage 250a. A
sealing means, such as a sealing cartridge 264a creates a seal
between the annular flange 262a and the interior surface of the
longitudinal passage 250. Similarly a sealing means, such as a
sealing cartridge 266a creates a seal between the exterior surface
of the piston tube 260 and the flange 254b. An annular pressure
chamber 268a may be defined between the bottom of the external
flange 262 of the piston tube 260 and the top of the annular flange
250b. Radial tubes 270a and 270b may connect the pressure chamber
268a to the longitudinal passage 261 of the piston tube 260.
[0038] An external annular flange 262b may be defined on the
exterior of the piston tube 260. The outside diameter of the
annular flange 262b is slightly smaller than the inside diameter of
the longitudinal passage 254a such that the annular flange 262b can
slide longitudinally within the longitudinal passage 254a. A
sealing means, such as a sealing cartridge 264b creates a seal
between the annular flange 262b and the interior surface of the
longitudinal passage 254a. Similarly a sealing means, such as a
sealing cartridge 266b creates a seal between the exterior surface
of the piston tube 260 and the flange 254b. An annular pressure
chamber 268b may be defined between the bottom of the external
flange 262b of the piston tube 260 and the top of the annular
flange 254b. Radial tubes 270c and 270d may connect the pressure
chamber 268b to the longitudinal passage 261 of the piston tube
260.
[0039] Similarly, an external annular flange 262c may be defined on
the exterior of the piston tube 260. The outside diameter of the
annular flange 262c is slightly smaller than the inside diameter of
the longitudinal passage 256a such that the annular flange 262c can
slide longitudinally within the longitudinal passage 256a.
Optionally, a sealing means, such as a sealing cartridge 264c
creates a seal between the annular flange 262c and the interior
surface of the longitudinal passage 256a. Similarly a sealing
means, such as a sealing cartridge 266c creates a seal between the
exterior surface of the piston tube 260 and the flange 256b. An
annular pressure chamber 268c may be defined between the bottom of
the external flange 262c of the piston tube 260 and the top of the
annular flange 256b. Radial tubes 270e and 270f may connect the
pressure chamber 268b to the longitudinal passage 261 of the piston
tube 260.
[0040] A lower end 272 of the piston tube may be adapted to be
coupled to another component, such as the casing lock 130.
Optionally, the casing lock 130 may be positioned above the
actuator 130. In several exemplary embodiments, the casing lock 134
may be any device capable of coupling the apparatus to the casing
while the apparatus is being positioned within the wellbore in a
conventional manner and/or using one or more of the methods and
apparatus disclosed in one or more of the following: (1) PCT
application no. serial no. PCT/US02/36267, attorney docket no.
25791.88, filed on Nov. 12, 2002, (2) U.S. provisional patent
application Ser. No. 60/338,996, attorney docket no. 25791.87,
filed on Nov. 12, 2001, (3) U.S. provisional patent application
Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar.
13, 2002, and (4) U.S. provisional patent application Ser. No.
60/339,013, attorney number attorney docket no. 25791.88, filed on
Nov. 12, 2001, the disclosures of which are incorporated herein by
reference.
[0041] FIG. 2d illustrates an alternative embodiment where a
sealing means 136, such as a packer cup assembly may provide a way
to create a pressurized zone within the casing 110. In several
exemplary embodiments, the sealing means 136 may be any device
capable of sealing between differential zones of pressure in a
conventional manner and/or using one or more of the methods and
apparatus disclosed in one or more of the following: (1) PCT
application no. serial no. PCT/US02/36267, attorney docket no.
25791.88, filed on Nov. 12, 2002, (2) U.S. provisional patent
application Ser. No. 60/338,996, attorney docket no. 25791.87,
filed on Nov. 12, 2001, (3) U.S. provisional patent application
Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar.
13, 2002, and (4) U.S. provisional patent application Ser. No.
60/339,013, attorney number attorney docket no. 25791.88, filed on
Nov. 12, 2001, the disclosures of which are incorporated herein by
reference.
[0042] For instance, an upper packer cup assembly 280 may be
coupled to a mandrel 282 proximate the upper end of the mandrel
282. The mandrel 282 may define an longitudinal passage 283. In an
exemplary embodiment, a packer cup 284 may be a Guiberson.TM.
packer cup. Optionally, a spacer sleeve (not shown) may mate with,
receives, and may be coupled to the mandrel 282 proximate an end of
the upper packer cup assembly 280. A lower packer cup assembly 286
may be coupled to the mandrel 282. In an exemplary embodiment, a
lower packer cup 286 is a Guiberson.TM. packer cup. Optionally, a
lower spacer sleeve may be coupled to the mandrel 282 to
longitudinally position the lower packer assembly 286.
[0043] An expansion cone 140 may be positioned below the sealing
means 136. In several exemplary embodiments, the expansion cone 140
may be any device capable of expanding the casing or tubing member
110 within the wellbore 105 in a conventional manner and/or using
one or more of the methods and apparatus disclosed in one or more
of the following: (1) PCT application no. serial no.
PCT/US02/36267, attorney docket no. 25791.88, filed on Nov. 12,
2002, (2) U.S. provisional patent application Ser. No. 60/338,996,
attorney docket no. 25791.87, filed on Nov. 12, 2001, (3) U.S.
provisional patent application Ser. No. 60/363,829, attorney docket
no. 25791.95, filed on Mar. 13, 2002, and (4) U.S. provisional
patent application Ser. No. 60/339,013, attorney number attorney
docket no. 25791.88, filed on Nov. 12, 2001, the disclosures of
which are incorporated herein by reference.
[0044] In an exemplary embodiment, an adjustable expansion cone may
be similar to a conventional adjustable expansion mandrel in that
may be expanded to a larger outside dimension or collapsed to a
smaller outside dimension and includes external surfaces for
engaging the casing 110 to thereby radially expand and plastically
deform the tubular member when the adjustable expansion mandrel is
expanded to the larger outside dimension. In an alternative
embodiment, the expansion cone 140 may include a rotary adjustable
expansion device such as, for example, the commercially available
rotary expansion devices of Weatherford International, Inc. In
several alternative embodiments, the cross sectional profile of the
expansion cone 140 for radial expansion operations may, for
example, be an n-sided shape, where n may vary from 2 to infinity,
and the side shapes may include straight line segments, arcuate
segments, parabolic segments, and/or hyperbolic segments. In
several alternative embodiments, the cross sectional profile of the
adjustable expansion cone 140 may, for example, be circular, oval,
elliptical, and/or multifaceted.
[0045] Alternatively, the expansion cone 140 may be comprised of a
plurality of circumferentially spaced apart upper cone segments
interleaved among the cam arms of an upper cam spaced around a
mandrel 291 defining longitudinal passage 293. In an exemplary
embodiment, each upper cone segment includes a first outer surface
that defines a hinge groove, a plurality of inner surfaces and a
plurality of outer surfaces. In an exemplary embodiment, there may
be a combination of arcuate and cylindrical segments. The upper
cone segments may be pivotally coupled to an upper cone retainer
290. A plurality of circumferentially spaced apart lower cone
segments interleaved among the cam arms of a lower cam. In an
exemplary embodiment, each lower cone segment includes a first
outer surface that defines a hinge groove, a plurality of inner
surfaces and a plurality of outer surfaces. In an exemplary
embodiment, there may be a combination of arcuate and cylindrical
segments. The lower cone segments may be pivotally coupled to a
lower cone retainer 292. Shear pins or another retaining mechanism
longitudinally position the lower retainer 292 relative to the
upper retainer 290 such that they remain positioned apart during
the positioning of the apparatus within the well. In one
embodiment, when the apparatus reaches the bottom of the well, the
impact shears the shear pins and drives the lower cone retainer
toward the upper cone retainer, causing the cone segments to pivot
outward in a lateral direction. As the cone segments pivot outward,
the diameter of the expansion cone 140 increases. A locking
mechanism then locks the cone segments together in an expanded
configuration.
[0046] The lower cone retainer 292 receives and may be threadably
coupled to an end of a release housing 300 that defines a
longitudinal passage 302. A lower end 304 of the release housing
300 defines a external flange 305 adapted to mate into a sleeve 306
in the anchoring device 148. In some exemplary embodiments, a
tubular cementing probe 308 may be slidingly disposed within the
longitudinal passage 302. The cementing probe 308 may be a tubular
shaped member which defines a longitudinal passage 310. A top end
of the cementing probe 308 has an annular exterior flange or rim
312, the diameter of which is slightly smaller than the interior
diameter of the longitudinal passage 302. During operation, an
interior annular seat 314 defined within the release housing 300
keeps the flange 312 of cementing probe within the longitudinal
passage 302. A lower end of the concrete probe narrows to form a
neck 316 which, as will be explained below, is adapted to mate with
a collet of the anchoring device 148. During positioning of the
apparatus, a probe shear pin 318 longitudinally retains the sliding
sleeve within the longitudinal passage 302. Once the cement probe
308 has been extended during operation, however, a probe locking
ring 320 may maintain the probe in an extended configuration.
[0047] In the illustrative embodiment, the anchoring device 148 may
be a an expandable float shoe 340. In some exemplary embodiments,
the float shoe 340 may be made out of aluminum or another
expandable material which may be relative easy to drill out. The
top end of the float shoe defines a tubular sleeve 342 defining an
annual passage 344. The tubular sleeve 342 is adapted to mate
within the release housing 300. A sliding sleeve valve 346 is
slidingly disposed within the longitudinal passage 344.
[0048] The sliding sleeve valve 346 is generally tubular in shape
defining an longitudinal passage 348. At a top end of the sliding
sleeve valve 346, there is an outwardly protruding flange or rim
350 which circumferentially extends around the top end of sliding
sleeve valve 346. Below the rim 350, there is a flexible or top
section defining a collet 346a. Below the collet 346a, there is a
lower section 346b of the sliding sleeve valve 346. The wall
thickness of the collet 346a is narrow relative to the lower
section 346b. There are also a predetermined number of longitudinal
slots (not shown) extending from the top of the rim 350 through the
collet 346a. Preferably these longitudinal slots are equally spaced
around the periphery of the collet 346a. The combination of the
longitudinal slots and the narrowed wall thickness of the collet
346a allow the diameter of the rim 350 to decrease when the rim 350
is not radially supported by a supporting mechanism. Thus, the rim
350 can be considered "flexible" in that it can contract from a
first radial position of a particular diameter to a second radial
position of a lesser diameter. In the running configuration
illustrated in FIG. 2f, the rim 350 is positioned in an interior
recess 352 defined in the sleeve 342. The neck 316 of the cementing
probe 308 radially supports rim 350, preventing the rim 350 from
slipping out of the recess 352 and thus longitudinally maintains
the sliding sleeve valve 346 within the sleeve 342. A side port 354
may be defined within the side wall of the lower section 346b.
[0049] In several exemplary embodiments, there is a annular seat
355 positioned within the longitudinal passage 344 of the float
shoe 340. The annular seat 355 is adapted to sealingly couple to a
plug. The plug may be any conventional plug, such as drill pipe
dart or phenolic ball that would provide a hydraulic seal upon
reaching the annular seat 355. The sleeve 342 of the float shoe 340
increases in diameter to accommodate a bypass passage 356. The
bypass passage 356 defines a passage that connects the portion of
the longitudinal passage 344 above the seat 356 to a portion of the
longitudinal passage 344 below the seat 356, thereby creating a
"bypass" around the seat 356. In the running position illustrated
in FIGS. 2a-2e, an entrance port 356a of the bypass passage 356 is
blocked by the sliding sleeve valve 346.
[0050] Positioned below the annular seat 355 is a one-way valve
358. In several exemplary embodiments, the one way valve 358 may be
a float valve assembly which allows for a fluid to flow in a
downward direction, but prevents fluid to flow in an upward
direction. The one-way valve 358 opens into an longitudinal passage
360. A sleeve, such as a dog locking sleeve 362 may be slidingly
disposed within the longitudinal passage 360. A shear pin 364
maintains the relative position of the dog locking sleeve relative
to the float shoe 340 such that a lower end 368 of the dog locking
sleeve is disposed below the float shoe 340. At the top end of the
dog locking sleeve 362, there is an external flange 366 adapted
such that an upward movement by the external flange 366 "expands"
or pushes out a plurality of dogs 370 through a plurality of radial
side openings 372 defined in the float shoe 340. In several
alternative embodiments, the dogs 370 or expansion mechanism 150
within the float shoe 340 may be replaced by a shoulder on the
float shoe for engaging the end of the radially expanded tubular
member.
[0051] In an exemplary embodiment, during operation of the
apparatus 200, as illustrated in FIGS. 2a-2e, the apparatus may be
initially positioned in the wellbore 100, partially within the
casing 110, with the expansion cone 140, the cementing probe 144,
and the float shoe 340 positioned outside the casing. In this
manner, fluidic materials within the interior of the apparatus 200
may pass through the longitudinal passages 203, 250a, 261, 283,
293, 302, 310, 344, 348, and 360 out of the apparatus through the
float valve 358, into the annulus between the apparatus 200 and the
casing 110 thereby preventing over pressurization of the
annulus.
[0052] Referring now to FIGS. 3a-3e, there is illustrated the
apparatus 200 positioned at the bottom of the wellbore 100. When
the apparatus 200 contacts with the bottom of the wellbore 100, the
dog locking sleeve 368 is driven up into the float shoe 340,
shearing the shear pin 360. The upward movement of the locking
sleeve 368 forces the dogs 370 through the side openings 372, where
a locking mechanism prevents their retraction.
[0053] In an alternative embodiment of the expansion cone, the
force of impact with the bottom of the well shears the retaining
mechanism, forcing the lower expansion cone retainer 292 towards
the upper expansion cone retainer 290. The interleaved cone
segments pivot outward in a lateral direction on top of one
another. As the cone segments pivot outward, the diameter of the
expansion cone 140 increases. A locking mechanism then locks the
upper cone segments in place. Thus, the expansion cone may expand
to a diameter that is greater than the interior diameter of the
casing 110.
[0054] Referring now to FIGS. 4a-4f, there is illustrated the
apparatus 200 when a plug, such as a ball 374 is then injected into
the apparatus with the fluidic material through the passages 203,
250a, 261, 283, 293, 302, 310, 344 and 348 until the dart is
positioned and seated on the annular seat 355 in the float shoe
340. As a result of the positioning of the ball 374 in the passage
344 of the float shoe 340, the passage 344 of the float shoe is
thereby closed.
[0055] The fluidic material is then injected into the apparatus
thereby increasing the operating pressure within the passages 203,
250a, 261, 283, 293, 302, 310, 344 and 348. Furthermore, the
continued injection of the fluidic material into the apparatus 200
causes the fluidic material to pass through the radial passages
220a and 220b, into the annular pressure chamber 222 of the
gripping device 132. When the pressure of the central passage 203
is large enough to overcome the biasing of the springs 208a and
208b, the pressure chamber 222 expands by driving the upper flange
207 away from the external flange 224. Thus, the upper flange 207a
acts like a piston pushing the retaining sleeve 206 in an
upperwardly direction with respect to the central mandrel 202. When
the retaining sleeve moves up, the steel balls 218a-218d are forced
up into thinner regions of the retaining chambers 216a-216d. A
portion of the steels balls 218a-218d, therefore, projects radially
through the circular openings 214a-214d. As the steel balls
218a-218d project through the circular openings 214a-214d, they
engage the interior surface of the casing 110.
[0056] The fluidic material is then injected into the apparatus
thereby increasing the operating pressure within the passages 203,
250a, 261, 283, 293, 302, 310, 344 and 348. Furthermore, the
continued injection of the fluidic material into the apparatus 200
also causes the fluidic material to pass through the radial tubes
270a through 270f, of the piston tube 260 into an annular pressure
chambers 268, 268a, and 268b, respectively.
[0057] The pressurization of the annular pressure chambers, 268a,
268b, and 268c then cause the piston flanges 262a, 262b, 262c to be
displaced upwardly relative to the casing 100. As a result, the
upper packer cup assembly 280, the lower packer cup assembly 286,
expansion cone 140, the release housing 300, the cementing probe
308, and the float shoe 340 are displaced upwardly relative to the
casing 110.
[0058] The continued injection of the fluidic material into the
apparatus 200 continues to pressurize annular pressure chambers,
268a, 268b, and 268c. The further upward displacement of the piston
flanges 262a, 262b, 262c in turn displaces the expansion cone 140
upwardly relative to the casing 110. As a result, the expansion
cone 140 radially expands and plastically deforms a portion of the
casing 110.
[0059] Referring to FIGS. 5a-5f, during the continued injection of
the fluidic material, the expansion cone 140 will continue to be
displaced upwardly relative to the casing 110 thereby continuing to
radially expand and plastically deform the casing until the locking
dogs 370a-370b engage the lower end of the casing 110. The
continued upward movement of the expansion cone 140, cement probe
308, and release housing 300 causes the release housing 300 to move
longitudinally upward--out of the sleeve 306 of the float shoe 340.
The external flange 305 of the release housing 300 causes the
sleeve 306 to radially expand against the casing 110. In some
embodiments, this radial expansion of the sleeve 306 also causes an
expansion and plastic deformation of a portion of the casing 110
which may also hydraulically seal the sleeve 306 to the casing 110.
Optionally, a elastomeric sealing material may be applied to the
exterior of the sleeve 306 to create a seal between the sleeve 306
and the casing 110.
[0060] Referring to FIGS. 6a to 6e, The continued upward movement
of the expansion cone 140, cement probe 308, and release housing
300 causes the probe shear pin 318 to shear. The force on the
cement probe 308 pulls the probe downward until the external flange
312 impacts the seat 314 defined with the passage 302 preventing
further movement of the cement probe. A probe lock ring 313
disposed on the exterior surface of the concrete probe contacts a
downward facing seat 315, thereby "locking" the concrete probe in
place. The continued upward movement of the cement probe 308 causes
the cement probe 308 to separate from the float shoe 340. At the
top of the stroke of the tension actuator 134, the casing lock 130
may be released. After separation, the apparatus 200 is free to
continue to advance up causing the casing 110 to expand as
necessary. Because there is an hydraulic seal between the sleeve
306 and the casing 110, the region between the float shoe 340 and
the packer cup assemblies 280 and 286 may be pressurized. This
pressurized region forces the expansion cone 140 upwardly, thereby
causing a continued radial expansion and plastic deformation of the
expandable casing 110. In this manner, the fluid pressure below the
packer cup assemblies 280 and 286 pulls the expansion cone 140
upwardly through the expandable casing 110. Thus, the use of the
tension actuator 134 to pull the expansion cone upwards is no
longer necessary.
[0061] At some point (e.g., at the top of the liner), it may become
desirable to stop expanding and to inject a hardenable fluidic
sealing material such as, for example, cement into the well
annulus. Referring to FIGS. 7a to 7f, to begin the cementing
operation, the apparatus 200 may be lowered into the wellbore 100
until the neck 316 of the cementing probe 308 impacts the collet
346a forcing the rim 350 of the collet from the recess 352, which
allows the sliding sleeve valve 346 to move downward until the
sliding sleeve valve impacts an upward facing seat 345 in the
passage 344. In this position, the sideport 354 is aligned with the
opening of the bypass flowpath 356 to permit fluidic materials to
bypass around the ball in the passage 344. As a result, the bypass
flow path 356 allows for cement or other fluidic materials to flow
around the ball.
[0062] Thus, the cement may flow through the through the bypass
flow path 356, and out through the one-way valve 358 into the
annulus between the radially expanded tubular member and the
wellbore. After the cement has been injected into the annulus, the
one way valve may prevent the cement from flowing backwards into
the flowpath 356.
[0063] After completing the injection of the cement into the
annulus, the drilling pipe may then pulled upwardly out of the
wellbore. The radial expansion and plastic deformation of the
expandable tubular member may then be continued by the resumed
injection of fluidic material into the apparatus. After the cement
has cured, the float shoe 340 may be drilled out and another
expandable tubular member may then be radially expanded and
plastically deformed within the wellbore with the upper end of the
other tubular member overlapping with the lower end of the earlier
expanded tubular member. In this manner, a mono diameter wellbore
casing may be formed that includes a plurality of radially expanded
tubular members.
[0064] In several alternative embodiments, a packer may be used
instead of the float shoe 340 to couple the end of the casing to
the apparatus. Referring to FIGS. 8a to 8e, an alternative
embodiment, an apparatus 500 for forming a mono diameter wellbore
casing 502 provides a one step monobore wellbore casing radial
expansion system. The one step monobore system can also be used as
a cased or open hole radial expansion system, or an open hole
cladding system where an expandable casing is clad against a
formation in open hole.
[0065] In an exemplary embodiment, the apparatus 500 includes an
expansion assembly 504 and a packer 506. The expansion assembly 504
includes, among other things, a safety sub 508, a gripping device
510, a casing lock device 512, a force multiplier or tension
actuator 514, an expansion cone 516, a packer setting sleeve 518,
an internal sleeve 520 and a stinger 522.
[0066] In an exemplary embodiment, the safety sub 508 allows a
quick connection and disconnection of the drill string to and from
the expansion system.
[0067] In several exemplary embodiments, the gripping device 510
may be any device capable of engaging the inside surface of the
tubular member or casing 502 in a conventional manner and/or using
one or more of the methods and apparatus disclosed in one or more
of the following: (1) PCT application no. serial no.
PCT/US02/36267, attorney docket no. 25791.88, filed on Nov. 12,
2002, (2) U.S. provisional patent application Ser. No. 60/338,996,
attorney docket no. 25791.87, filed on Nov. 12, 2001, (3) U.S.
provisional patent application Ser. No. 60/363,829, attorney docket
no. 25791.95, filed on Mar. 13, 2002, and (4) U.S. provisional
patent application Ser. No. 60/339,013, attorney number attorney
docket no. 25791.88, filed on Nov. 12, 2001, the disclosures of
which are incorporated herein by reference. In the embodiment as
illustrated in FIGS. 8a-8f, the gripping device 510 comprises
hydraulic slips 510a-510c are isolated from internal pressure by a
rupture disc 524. In an exemplary embodiment, a packer cup 526 acts
as a check valve to allow external pressure to equalize behind the
hydraulic slips 510a-510c when in a running configuration, but
holds internal pressure when the rupture disc is ruptured. In an
exemplary embodiment, the hydraulic slips 510a-510c are actuated by
rupturing the rupture disc 524 with internal pressure. In an
exemplary embodiment, the internal pressure then acts on the
hydraulic slips 510a-510c, moving them out against the internal
diameter of the expandable casing 502. The hydraulic slips
510a-510c thereby provide an anchor for the tension actuator to
pull the expansion cone 504 against and expand the expandable
casing. When the internal pressure is released, the hydraulic slips
510a-510c retract away from the internal diameter of the expandable
casing 502.
[0068] In an exemplary embodiment, a casing lock 512 holds the
weight of the expandable casing string as it is run in the well. In
several exemplary embodiments, the casing lock 512 may be any
device capable of coupling the apparatus to the casing while the
apparatus is being positioned within the wellbore in a conventional
manner and/or using one or more of the methods and apparatus
disclosed in one or more of the following: (1) PCT application no.
serial no. PCT/US02/36267, attorney docket no. 25791.88, filed on
Nov. 12, 2002, (2) U.S. provisional patent application Ser. No.
60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001,
(3) U.S. provisional patent application Ser. No. 60/363,829,
attorney docket no. 25791.95, filed on Mar. 13, 2002, and (4) U.S.
provisional patent application Ser. No. 60/339,013, attorney number
attorney docket no. 25791.88, filed on Nov. 12, 2001, the
disclosures of which are incorporated herein by reference.
[0069] In the illustrative embodiment, casing lock dogs 530 fit in
upsets formed in the internal diameter of the expandable casing and
are held in place with a retaining sleeve 532. When the retaining
sleeve 532 is shifted by the tension actuator 514, the dogs 530
retract and the expansion 504 is released from the expandable
casing 502.
[0070] In several exemplary embodiments, the tension actuator 514
may be any device capable of pulling the expansion cone 140 into
the casing 110 in a conventional manner and/or using one or more of
the methods and apparatus disclosed in one or more of the
following: (1) PCT application no. serial no. PCT/US02/36267,
attorney docket no. 25791.88, filed on Nov. 12, 2002, (2) U.S.
provisional patent application Ser. No. 60/338,996, attorney docket
no. 25791.87, filed on Nov. 12, 2001, (3) U.S. provisional patent
application Ser. No. 60/363,829, attorney docket no. 25791.95,
filed on Mar. 13, 2002, and (4) U.S. provisional patent application
Ser. No. 60/339,013, attorney number attorney docket no. 25791.88,
filed on Nov. 12, 2001, the disclosures of which are incorporated
herein by reference. The tension actuator 514 may also be similar
to the tension actuator 134 described above.
[0071] In an exemplary embodiment, the tension actuator 514
provides several stages of differential area for internal pressure
to act upon and thereby provide an upward force to the expansion
cone 504 to thereby expand the expandable casing 502. The tension
actuator 514 may be used to initially expand the expandable casing
502 and to pull the packer 506 into the radially expanded casing
502. The tension actuator 514 may be used at any time during radial
expansion process when the hydraulic slips 510a-510b are actuated
to provide additional upward force to the expansion cone. In an
exemplary embodiment, the tension actuator 514 may be used to
assist in the radial expansion process when the portion of the
expandable casing that overlaps with another casing is radially
expanded and plastically deformed.
[0072] In several exemplary embodiments, the expansion cone 504 be
any device capable of expanding the casing or tubing member 110
within the wellbore 105 in a conventional manner and/or using one
or more of the methods and apparatus disclosed in one or more of
the following: (1) PCT application no. serial no. PCT/US02/36267,
attorney docket no. 25791.88, filed on Nov. 12, 2002, (2) U.S.
provisional patent application Ser. No. 60/338,996, attorney docket
no. 25791.87, filed on Nov. 12, 2001, (3) U.S. provisional patent
application Ser. No. 60/363,829, attorney docket no. 25791.95,
filed on Mar. 13, 2002, and (4) U.S. provisional patent application
Ser. No. 60/339,013, attorney number attorney docket no. 25791.88,
filed on Nov. 12, 2001, the disclosures of which are incorporated
herein by reference. Thus, the expansion cone 516 may be an
adjustable expandable expansion cone, or it may be expandable or
non-expandable for use in cased or open hole expansion systems or
open hole clad systems.
[0073] In an exemplary embodiment, an internal sleeve 534 blocks
ports 536 which lead from the internal passage 528 to the packer
setting sleeve 538. In an exemplary embodiment, the internal sleeve
534 may be moved away from the ports 536 by the tension actuator
514 at the end of the tension actuator stroke to allow internal
pressure to act on the packer setting sleeve 538 and thereby set
the packer 506 in the expanded casing 502. Thus, in an exemplary
embodiment, the packer setting sleeve 538 is moved downwardly
against the packer 506 to set the packer by internal pressure.
[0074] In an exemplary embodiment, the packer 506 may be a fas dril
packer which is a composite drillable packer that is set in the
expanded casing and contains the expansion pressure. The fas dril
packer includes an internal pressure balanced sliding sleeve valve
540 which is used to open and close fluid ports 542 The sleeve
valve 540 has two external seals which seal against the internal
diameter of the fas dril packer and isolate fluid ports in the fas
dril packer when the sleeve valve is in the up position. When the
sleeve valve is moved downwardly, ports 544 in the sleeve valve 540
align with ports 542 in the fas dril packer and allow fluid to be
displaced into a bypass passage 546 in the fas dril packer. Collets
at the top of the sleeve valve fit in an internal groove provided
in the internal diameter of the fas dril packer when the sleeve
valve is in the up position and allow the end of the stinger to
pass and shoulder against the sleeve valve. When a stinger 548
pushes the sleeve valve 540 downwardly to open the ports 542, the
collets are pulled out of the groove and retract inward into an
external undercut on the bottom of the stinger 548.
[0075] When the stinger 548 is moved up to close the ports 542, a
lower shoulder on the external undercut contacts the inward
retracted collets and pulls the sliding sleeve valve 540 upwardly
until the collets expand out into the internal groove. The sleeve
valve 540 is operated with a stinger 548 attached to the expansion
assembly 504. Below the sleeve valve 540 are two ball seats 550a
and 550b with a rupture disc 552 in between. The bypass passage 546
connects the ports 542 covered by the sleeve valve, the rupture
disc ports 554, and ports 556 positioned below the bottom ball
seat.
[0076] A check valve 558 may be disposed at the bottom of the fas
dril packer. Other types of commercially available drillable
packers may also be used, such as, for example, the EZ Drill.
Additionally, for open and cased hole cladding systems where cement
is not going to be used, retrievable packers can be used and
retrieved after expansion instead of drilled.
[0077] In an exemplary embodiment, the stinger 548 may be attached
to the expansion assembly 504 and includes an external seal 560
which seals against the inside diameter of the fas dril packer. At
the bottom end of the stinger is an external undercut which is used
to close the sliding sleeve valve.
[0078] Turning now to FIGS. 9a-9e, which illustrates some aspects
of the operation of the apparatus 500. In FIG. 9a, the expansion
assembly 504 is run through the casing 502 until the packer 506 is
in open hole beyond the casing.
[0079] A first plug, which may be a ball or a dart, may be dropped
to the plug seat 550a in the packer central passage 528. Continued
pumping of fluids causes the internal pressure to be increased. As
described above with reference to FIGS. 1a to 7f, the pressure
actuates the tension actuator 514 which pulls the expansion cone
516 up against the bottom of the casing 510.
[0080] The expansion cone 516 expands in size and then expands the
expandable casing 502, pulling the packer 506 upwardly along with
it. Near the end of the tension actuator stroke, the packer 506 is
positioned in the expanded casing and the lower end of the tension
actuator shoulders against the internal sleeve 520, shifting it
downward. As a result, the ports 536 open allowing fluidic
communication from the central passage 528 to the packer setting
sleeve 538. The internal pressure then causes the setting sleeve
538 to down, which pushes against and sets the packer 506.
[0081] The tension actuator 514 then pulls against a connecting
mechanism, such as a plurality of shear pins, connecting the packer
506 to the expansion assembly 504 until they shear.
[0082] At the end of the tension actuator stroke, an upper end 562
of the tension actuator 514 shoulders against the dog retaining
sleeve 532 and moves it upward, releasing the dogs 530 and
unlocking the expansion assembly 504 from the casing 502.
[0083] Continued injection of the fluidic material into the
apparatus 500 causes an increase in the internal pressure in the
central passage 528. The increase pressure ruptures the rupture
disc 554, which allows the fluid to flow into the bypass passage
546. The casing 502 can now be run to the bottom of the well.
[0084] Once the casing has reached the bottom of the well, a second
plug may be dropped. The second plug sized to sealingly fit the
second plug seat 550b. The second plug stops circulation through
the bypass passage 546. Continued injection of fluid increases the
internal pressure in the central passage 528 so that the casing
expansion can be partially or completely continued, or the
expansion assembly can be set down to open the sliding sleeve valve
to circulate mud or displace cement. Picking back up on the
expansion assembly 504 will close the sliding sleeve valve. At any
point during expansion, the expansion assembly 504 can be set down
on the packer 506 to open the sliding sleeve valve 540 to continue
circulation.
[0085] Once the expansion assembly 504 reaches an overlap section
of the expandable casing 502, the expansion pressure increases
until the upper rupture disc 524 ruptures. The hydraulic slips
510a-510c then move out against the internal diameter of the
expandable casing 502, providing an anchor for the tension actuator
to pull the expansion cone against. When the tension actuator 514
reaches the end of its stroke, the internal pressure is released,
the hydraulic slips 510a-510c retract, and the tension actuator 514
is extended for another stroke. In an exemplary embodiment, the
hydraulic slips 510a-510c may be designed to not only contact the
unexpanded casing, but will also extend out far enough the contact
the previously expanded casing string at the final expansion
stroke.
[0086] After the expansion assembly 504 is pulled out of the well,
the packer 506 may be drilled out and another section of hole may
be drilled. An identical expansion system is then run and expanded
to the same ID as the previous string.
[0087] It is understood that variations may be made in the
foregoing without departing from the scope of the invention. For
example, the teachings of the present illustrative embodiments may
be used to provide a wellbore casing, a pipeline, or a structural
support. Furthermore, the elements and teachings of the various
illustrative embodiments may be combined in whole or in part in
some or all of the illustrative embodiments.
[0088] It is understood that variations may be made in the
foregoing without departing from the scope of the invention. For
example, the teachings of the present illustrative embodiments may
be used to provide a wellbore casing, a pipeline, or a structural
support. Furthermore, the elements and teachings of the various
illustrative embodiments may be combined in whole or in part in
some or all of the illustrative embodiments.
[0089] 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.
* * * * *