U.S. patent application number 10/528219 was filed with the patent office on 2006-03-16 for mono diameter wellbore casing.
Invention is credited to David Paul Brisco, Lev Ring, Brock Wayne Watson.
Application Number | 20060054330 10/528219 |
Document ID | / |
Family ID | 32030901 |
Filed Date | 2006-03-16 |
United States Patent
Application |
20060054330 |
Kind Code |
A1 |
Ring; Lev ; et al. |
March 16, 2006 |
Mono diameter wellbore casing
Abstract
An apparatus for radially expanding and plastically deforming an
expandable tubular members to form a mono diameter wellbore casing
includes an adjustable expansion assembly having a first diameter
for forming a bell portion of in each tubular member and a second
diameter for forming a mono diameter portion that nests into the
bell portion of the preceding tubular member.
Inventors: |
Ring; Lev; (Houston, TX)
; Watson; Brock Wayne; (Carrolton, TX) ; Brisco;
David Paul; (Duncan, OK) |
Correspondence
Address: |
HAYNES AND BOONE, LLP
901 MAIN STREET, SUITE 3100
DALLAS
TX
75202
US
|
Family ID: |
32030901 |
Appl. No.: |
10/528219 |
Filed: |
September 22, 2003 |
PCT Filed: |
September 22, 2003 |
PCT NO: |
PCT/US03/29859 |
371 Date: |
November 8, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60412542 |
Sep 20, 2002 |
|
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Current U.S.
Class: |
166/380 ;
166/207; 166/242.1 |
Current CPC
Class: |
E21B 43/105
20130101 |
Class at
Publication: |
166/380 ;
166/242.1; 166/207 |
International
Class: |
E21B 43/10 20060101
E21B043/10 |
Claims
1. An apparatus for radially expanding and plastically deforming an
expandable tubular member from an initial inside diameter to a
desired diameter of a mono diameter wellbore casing, comprising: an
upper tubular support member defining a first passage; one or more
cup seals coupled to the exterior surface of the upper tubular
support member for sealing an interface between the upper tubular
support member and the expandable tubular member; an expansion cone
assembly coupled to the upper tubular support member adjustable to
one expansion diameter corresponding to the desired diameter of the
bell portion of the wellbore casing for forming an expanded bell
portion in the expandable tubular member and adjustable to another
expansion diameter corresponding to the desired diameter of the
mono diameter casing for forming the mono diameter wellbore casing;
means for actuating the expandable tubular member to adjust from
the one diameter to the other diameter; and an actuator for moving
the cone through the expandable tubular member a desired distance
with the expansion cone assembly adjusted to the diameter of the
bell portion and for moving the expansion cone assembly through the
expandable tubular member for another distance with the expansion
cone assembly adjusted to the desired diameter of the mono diameter
portion of the expandable tubular member.
2. The apparatus of claim 1, wherein the expansion cone assembly
comprises a one adjustable cone having an external surface
adjustable to the diameter of the bell portion of the expandable
tubular member; and wherein the external surface of the one
adjustable cone is also adjustable to the diameter corresponding to
the desired diameter of the mono diameter wellbore casing.
3. The apparatus of claim 1, wherein the expansion cone assembly
comprises: a first adjustable cone having an external surface
adjustable to the diameter of the bell portion of the expandable
tubular member; and a second adjustable cone having an external
surface adjustable to the diameter corresponding to the desired
diameter of the mono diameter wellbore casing.
4. The apparatus of claim 1, wherein the expansion cone assembly
comprises: a first adjustable cone having an external surface
adjustable to the diameter of the bell portion of the expandable
tubular member and collapsible after expanding the bell portion;
and a second cone having a fixed diameter corresponding to the
desired diameter of the mono diameter wellbore casing such that
collapsing the first cone effectively adjusts the effective
expansion diameter to the fixed diameter of the second cone.
5. The apparatus of claim 1, wherein the expansion cone assembly
comprises: an upper cam assembly coupled to the upper tubular
support member comprising: a tubular base coupled to the upper
tubular support member; and a plurality of cam arms extending from
the tubular base in a downward longitudinal direction, each cam arm
defining an inclined surface; a plurality of upper expansion cone
segments interleaved with the cam arms of the upper cam assembly
and pivotally coupled to the tubular support member, and each upper
expansion segment movable relative to the inclined surface of one
of the plurality of cam arms to adjust the radial position of an
eternal surface of the segment to adjust the diameter of the
expansion cone assembly; a lower tubular support member defining a
second passage fluidicly coupled to the first passage releasably
coupled to the upper tubular support member; a lower cam assembly
coupled to the lower tubular support member comprising: a tubular
base coupled to the lower tubular support member; and a plurality
of cam arms extending from the tubular base in an upward
longitudinal direction, each cam arm defining an inclined surface
that mates with the inclined surface of a corresponding one of the
upper expansion cone segments; wherein the cams arms of the upper
cam assembly are interleaved with and overlap the cam arms of the
lower cam assembly; and a plurality of lower expansion cone
segments interleaved with cam arms of the lower cam assembly, each
lower expansion cone segment pivotally coupled to the lower tubular
support member and mating with the inclined surface of a
corresponding one of the cam arms of the upper cam assembly and
each lower expansion segment movable relative to the inclined
surface of one of the plurality of cam arms to adjust the radial
position of an eternal surface of the segment to adjust the
diameter of the expansion cone assembly; wherein the lower
expansion cone segments interleave and overlap the upper expansion
cone segments; and wherein the upper and lower expansion cone
segments each approximate an arcuate spherical external surface for
plastically deforming and radially expanding the expandable tubular
member.
6. An apparatus for radially expanding and plastically deforming an
expandable tubular member, comprising: a tubular support member; a
adjustable expansion cone assembly coupled to the tubular support
member; an expandable tubular member coupled to the adjustable
expansion cone assembly; means for displacing the adjustable
expansion cone assembly relative to the expandable tubular member;
and means for adjusting the adjustable expansion cone assembly from
one effective expansion diameter to another effective expansion
diameter.
7. The apparatus of claim 6, wherein the tubular support member
comprises an upper tubular support member comprising an internal
flange and a lower tubular support member comprising an internal
flange; wherein the expansion cone comprises: an upper cam assembly
coupled to the upper tubular support member comprising: a tubular
base coupled to the upper support member; and a plurality of cam
arms extending from the tubular base in a downward longitudinal
direction, each cam arm defining an inclined surface; a plurality
of upper expansion cone segments interleaved with the cam arms of
the upper cam assembly and pivotally coupled to the internal flange
of the upper tubular support member; a lower cam assembly coupled
to the lower tubular support member comprising: a tubular base
coupled to the lower tubular support member; and a plurality of cam
arms extending from the tubular base in an upward longitudinal
direction, each cam arm defining an inclined surface that mates
with the inclined surface of a corresponding one of the upper
expansion cone segments; wherein the cams arms of the upper cam
assembly are interleaved with and overlap the cam arms of the lower
cam assembly; and a plurality of lower expansion cone segments
interleaved with cam arms of the lower cam assembly, each lower
expansion cone segment pivotally coupled to the internal flange of
the lower tubular support member and mating with the inclined
surface of a corresponding one of the cam arms of the upper cam
assembly; and wherein the apparatus further comprises: means for
releasably coupling the upper tubular support member to the lower
tubular support member; and means for limiting movement of the
upper tubular support member relative to the lower tubular support
member.
8. The apparatus of claim 6, further comprising: means for pivoting
the upper expansion cone segments; and means for pivoting the lower
expansion cone segments.
9. The apparatus of claim 6, further comprising: means for pulling
the adjustable expansion cone assembly through the expandable
tubular member.
10. A adjustable expansion cone assembly, comprising: an upper cam
assembly comprising: a tubular base; and a plurality of cam arms
extending from the tubular base in a downward longitudinal
direction, each cam arm defining an inclined surface; a plurality
of upper expansion cone segments interleaved with the cam arms of
the upper cam assembly; a lower cam assembly comprising: a tubular
base; and a plurality of cam arms extending from the tubular base
in an upward longitudinal direction, each cam arm defining an
inclined surface that mates with the inclined surface of a
corresponding one of the upper expansion cone segments; wherein the
cams arms of the upper cam assembly are interleaved with and
overlap the cam arms of the lower cam assembly; a plurality of
lower expansion cone segments interleaved with cam arms of the
lower cam assembly, each lower expansion cone segment mating with
the inclined surface of a corresponding one of the cam arms of the
upper cam assembly; means for moving the upper cam assembly toward
or away from the lower expansion cone segments to adjust the radial
position of an external surface of the lower expansion cone
segments; and means for moving the lower cam assembly toward or
away from the upper expansion cone segments to adjust the radial
position of an external surface of the upper expansion cone
segments.
11. The apparatus of claim 10, wherein the upper and lower
expansion cone segments together approximate an arcuate spherical
external surface.
12. The apparatus of claim 10, wherein each upper expansion cone
segment comprises: an inner portion defining an arcuate cylindrical
upper surface and arcuate cylindrical lower surfaces; an
intermediate portion defining arcuate cylindrical and spherical
upper surfaces and an arcuate conical lower surface; and an outer
portion defining arcuate cylindrical upper and lower surfaces; and
wherein each lower expansion cone segment comprises: an inner
portion defining an arcuate cylindrical upper surface and arcuate
cylindrical lower surfaces; an intermediate portion defining
arcuate cylindrical and spherical upper surfaces and an arcuate
conical lower surface; and an outer portion defining arcuate
cylindrical upper and lower surfaces.
13. The apparatus of claim 12, wherein each upper expansion cone
segment is tapered in the longitudinal direction from the
intermediate portion to the outer portion; and wherein each lower
expansion cone segment is tapered in the longitudinal direction
from the intermediate portion to the outer portion.
14. An apparatus for radially expanding and plastically deforming
an expandable tubular member from an initial inside diameter to a
desired diameter of a mono diameter wellbore casing, comprising: an
upper tubular support member defining a first passage; one or more
cup seals coupled to the exterior surface of the upper tubular
support member for sealing an interface between the upper tubular
support member and the expandable tubular member; an expansion
assembly coupled to the upper tubular support member adjustable to
one expansion diameter corresponding to the desired diameter of the
bell portion of the wellbore casing for forming an expanded bell
portion in the expandable tubular member and adjustable to another
expansion diameter corresponding to the desired diameter of the
mono diameter casing for forming the mono diameter wellbore casing;
means for actuating the expandable tubular member to adjust from
the one diameter to the other diameter; and an actuator for moving
the expansion assembly through the expandable tubular member a
desired distance with the expansion assembly adjusted to the
diameter of the bell portion and for moving the expansion assembly
through the expandable tubular member for another distance with the
expansion assembly adjusted to the desired diameter of the mono
diameter portion of the expandable tubular member.
15. The apparatus of claim 14, wherein the expansion assembly
comprises a expansion cone device
16. The apparatus of claim 14, wherein the expansion assembly
comprises a rotary expansion device.
17. The apparatus of claim 14, wherein the expansion assembly
comprises compliant expansion device.
18. The apparatus of claim 14, wherein the expansion assembly
comprises a hydroforming expansion device.
19. The apparatus of claim 14, wherein: the expansion assembly
comprises an adjustable expander device having adjustable to the
diameter of the bell portion of the expandable tubular member; and
wherein the one adjustable expander device is also adjustable to
the diameter corresponding to the desired diameter of the mono
diameter wellbore casing.
20. The apparatus of claim 19, wherein the adjustable expander
device comprises an adjustable expansion cone device
21. The apparatus of claim 19, wherein the adjustable expander
device comprises an adjustable rotary expansion device.
22. The apparatus of claim 19, wherein the adjustable expander
device comprises an adjustable compliant expansion device.
23. The apparatus of claim 19, wherein the adjustable expander
device comprises an adjustable hydroforming expansion device.
25. The apparatus of claim 14, wherein the expansion assembly
comprises: a first adjustable expander device adjustable to the
diameter of the bell portion of the expandable tubular member; and
a second adjustable expander device adjustable to the diameter
corresponding to the desired diameter of the mono diameter wellbore
casing.
26. The apparatus of claim 14, wherein the expansion assembly
comprises: a first adjustable expander device adjustable to the
diameter of the bell portion of the expandable tubular member and
collapsible after expanding the bell portion; and a second expander
device having a fixed diameter corresponding to the desired
diameter of the mono diameter wellbore casing such that collapsing
the first adjustable expander device effectively adjusts the
effective expansion diameter to the fixed diameter of the second
expander device.
27. A method of forming a mono diameter casing in a wellbore,
comprising: supporting a first expandable tubular member in the
wellbore using a tubular support member and an adjustable expansion
assembly having a first diameter smaller than the inside diameter
of the expandable tubular member; injecting a fluidic material into
the tubular support member; sensing the operating pressure of the
injected fluidic material within a first interior portion of the
tubular support member; displacing the adjustable expansion
assembly relative to the expandable tubular member and into the
wellbore when the sensed operating pressure of the injected fluidic
material exceeds a predetermined level within the first interior
portion of the tubular support member; sensing the operating
pressure of the injected fluidic material within a second interior
portion of the tubular support member; adjusting the effective
expansion diameter of the adjustable expansion assembly to a second
diameter larger than the inside diameter of the expandable tubular
member when the sensed operating pressure of the injected fluidic
material exceeds a predetermined level within the second interior
portion of the tubular support member; moving the adjustable
expansion assembly having the second diameter a predetermined
distance into the expandable tubular member to radially expand and
plastically deform a first portion of the expandable tubular
member; activating the effective expansion diameter of the
adjustable expansion assembly to adjust to a second diameter
smaller than the first effective expansion diameter; and moving the
adjustable expansion assembly through the expandable tubular member
when the adjustable expansion assembly is adjusted to the third
diameter, to thereby radially expand and plastically deform the
remaining portion of the expandable tubular member.
28. The method of forming a mono diameter wellbore casing as in
claim 27 further comprising: supporting a second expandable tubular
member in the wellbore using a tubular support member and an
adjustable expansion assembly having a first diameter smaller than
the inside diameter of the expandable tubular member; positioning
the second expandable tubular member in the expanded first
expandable tubular member with the first portion thereof
overlapping the second expandable tubular member; injecting a
fluidic material into the tubular support member; sensing the
operating pressure of the injected fluidic material within a first
interior portion of the tubular support member; displacing the
adjustable expansion assembly relative to the second expandable
tubular member and into the wellbore when the sensed operating
pressure of the injected fluidic material exceeds a predetermined
level within the first interior portion of the tubular support
member; sensing the operating pressure of the injected fluidic
material within a second interior portion of the tubular support
member; adjusting the effective expansion diameter of the
adjustable expansion assembly to the second diameter when the
sensed operating pressure of the injected fluidic material exceeds
a predetermined level within the second interior portion of the
tubular support member; moving the adjustable expansion assembly
having the second diameter a predetermined distance into the second
expandable tubular member to radially expand and plastically deform
a first portion of the second expandable tubular member below the
first portion of the first expandable tubular member; activating
the effective expansion diameter of the adjustable expansion
assembly to adjust to the second diameter; and moving the
adjustable expansion assembly through the second expandable tubular
member and past the portion overlapping with the first expandable
tubular member when the adjustable expansion assembly is adjusted
to the third diameter, and to thereby radially expand and
plastically deform a second portion of the second expandable
tubular member to the same diameter as the expanded remaining
portion of the first expandable tubular member.
29. The method of claim 27, wherein the adjustable expansion
assembly comprises an adjustable expansion cone device
30. The apparatus of claim 27, wherein the adjustable expansion
assembly comprises an adjustable a rotary expansion device.
31. The apparatus of claim 27, wherein the adjustable expansion
assembly comprises an adjustable compliant expansion device.
32. The apparatus of claim 27, wherein the adjustable expansion
assembly comprises an adjustable hydroforming expansion device.
33. A method of forming a casing in a wellbore, comprising:
inserting an expandable tubular member into the wellbore radially
expanding and plastically deforming a lower portion of the
expandable tubular member to a first inside diameter; and radially
expanding and plastically deforming an upper portion of the
expandable tubular member to a second inside diameter, wherein the
first inside diameter is larger than the second inside
diameter.
34. The method of claim 33 further comprising: inserting a second
expandable tubular member, into the expanded expandable tubular
member so that a top portion of the second expandable tubular
member is overlapped by the expanded lower portion of the expanded
expandable tubular member; and expanding the top portion of the
second expandable tubular member to the second diameter so that the
top portion of the second expandable tubular member is expanded
radially outward in the expanded lower portion of the expanded
expandable tubular member.
35. The method of claim 33, wherein the expanding the lower and
upper portions of the expandable tubular members comprises
expanding using an expansion cone device.
36. The method of claim 33, wherein the expanding the lower and
upper portions of the expandable tubular members comprises
expanding using a rotary expansion device.
37. The method of claim 33, wherein the expanding the lower and
upper portions of the expandable tubular members comprises
expanding using a compliant expansion device.
38. The method of claim 33, wherein the expanding the lower and
upper portions of the expandable tubular members comprises
expanding using a hydroforming expansion device.
39. A method of forming a mono diameter casing in a wellbore,
comprising: supporting a first expandable tubular member in the
wellbore using a tubular support member and an adjustable expansion
cone assembly having a first diameter smaller than the inside
diameter of the expandable tubular member; injecting a fluidic
material into the tubular support member; sensing the operating
pressure of the injected fluidic material within a first interior
portion of the tubular support member; displacing the adjustable
expansion cone assembly relative to the expandable tubular member
and into the wellbore when the sensed operating pressure of the
injected fluidic material exceeds a predetermined level within the
first interior portion of the tubular support member; sensing the
operating pressure of the injected fluidic material within a second
interior portion of the tubular support member; adjusting the
effective expansion diameter of the adjustable expansion cone
assembly to a second diameter larger than the inside diameter of
the expandable tubular member when the sensed operating pressure of
the injected fluidic material exceeds a predetermined level within
the second interior portion of the tubular support member; moving
the adjustable expansion cone assembly having the second diameter a
predetermined distance into the expandable tubular member to
radially expand and plastically deform a first portion of the
expandable tubular member; activating the effective expansion
diameter of the adjustable expansion cone assembly to adjust to a
second diameter smaller than the first effective expansion
diameter; and moving the adjustable expansion cone assembly through
the expandable tubular member when the adjustable expansion cone
assembly is adjusted to the third diameter, to thereby radially
expand and plastically deform the remaining portion of the
expandable tubular member.
40. The method of forming a mono diameter wellbore casing as in
claim 39 further comprising: supporting a second expandable tubular
member in the wellbore using a tubular support member and an
adjustable expansion cone assembly having a first diameter smaller
than the inside diameter of the expandable tubular member;
positioning the second expandable tubular member in the expanded
first expandable tubular member with the first portion thereof
overlapping the second expandable tubular member; injecting a
fluidic material into the tubular support member; sensing the
operating pressure of the injected fluidic material within a first
interior portion of the tubular support member; displacing the
adjustable expansion cone assembly relative to the second
expandable tubular member and into the wellbore when the sensed
operating pressure of the injected fluidic material exceeds a
predetermined level within the first interior portion of the
tubular support member; sensing the operating pressure of the
injected fluidic material within a second interior portion of the
tubular support member; adjusting the effective expansion diameter
of the adjustable expansion cone assembly to the second diameter
when the sensed operating pressure of the injected fluidic material
exceeds a predetermined level within the second interior portion of
the tubular support member; moving the adjustable expansion cone
assembly having the second diameter a predetermined distance into
the second expandable tubular member to radially expand and
plastically deform a first portion of the second expandable tubular
member below the first portion of the first expandable tubular
member; activating the effective expansion diameter of the
adjustable expansion cone assembly to adjust to the second
diameter; and moving the adjustable expansion cone assembly through
the second expandable tubular member and past the portion
overlapping with the first expandable tubular member when the
adjustable expansion cone assembly is adjusted to the third
diameter, and to thereby radially expand and plastically deform a
second portion of the second expandable tubular member to the same
diameter as the expanded remaining portion of the first expandable
tubular member.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is the National Stage patent
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provisional patent application Ser. No. 60/412,187, attorney docket
no. 25791.128, filed on Sep. 20, 2002, (46) U.S. provisional patent
application Ser. No. 60/412,187, attorney docket no. 25791.127,
filed on Sep. 20, 2002, (47) U.S. provisional patent application
Ser. No. 60/412,487, attorney docket no. 25791.112, filed on Sep.
20, 2002, and (48) U.S. provisional patent application Ser. No.
60/412,488, attorney docket no.25791.114, filed on Sep. 20, 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.
[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 procedures for forming and/or
repairing wellbore casings.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the present invention, an
expansion cone assembly having two diameters for forming a skirt or
bell section at which nested expandable tubular members overlap and
for forming a mono diameter section of an expandable wellbore
casing is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic fragmentary cross-sectional
illustration of an expandable tubular member and expansion cone
assembly running through a mono diameterwell bore casing formed
according to one aspect to the invention.
[0009] FIG. 2 is a schematic fragmentary cross-sectional
illustration of an expandable tubular member and expansion cone
assembly forming a bell portion of the mono diameter well bore
casing of FIG. 1 according to one aspect to the invention.
[0010] FIG. 3 is a schematic fragmentary cross-sectional
illustration of an expandable tubular member and expansion cone
assembly forming a mono diameter portion of the mono diameter
wellbore casing of FIGS. 1 and 2 according to another aspect to the
invention.
[0011] FIG. 4 is a schematic fragmentary cross-sectional
illustration of an expandable tubular member, a gripping mechanism
within the tubular member, an actuator, an expansion cone assembly
for forming a mono diameter casing and a float shoe supporting the
tubular member for running into a wellbore.
[0012] FIG. 5 is a schematic fragmentary cross-sectional
illustration of an expandable tubular member, a gripping mechanism
engaging the tubular member, an actuator and expansion cone
assembly for forming a mono diameter casing, with the tubular
member lifted off the bottom of the wellbore and with the expansion
cone assembly pushed by the actuator into an open wellbore.
[0013] FIG. 6 is a schematic fragmentary cross-sectional
illustration of the expansion cone assembly expanded for radially
expanding and plastically deforming the expandable tubular
member.
[0014] FIGS. 7a-7e 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.
[0015] FIGS. 8a-8e are fragmentary cross-sectional illustrations of
the apparatus of FIGS. 7a-7e after placement on the bottom of the
wellbore.
[0016] FIGS. 9a-9e are fragmentary cross-sectional illustrations of
the apparatus of FIGS. 8a-8e 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.
[0017] FIGS. 10a-10e are fragmentary cross-sectional illustrations
of the apparatus of FIGS. 9a-9e after the initiation of the radial
expansion and plastic deformation of the aluminum sleeve within the
shoe.
[0018] FIG. 11a-11b is a fragmentary cross-sectional illustration
of an exemplary embodiment of an apparatus for radially expanding
and plastically deforming a tubular member that includes an
adjustably expandable expansion cone assembly.
[0019] FIG. 12 is a fragmentary cross-sectional illustration of an
upper cone portion of the apparatus for radially expanding and
plastically deforming a tubular member of FIGS. 11a-11b.
[0020] FIG. 13 is a fragmentary cross-sectional illustration of a
lower cone portion of the apparatus for radially expanding and
plastically deforming a tubular member of FIGS. 11a-11b.
[0021] FIG. 14 is a fragmentary cross-sectional illustration of an
overlapping portion of the apparatus for radially expanding and
plastically deforming a tubular member of FIGS. 11a-11b, 12 and
13.
[0022] FIG. 15 is a fragmentary cross-sectional and perspective
illustrations of the upper cam assembly of the apparatus for
radially expanding and plastically deforming a tubular member of
FIGS. 11a-11b.
[0023] FIG. 16 is a fragmentary cross-sectional and perspective
illustrations of the lower cam assembly of the apparatus for
radially expanding and plastically deforming a tubular member of
FIGS. 11a-11b.
[0024] FIG. 17a-17b is a fragmentary cross-sectional illustration
of an exemplary embodiment of an apparatus for radially expanding
and plastically deforming a tubular member that includes an
adjustably expandable expansion cone assembly of FIGS. 11a-11b
activated for cementing.
[0025] FIG. 18a-18b is a fragmentary cross-sectional illustration
of an exemplary embodiment of an apparatus for radially expanding
and plastically deforming a tubular member that includes an
adjustably expandable expansion cone assembly of FIGS. 11a-11b
activated for adjusting the expansion diameter.
[0026] FIG. 19 is a fragmentary cross-sectional illustration of an
overlapping portion of the apparatus for radially expanding and
plastically deforming a tubular member adjusted to an intermediate
expansion diameter.
[0027] FIG. 20a-20b are fragmentary cross sectional illustrations
of the apparatus of FIGS. 10d-10e after the completion of the
radial expansion and plastic deformation of the aluminum sleeve
within the shoe.
[0028] FIGS. 21a-21b are fragmentary cross-sectional illustrations
of the apparatus of FIGS. 20a-20b after displacing the sliding
sleeve valve within the shoe to permit circulation around the ball
or dart.
[0029] FIGS. 22a-22b are fragmentary cross sectional illustrations
of the apparatus of FIGS. 21a-21b during the injection of cement
into the annulus between the radially expanding tubular member and
the wellbore using the bypass circulation provided by the displaced
sliding sleeve valve within the shoe.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0030] FIGS. 1-6 illustrate several illustrative embodiments of a
device and method for forming a mono diameter well bore casing
using an expansion assembly including two cone diameters, one of
which is larger than the other for forming a bell (sometimes called
a skirt) section for overlapping expandable tubular members so that
the effort required for the expansion assembly to expanded two
overlapping tubular members is reduced. The other cone diameter is
sized for expanding the tubular members to the desired diameter
along the length of the tubular member thereby resulting in a
mono-diameter well bore casing. The two diameters may be provided
with a conventional adjustable size expansion cone having two
expansion diameters, one larger than the other. The larger diameter
is adjusted to a smaller diameter after a bell section of an
expandable tubular member is formed and then the remainder of the
expandable tubular member is expanded to a the desired internal
diameter for the mono diameter wellbore casing. Conventional
adjustably expandable cones can be used according to the invention.
In several alternative embodiments, the invention is implemented as
described in FIGS. 7a-7e, 8a-8e, 9a-9e, 10a-10e, 11a-11b and
17a-17b, 18a-18b and 19a-19b with an exemplary adjustably
expandable cone assembly as described in greater detail herein with
reference to FIGS. 11a-11b, 12, 13, 14, 15 and 16. In other
alternative embodiments the adjustably expandable cones of the
invention may be implemented or using the methods and/or apparatus
disclosed one or more of 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. Pat. No. 6,328,113, (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. 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,
(34) U.S. provisional patent application Ser. No. 60/380,147,
attorney docket no. 25791.104, filed on May 6, 2002, (35) U.S.
provisional patent application Ser. No. 60/387,486, attorney docket
no. 25791.107, filed on Jun. 10, 2002, (36) U.S. provisional patent
application Ser. No. 60/387,961, attorney docket no. 25791.108,
filed on Jun. 12, 2002, (37) U.S. provisional patent application
Ser. No. 60/391,703, attorney docket no. 25791.90, filed on Jun.
26, 2002, (38) U.S. provisional patent application Ser. No.
60/397,284, attorney docket no. 25791.106, filed on Jul. 19, 2002,
(39) U.S. provisional patent application Ser. No. 60/398,061,
attorney docket no. 25791.110, filed on Jul. 24, 2002, (40) U.S.
provisional patent application Ser. No. 60/405,610, attorney docket
no. 25791.119, filed on Aug. 23, 2002, (41) U.S. provisional patent
application Ser. No. 60/405,394, attorney docket no. 25791.120,
filed on Aug. 23, 2002, (42) U.S. provisional patent application
Ser. No. 60/412,177, attorney docket no. 25791.117, filed on Sep.
20, 2002, (43) U.S. provisional patent application Ser. No.
60/412,653, No. 60/412,544, attorney docket no. 25791.121, filed on
Sep. 20, 2002, (45) U.S. provisional patent application Ser. No.
60/412,187, attorney docket no. 25791.128, filed on Sep. 20, 2002,
(46) U.S. provisional patent application Ser. No. 60/412,187,
attorney docket no. 25791.127, filed on Sep. 20, 2002, (47) U.S.
provisional patent application Ser. No. 60/412,487, attorney docket
no. 25791.112, filed on Sep. 20, 2002, and (48) U.S. provisional
patent application Ser. No. 60/412,488, attorney docket no.
25791.114, filed on Sep. 20, 2002, the disclosures of which are
incorporated herein by reference.
[0031] FIG. 1 shows a schematic illustration of an apparatus 10 in
a wellbore 12 with an expandable tubular member 14 and an expansion
cone assembly 16 supported by a tubular support 30 (such as a drill
pipe 30), all supported by a float shoe 32 for running into a
wellbore 12 through a plurality of casing sections 18a and 18b of a
mono diameter wellbore casing 18 in the process of being formed,
according to one aspect to the invention. The existing casing 18
sections 18a and 18b have been formed from expandable tubular
members 14 and according to the teachings of the present invention
include mono diameter portions 28a and 28b with a first inside
diameter ID1 and bell portions 22a and 22b having a second inside
diameter inside diameter ID2 and a length L. There is an
overlapping portion 26 where the bell portions 22a overlap of the
casing section 18b.
[0032] FIG. 2 shows a schematic illustration of the expandable
tubular member 14, acted upon by a large cone 20 of the expansion
cone assembly 16 to expand the diameter of the lower end of the
expandable tubular member 14 to form a bell portion 22. The bell
portion 22 is formed by the large cone 20 of the expansion cone
assembly 16 that has an adjustable cone diameter sufficiently large
so that the resulting expanded inside diameter of the bell portion
20 is at least slightly larger than a desired inside diameter of
the mono diameter wellbore casing 18. The length of the bell
portion 20 depends upon the desired length of overlapping lengths
26 between nested casing sections 18a, 18b, and 18c. For example,
it is contemplated applicants that the overlap length 26 and
therefore the bell portion 22 may have a length up to about 100
feet or up to about 150 feet.
[0033] FIG. 3 shows a schematic illustration of the expandable
tubular member 14 of FIG. 2, with the expansion cone assembly 16
positioned for expanding the expandable tubular member 14 to the
desired mono diameter at the portion 28 above the bell portion 22.
In this configuration the diameter of the large adjustable cone 20
is collapsed, or is other wise adjusted, to a smaller diameter.
Another cone 24, having a diameter smaller than the large diameter
of cone 20, is provided for radially expanding the tubular member
14 to the desired inside diameter of the mono diameter wellbore
casing. The wellbore casing section 18c of the mono diameter well
bore casing 18 of FIGS. 1 and 2, overlaps with the wellbore casing
section 18b along the overlapping length 26 and at the bell portion
22b. The inside diameter or the bell portion 22 and the outside
diameter of the mono diameter portion 28 are the same to provide a
tight fitting junction between the nested sections 18a, b, c and
etc. For example, where the expandable tubular member 14 has a wall
thickness of about 0.35 inches and for the desired inside diameter
of the mono diameter wellbore casing is about 10.3 inches, after
expansion, the inside diameter of the bell portion might be about
11.0 inches, or slightly less to provide a tight fit between the
overlapping portions of the casing sections 18a, b, c and etc.
[0034] The large diameter cone 20 can be positioned above, below or
effectively at the same position as the small diameter cone 24,
without departing from certain aspects of the invention. Also, it
will be understood by those of ordinary skill in the art, and based
upon this disclosure, that the large diameter corresponding to the
inside diameter of the bell portion can be provided by a first
collapsible or adjustable cone 22, that provides the desired bell
portion diameter and that can be collapsed to a smaller diameter,
together with a second cone 24 that provides the diameter for
forming the mono diameter well bore casing. It will also be
understood that in an alternative embodiment the expansion to the
mono diameter can be provided by adjusting the diameter of cone 22
to effectively become the smaller diameter cone 24 having a
diameter corresponding to the desired mono diameter. It will
further be understood that in another alternative embodiment the
cone 24 is a distinct cone 24 either fixed at the desired mono
diameter size or expandable to the desired mono diameter size.
[0035] FIG. 4 shows a schematic mono diameter casing forming
apparatus 10, further depicting one arrangement of a mechanism for
activating the expansion cone assembly 16 to expand the tubular
member 14. The apparatus 10 is shown in a configuration for running
into a wellbore 12. A drill pipe 30 supports the apparatus 10, as
it is running down into the wellbore 12, with a connected float
shoe 32. The drill pipe 30 may be a conventional drill pipe or
other conventional down hole tubular support member. The float shoe
may be a conventional float shoe or other tool guiding structure
that serves the describe purpose attached to the drill pipe or
other tubular support member. The float shoe 32 thus supports the
new expandable tubular member 14 that is to be added to and
expanded for engagement with the lower end of the mono diameter
wellbore casing 18 that has been previously formed. An gripping
tool 34, sometimes called an anchor that may be a device as shown
or a conventional gripping tool or anchor, is provided to hold the
expandable tubular member 14 fixed relative to one end of a
hydraulic actuator 36, sometimes called a force multiplier
mechanism that may be a device as shown or a conventional actuator
or force multiplier. The hydraulic actuator 36 is configured and
actuatable for moving the expansion cone assembly 16 relative to
the expandable member 14, either in tension using sub 36a or in
compression using sub 36b.
[0036] FIG. 5 schematically shows an embodiment of the mono
diameter casing forming apparatus 10, with the gripping mechanism
34 engaging the tubular member 14, with the tubular member 14
lifted off the bottom of the well bore 12 and with the expansion
cone 16 pushed by actuator 36 into the open wellbore 12. A
conventional dart 53 or ball is dropped to seal the float shoe 32,
or another conventional shut-off device such as a mechanical valve
or a velocity valve is used and activated, so that fluid 38 forced
through the drill pipe 22 increases pressure to activate the
gripping tool 26. When the drill pipe 22 is set down at the bottom
of the hole, the tension sub 36a of the actuator mechanism 36 is
actuated. Pressure is increased in the drill pipe 30 and the
gripping mechanism 34 is engaged to anchor the tubular member 14.
Compression sub 36b is activated to lift the tubular liner 14 off
the bottom of the wellbore and to push the cone assembly 16 into
the open hole of wellbore 12.
[0037] FIG. 6 shows the expansion cone assembly 16 expanded for
radially expanding and plastically deforming the expandable tubular
member 14. The expansion of the expansion cone assembly is
activated in a conventional manner, as with a dart 42 that is
passed with the fluid 38 down through the drill pipe 30 to thereby
cause appropriate port alignment and/or appropriate valve
activation for the expansion cone assembly 16. An optional
sacrificial protective sleeve 40 that protects the expansion cone
assembly 16 while it is running into the wellbore breaks off when
the expansion cone assembly is expanded. The protective sleeve 40
may be formed of a plastic or composite material so that the
sacrificial protective sleeve easily breaks off and does not
interfere with the expansion of the tubular member 14.
[0038] In an exemplary embodiment, as illustrated in FIGS. 7a-7e,
an apparatus 10 for forming a mono diameter wellbore casing 18 is
positioned within a wellbore 12. The apparatus 10 includes, among
other things, an expandable tubular member 14 and an adjustable
expansion cone assembly 16. During placement of the apparatus 10
within the wellbore 12, the expandable tubular member 14 may be
supported by the grip tool 34 and/or the expansion cone assembly 16
and/or the float shoe 32.
[0039] In an exemplary embodiment, as illustrated in FIGS. 8a-8e,
the apparatus 10 is then positioned into contact with the bottom 44
of the wellbore 12. As a result, a shear pin 46 is sheared and a
dog locking sleeve 48 is driven upwardly thereby displacing a
plurality of dogs 50 outwardly in the radial direction in a
conventional manner.
[0040] In an exemplary embodiment, as illustrated in FIGS. 9a- 9e,
a ball 52 or conventional dart may then be placed within the ball
or dart seat 54 of the apparatus by injecting fluidic material 38
into the apparatus 10. As a result, the flow of fluidic material 38
through the float shoe 32 is blocked. The expansion cone assembly
is also actuated in a conventional manner, for example with the
pressure caused by the ball 52 or a dart 42 (as shown in FIG. 6
above), to expand to the large diameter for expanding the bell.
Pressure builds and the actuator 36 is activated in tension to draw
the large cone 20 upward partially through the expandable tubular
member 14. Pressure can be released and reactivated in the actuator
36 and gripping tool 34 to repeatedly stroke the large cone 20 of
the expansion cone assembly 16 along the desired overlapping length
L of the casing to thereby form the bell portion 22 of the
casing.
[0041] In an exemplary embodiment, as illustrated in FIGS. 10a-10e,
the large diameter cone 20 is actuated to collapse or adjust to a
smaller diameter cone 24 corresponding to the desired diameter of
the mono diameter casing 18, using conventional actuation, for
example, increased fluidic pressure and a rupture disc in an
appropriate port (not shown) or an additional dart 56 injected with
the fluidic material 38 into the apparatus 10 to a conventional
dart seat 58. The gripping tool 34 is activated to lock the top end
of the hydraulic actuator 36 to the expandable tubular member 14.
The injected fluidic material 38 also causes the adjustable cone 24
to reach the desired diametrical size for forming the mono diameter
casing 18. The continued injection of the fluidic material 38
furthermore increases the operating pressure within the apparatus
thereby causing the hydraulic actuator 36 to pull the expansion
cone 24 into the expandable tubular member 14. As a result, the
expandable tubular member 14 is radially expanded.
[0042] The continued upward movement of the expansion cone pulls
the float shoe 32 to the bottom end of the radially expanded
tubular member 14. As a result, the end of the radially expanded
tubular member 14 will impact the dogs 50 thereby preventing the
float shoe 32 from moving further in the upward direction. The
continued upward movement of the expansion cone then will pull a
sleeve expander cone 60 for the sleeve 62 upwardly thereby radially
expanding a sleeve of the float shoe within the float shoe.
[0043] In one exemplary embodiment, as illustrated in FIGS.
11a-11b, 12, 13, 14, 15 and 16, the expansion cone assembly 16 is
adjustable for providing two outside diameters, one outside
diameter larger than the other outside diameter. The construction
of the expandable cone assembly may also be constructed in
accordance with the principles and design disclosed in U.S.
provisional patent application Ser. No. 60/387,961, attorney docket
no. 25791.108, filed on Jun. 12, 2002, the disclosure of which is
incorporated herein by reference. An exemplary embodiment includes
a tubular support member 64 coupled to an end of a safety collar 66
that defines a passage 66a and a recess 66b, at one end for
receiving the end of the tubular support member 14, and recesses
66c and 66d at another end.
[0044] A torque plate 68 is received within and is coupled to the
recess 66c of the safety collar 66 that defines a passage 68a and a
plurality of meshing teeth 68b at one end. An end of an upper
mandrel collar 70 is received with and is coupled to the recess 66d
of the safety collar 66 proximate an end of the torque plate 68
that defines a passage 68a. Torque pins 72a and 72b further couple
the end of the upper mandrel collar 70 to the end of the safety
collar 66.
[0045] An end of an upper mandrel 74 is received within and is
coupled to the upper mandrel collar 70 that defines a passage 74a,
a plurality of meshing teeth 74b that mate with and transmit torque
to and from the meshing teeth 68b of the torque plate 68, and an
external flange 74c at another end.
[0046] An upper packer cup 76 mates with, receives and is coupled
to the upper mandrel 74 proximate the end of the upper mandrel
collar 70. In an exemplary embodiment, the upper packer cup 76 is a
conventional Guiberson.TM. packer cup. An upper spacer sleeve 78
mates with, receives, and is coupled to the upper mandrel 74
proximate an end of the upper packer cup 76. A lower packer cup 80
mates with, receives and is coupled to the upper mandrel 74
proximate an end of the upper spacer sleeve 78. In an exemplary
embodiment, the lower packer cup 80 is a conventional Guiberson.TM.
packer cup. A lower spacer sleeve 82 mates with, receives, and is
coupled to the upper mandrel 74 proximate an end of the lower
packer cup 80 and the external flange 74c of the upper mandrel. A
retaining sleeve 84 mates with, receives, and is coupled to an end
of the lower spacer sleeve proximate the external flange 74c of the
upper mandrel 74.
[0047] An end of a lower mandrel 86 defines a recess 86a that mates
with, receives, and is coupled to the external flange 74c of the
upper mandrel 74, a recess 86b that mates with, receives, and is
coupled to the end of the upper mandrel, a passage 86c, and an
external flange 86d including circumferentially spaced apart
meshing teeth 86da on an end face of the external flange. Torque
pins 88a and 88b further couple the recess 86a of the end of the
lower mandrel 86 to the external flange 74c of the upper mandrel
74. During operation, the torque pins 88a and 88b transmit torque
loads between the recess 86a of the end of the lower mandrel 86 and
the external flange 74c of the upper mandrel 74.
[0048] An upper cam assembly 90 includes a tubular base 90a for
receiving and mating with the lower mandrel 86 that includes an
external flange 90aa, a plurality of circumferentially spaced apart
meshing teeth 90b that extend from one end of the tubular base in
the longitudinal and radial directions for engaging the meshing
teeth 86da of the end face of the external flange 86d of the lower
mandrel 86, and a plurality of circumferentially spaced apart cam
arms 90c that extend from the other end of the tubular base in the
opposite longitudinal direction and mate with and receive the lower
mandrel 86. During operation, the meshing teeth 86da of the end
face of the external flange 86d of the lower mandrel 86 transmit
torque loads to the meshing teeth 90b of the upper cam assembly 90.
Each of the cam arms 90c include an inner portion 90ca extending
from the tubular base 90a that has arcuate cylindrical inner 90caa
and outer 90cab surfaces, a tapered intermediate portion extending
from the inner portion 90cb that has an arcuate cylindrical inner
surface 90cba and an arcuate conical outer surface 90bbb, and an
outer portion 90cc extending from the intermediate portion 90cc
that has arcuate cylindrical inner 90cca and outer surfaces
90ccb.
[0049] A lower cam assembly 92 includes a tubular base 92a for
receiving and mating with the lower mandrel 86 that includes an
external flange 92aa, a plurality of circumferentially spaced apart
meshing teeth 92b that extend from one end of the tubular base in
the longitudinal and radial directions, and a plurality of
circumferentially spaced apart cam arms 92c that extend from the
other end of the tubular base in the opposite longitudinal
direction and mate with and receive the lower mandrel 86. Each of
the cam arms 92c include an inner portion 92ca extending from the
tubular base 92a that has arcuate cylindrical inner 92caa and outer
92cab surfaces, a tapered intermediate portion 92cb extending from
the inner portion 92ca that has an arcuate cylindrical inner
surface 92cba and an arcuate conical outer surface 92cbb, and an
outer portion 92cc extending from the intermediate portion 92cb
that has arcuate cylindrical inner 92cca and outer 92ccb
surfaces.
[0050] In an exemplary embodiment, the upper and lower cam
assemblies, 90 and 92, are substantially identical. In an exemplary
embodiment, the cam arms 90c of the upper cam assembly 90
interleave the cam arms 92c of the lower cam assembly 92.
Furthermore, in an exemplary embodiment, the cam arms 90c of the
upper cam assembly also overlap with the cam arms 92c of the lower
cam assembly 92 in the longitudinal direction thereby permitting
torque loads to be transmitted between the upper and lower cam
assemblies.
[0051] A plurality of upper expansion cone segments 96 are
interleaved among the cam arms 90c of the upper cam assembly 90.
Each of the upper expansion cone segments 96 include inner portions
96a having arcuate cylindrical inner surfaces 96aa, and an arcuate
cylindrical outer surface 96ab, intermediate portions 96b extending
from the interior portions that have an arcuate conical inner
surface 96ba and arcuate cylindrical and spherical outer surfaces,
96bb, and outer portions 96c having arcuate cylindrical inner and
outer surfaces, 96ca and 96cb. In an exemplary embodiment, the
outer surfaces 96ab of the inner portions 96a of the upper
expansion cone segments 96 define hinge grooves 96d that receive
and are pivotally mounted upon the internal flange 94d of the upper
retaining sleeve 94.
[0052] The arcuate inner cylindrical surfaces of the inner portion
96a mate with and receive the lower mandrel 86, the arcuate inner
cylindrical surfaces of the inner portion 96a also mate with and
receive the arcuate cylindrical outer surfaces of the outer
portions 92cc of the corresponding cam arms 92c of the lower cam
assembly 92, and the arcuate inner conical surfaces 96ba of the
inner portion 96a mate with and receive the arcuate conical outer
surfaces of the intermediate portions 92cb of the corresponding cam
arms 92c of the lower cam assembly 92.
[0053] A plurality of lower expansion cone segments 98 are
interleaved among, and overlap, the upper expansion cone segments
96 and the cam arms 90c of the lower cam assembly 90. In this
manner, torque loads may be transmitted between the upper and lower
expansion cone segments, 96 and 98. Each of the lower expansion
cone segments 98 include inner portions 98a having arcuate
cylindrical inner surfaces, 98aa, and an arcuate cylindrical outer
surface 98ab, intermediate portions 98b extending from the interior
portions that have an arcuate conical inner surface 98ba and
arcuate cylindrical and spherical outer surfaces, 98bb, and outer
portions 98c having arcuate cylindrical inner and outer surfaces,
98ca and 98cb. In an exemplary embodiment, the outer surfaces 98ab
of the inner portions 98a of the upper expansion cone segments 98
define hinge grooves 98aba that receive and are pivotally mounted
upon the internal flange 100d of a lower retaining sleeve 100.
[0054] The arcuate inner cylindrical surfaces 98aa mate with and
receive the lower mandrel 86, the arcuate inner cylindrical
surfaces 98aa also mate with and receive the arcuate cylindrical
outer surfaces of the outer portions 90cc of the corresponding cam
arms 90c of the upper cam assembly 90, and the arcuate inner
conical surfaces 98ba mate with and receive the arcuate conical
outer surfaces of the intermediate portions 90cb of the
corresponding cam arms 90c of the lower cam assembly 90.
[0055] In an exemplary embodiment, the geometries of the upper and
lower expansion cone segments 96 and 98 are substantially
identical. In an exemplary embodiment, the upper expansion cone
segments 96 are tapered in the longitudinal direction from the ends
of the intermediate portions 96b to the ends of the outer portions
96c, and the lower expansion cone segments 98 are tapered in the
longitudinal direction from the ends of the intermediate portions
98b to the ends of the outer portions 98c. In an exemplary
embodiment, when the upper and lower expansion segments, 96 and 98,
are positioned in a fully expanded position, the arcuate
cylindrical outer surfaces 96ab of the upper and lower expansion
cone segments 96 define a contiguous cylindrical surface, the
arcuate spherical outer surfaces of the upper and lower expansion
cone segments, 96bb and 98bb, define a contiguous arcuate spherical
surface, and the arcuate cylindrical outer surfaces of the upper
and lower expansion cone segments define a contiguous cylindrical
surface.
[0056] An end of a lower retaining sleeve 100 defines a passage
100a for receiving and mating with the outer circumferential
surfaces of the external flange 92aa and the meshing teeth 92b of
the lower cam assembly 92, and an inner annular recess 100b, and
includes an internal flange 100c for retaining the external flange
of the lower cam assembly, and an internal flange 100d at one end
of the lower retaining sleeve that includes a rounded interior end
face for mating with corresponding hinge grooves of the lower
expansion cone segments 98 thereby pivotally coupling the lower
expansion cone segments to the lower retaining sleeve.
[0057] In an exemplary embodiment, the arcuate cylindrical outer
surfaces of the upper expansion cone segments 96 and the arcuate
cylindrical outer surfaces of the lower expansion cone segments 98
are aligned with the outer surface of the upper retaining sleeve
94. In an exemplary embodiment, the arcuate cylindrical outer
surfaces of the upper expansion cone segments 96 and the arcuate
cylindrical outer surfaces of the lower expansion cone segments are
aligned with the outer surface of the lower retaining sleeve
100.
[0058] An end of a float shoe adaptor 102 that includes a plurality
of circumferentially spaced apart meshing teeth 102a for engaging
the meshing teeth 92b of the lower cam assembly 92 is received
within and threadably coupled to an end of the lower retaining
sleeve 100 that defines a passage 102b at one end for receiving an
end of the lower mandrel 86, a passage 102c having a reduced inside
diameter at another end, a plurality of radial passages 102d at the
other end, and includes an internal flange 102e, and a torsional
coupling 102f at the other end that includes a plurality of
torsional coupling members 102fa. During operation, the meshing
teeth 92b of the lower cam assembly 92 transmit toque loads to and
from the meshing teeth 102a of the float shoe adaptor.
[0059] An end of a retaining sleeve 104 abuts the end face of the
tubular base 92a of the lower cam assembly 92 and is received
within and mates with the passage 102b of the float shoe adaptor
102 that defines a passage 104a for receiving an end of the lower
mandrel 86, a throat passage 104b including a ball valve seat 104c,
and includes a flange 104d, and another end of the retaining
sleeve, having a reduced outside diameter, is received within and
mates with the passage 102c of the float shoe adaptor 102.
[0060] A stop nut 106 receives and is threadably coupled to the end
of the lower mandrel 86 within the passage 104a of the retaining
sleeve 104, and shear pins 108 releasably couple the stop nut 106
to the retaining sleeve 104. Locking dogs 110 are positioned within
an end of the retaining sleeve 104 that receive and are releasably
coupled to the lower mandrel 86, and a disc shaped adjustment shim
112 receives the lower mandrel 86 and is positioned within an end
of the retaining sleeve 104 between the opposing ends of the
tubular base 92a of the upper cam assembly 92 and the locking dogs
110. Burst discs 114 are releasably coupled to and positioned
within the radial passages 102d of the float shoe adaptor 102.
[0061] An end of a float shoe 116 mates with and is releasably
coupled to the torsional coupling 102f of the float shoe adaptor
102 that defines a passage 116a and a valveable passage 116b. In
this manner torsional loads may be transmitted between the float
shoe adaptor 102 and the float shoe 116. An end of an expandable
tubular member 14 that surrounds the tubular support member 64, the
safety collar 66, the upper mandrel collar 70, the upper packer cup
76, the lower packer cup 80, the lower mandrel 86, the upper
expansion cone segments 96, the lower expansion cone segments 98,
and the float shoe adaptor 102, is coupled to and receives an end
of the float shoe 116 and is movably coupled to and supported by
the arcuate spherical external surfaces, 96bb and 98bb, of the
upper and lower expansion cone segments, 96 and 98.
[0062] During operation, the apparatus 10 is at least partially
positioned within a preexisting structure such as, for example, a
borehole 12 that traverses a subterranean formation that may
include a preexisting wellbore casing 18. The borehole 12 may be
oriented in any position, for example, from vertical to horizontal.
A fluidic material 38 is then injected into the apparatus 10
through the passages 64a, 66a, 74a, 86c, 102c, 116a, and 116b into
the annulus between the expandable tubular member 14 and the
borehole 12. In an exemplary embodiment, the fluidic material 104
is a hardenable fluidic sealing material. In this manner, an
annular sealing layer may be formed within the annulus between the
expandable tubular member 14 and the borehole 12.
[0063] As illustrated in FIGS. 17a and 17b, a ball 55 is then be
positioned within and blocking the valveable passage 116b of the
float shoe 116 by injecting a fluidic material 38 into the
apparatus 10 through the passages 64a, 66a, 74a, 86c, and 102c. As
a result, the increased operating pressure within the passage 102c
bursts open the burst discs 114 positioned within the radial
passages 102d of the float shoe adaptor 102. The continued
injection of the fluidic material 38 thereby pressurizes the
interior of the expandable tubular member 14 below the lower packer
cup 80 thereby displacing the upper and lower expansion cone
segments, 96 and 98, upwardly relative to the float shoe 116 and
the expandable tubular member 14. As a result, the expandable
tubular member 14 is plastically deformed and radially expanded.
Thus, the burst discs 114 sense the operating pressure of the
injected fluidic material 38 within the passage 102c and thereby
control the initiation of the radial expansion and plastic
deformation of the expandable tubular member 14.
[0064] In an exemplary embodiment, any leakage of the pressurized
fluidic material 38 past the lower packer cup 80 is captured and
sealed against further leakage by the upper packer cup 76. In this
manner, the lower packer cup 80 provides the primary fluidic seal
against the interior surface of the expandable tubular member 14,
and the upper packer cup 76 provides a secondary, back-up, fluidic
seal against the interior surface of the expandable tubular member.
Furthermore, because the lower packer cup 80 and/or the upper
packer cup 76 provide a fluid tight seal against the interior
surface of the expandable tubular member 14, the upper and lower
expansion cone segments, 96 and 98, are pulled upwardly through the
expandable tubular member by the axial forces created by the packer
cups.
[0065] In an exemplary embodiment, during the radial expansion
process, the interface between the arcuate spherical external
surfaces, 96bb and 98bb, of the upper and lower expansion cone
segments, 96 and 98, and the interior surface of the expandable
tubular member 14 is not fluid tight. As a result, the fluidic
material 38 may provide lubrication to the entire extent of the
interface between the cylindrical external surfaces, 96bba and
98cb, and the arcuate spherical external surfaces, 96bb and 98bb,
of the upper and lower expansion cone segments, 96 and 98, and the
interior surface of the expandable tubular member 14. Moreover,
experimental test results have indicated the unexpected result that
the required operating pressure of the fluidic material 38 for
radial expansion of the expandable tubular member 14 is less when
the interface between the cylindrical external surfaces, 96bba and
98cb, and the arcuate spherical external surfaces, 96bb and 98bb,
of the upper and lower expansion cone segments, 96 and 98, and the
interior surface of the expandable tubular member 14 is not fluid
tight. Furthermore, experimental test results have also
demonstrated that the arcuate spherical external surface provided
by the arcuate spherical external surfaces, 96bb and 98bb, of the
upper and lower expansion cone segments, 96 and 98, provides radial
expansion and plastic deformation of the expandable tubular member
14 using lower operating pressures versus an expansion cone having
a conical outer surface.
[0066] In an exemplary embodiment, as illustrated in FIGS. 18a, 18b
and 19, the upper and lower expansion cone segments, 96 and 98, may
then be adjusted to a desired expansion diameter by placing a ball
57 within the ball valve seat 104c of the throat passage 104b of
the retaining sleeve 104. The continued injection of the fluidic
material 38, after the placement of the ball 57 within the ball
valve seat 104c, creates a differential pressure across the ball 57
thereby applying a downward longitudinal force onto the retaining
sleeve 104 thereby shearing the shear pins 108. As a result, the
retaining sleeve 104 is displaced in the downward longitudinal
direction relative to the float shoe adaptor 102 thereby permitting
the locking dogs 110 to be displaced outwardly in the radial
direction. The outward radial displacement of the locking dogs 110
disengages the locking dogs from engagement with the lower mandrel
86. Thus, the shear pins 108 sense the operating pressure of the
injected fluidic material 38 within the throat passage 104b and
thereby controlling the initiation of the collapsing of the upper
and lower expansion cone segments, 96 and 98 to a smaller
diameter.
[0067] The continued injection of the fluidic material 38 continues
to displace the retaining sleeve 104 in the downward longitudinal
direction relative to the float shoe adaptor 102 until the external
flange 104d of the retaining sleeve 104 impacts, and applies a
downward longitudinal force to, the internal flange 102e of the
float shoe adaptor. As a result, the float shoe adaptor 102 is then
also displaced in the downward longitudinal direction relative to
the lower mandrel 86. The downward longitudinal displacement of the
float shoe adaptor 102 relative to the lower mandrel 86 causes the
lower cam assembly 92, the lower expansion cone segments 98, and
the lower retaining sleeve 100, which are rigidly attached to the
float shoe adaptor, to also be displaced downwardly in the
longitudinal direction relative to the lower mandrel 86, the upper
cam assembly 90, and the upper expansion cone segments 96. The
downward longitudinal displacement of the lower cam assembly 92
relative to the upper expansion cone segments 96 causes the upper
expansion cone segments to slide down the conical external surfaces
92cbb of the lower cam assembly and thereby pivot inwardly in the
radial direction about the internal flange 94d of the upper
retaining sleeve 94. The downward longitudinal displacement of the
lower expansion cone segments 98 relative to the upper cam assembly
90 causes the lower expansion cone segments 98 to slide down the
external conical surfaces 90cbb of the upper cam assembly and
thereby pivot inwardly in the radial direction about the internal
flange 100d of the lower retaining sleeve. As a result of the
inward radial movement of the upper and lower expansion cone
segments, 96 and 98, the arcuate external spherical surfaces, 96bb
and 98bb, of the upper and lower expansion cone segments, 96 and
98, provide outer arcuate expansion surfaces having a smaller
diameter.
[0068] The downward longitudinal movement of the retaining sleeve
94 and float shoe adaptor 102 relative to the lower mandrel 86 is
stopped when the stop nut 106 impacts the locking dogs 110. At this
point, the apparatus 10 may then be removed from the interior of
the expandable tubular member 14.
[0069] Thus, the apparatus 10 may be removed from the expandable
tubular member 14 prior to the complete radial expansion and
plastic deformation of the expandable tubular member by
controllably collapsing the upper and lower expansion cone
segments, 96 and 98. As a result, the apparatus 10 provides the
following benefits: (1) the apparatus is removable when expansion
problems are encountered; (2) lower expansion forces are required
because the portion of the expandable tubular member 14 between the
packer cups, 76 and 80, and the expansion cone segments is exposed
to the expansion fluid pressure; (3) the expansion cone segments
can be run down through the expandable tubular member, prior to
radial expansion, and then the expansion cone segments can be
expanded; (4) the expansion cone segments can be expanded to one
diameter for forming a bell portion; and (5) the expansion cone
segments can be adjusted to a second diameter for expanding the
remainder of the expandable tubular member.
[0070] In another exemplary embodiment, as illustrated in FIGS.
20a-20b, upward movement of the apparatus 10 causes the expansion
cone for the sleeve 60 to completely radially expand the sleeve 62
of the float shoe 32 and a cementing probe 118 is pulled downward
until stopped from further movement by the cementing probe locking
ring 119. As a result of the complete radial expansion of the
sleeve, the float shoe is now firmly coupled to the end of the
radially expanded tubular member.
[0071] In an exemplary embodiment, as illustrated in FIGS. 21a-21b,
the drill pipe 30 is lowered into the wellbore 12 until the
cementing probe 118 stabs into the end 120 of the sliding sleeve
valve 122 thereby permitting fluidic materials 38 to bypass around
the dart or ball 52. As a result, a bypass flow path 124 is now
provided for cement or other fluidic materials 38 to flow around
the ball 52 or dart.
[0072] In an exemplary embodiment, as illustrated in FIGS. 22a
-22b, a hardenable fluidic sealing material 38 such as, for
example, cement, may then be injected into the apparatus 10. The
cement flows through the interior of the apparatus, through the
bypass flow path 124, and out through the float valve 126 into the
annulus 128 between the radially expanded tubular member 22 and the
wellbore 12. After the cement 38 has been injected into the annulus
128, the float valve 126 prevents the cement from flowing backwards
into the apparatus.
[0073] After completing the injection of the cement into the
annulus, the drilling pipe 30 is then pulled upwardly out of the
wellbore 12 thereby causing the cementing probe 118 to close the
sliding sleeve valve 122. The radial expansion and plastic
deformation of the expandable tubular member 14 may then be
continued by the resumed injection of fluidic material 38 into the
apparatus 10. In several alternative embodiments, the continued
radial expansion and plastic deformation of the expandable tubular
member 14 may be provided by pressurizing the interior of the
apparatus 10 below the expansion cone 24 and/or by displacing the
expansion cone 24 upwardly using the hydraulic actuator 36.
[0074] After the cement has cured, the float collar 32 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.
[0075] In several alternative embodiments, Guiberson.TM. cup seals
may be added above the expansion cone that provide a fluid tight
seal between the drill pipe and the interior surface of the
expandable tubular member. In this manner, in the alternative
embodiment, the fluid pressure below the cup seals pulls the
expansion cone upwardly through the expandable tubular member.
[0076] In several alternative embodiments, the expandable
adjustable expansion cone assembly having two adjustable expansion
diameters may be replaced with two separate adjustable cones one
adjustable to a diameter corresponding to the desired bell portion
diameter, and the other adjustable to a diameter corresponding to
the desired diameter of the mono diameter casing.
[0077] In several alternative embodiments, the expandable
adjustable expansion cone assembly having two adjustable expansion
diameters may be replaced with an adjustable cone that is
adjustable to a diameter corresponding to the desired bell portion
diameter, and a non-adjustable cone having a fixed diameter
corresponding to the desired diameter of the mono diameter
casing.
[0078] In several alternative embodiments, a conventional rotary
expansion device, a conventional compliant expansion device, and/or
a conventional hydroforming expansion device may used instead of,
or in combination with, the expansion cone assembly 16.
[0079] In several alternative embodiments, one or more of the
conventional commercially available expansion devices available
from Weatherford International, Baker Hughes, Halliburton Energy
Services, Schlumberger, and/or Enventure Global Technology may be
used instead of, or in combination with, the expansion cone
assembly 16.
[0080] There has been disclosed in the several embodiments, an
apparatus for radially expanding and plastically deforming an
expandable tubular member from an initial inside diameter to a
desired diameter of a mono diameter wellbore casing. The apparatus
includes an upper tubular support member defining a first passage,
one or more cup seals coupled to the exterior surface of the upper
tubular support member for sealing an interface between the upper
tubular support member and the expandable tubular member, an
expansion cone assembly coupled to the upper tubular support member
adjustable to one expansion diameter corresponding to the desired
diameter of the bell portion of the wellbore casing for forming an
expanded bell portion in the expandable tubular member and
adjustable to another expansion diameter corresponding to the
desired diameter of the mono diameter casing for forming the mono
diameter wellbore casing, means for actuating the expandable
tubular member to adjust from the one diameter to the other
diameter, and an actuator for moving the cone through the
expandable tubular member a desired distance with the expansion
cone assembly adjusted to the diameter of the bell portion and for
moving the expansion cone assembly through the expandable tubular
member for another distance with the expansion cone assembly
adjusted to the desired diameter of the mono diameter portion of
the expandable tubular member.
[0081] In one embodiment the expansion cone assembly includes one
adjustable cone having an external surface adjustable to the
diameter of the bell portion of the expandable tubular member; and
wherein the external surface of the one adjustable cone is also
adjustable to the diameter corresponding to the desired diameter of
the mono diameter wellbore casing.
[0082] In another embodiment the expansion cone assembly includes a
first adjustable cone having an external surface adjustable to the
diameter of the bell portion of the expandable tubular member and a
second adjustable cone having an external surface adjustable to the
diameter corresponding to the desired diameter of the mono diameter
wellbore casing.
[0083] In another embodiment the expansion cone assembly includes a
first adjustable cone having an external surface adjustable to the
diameter of the bell portion of the expandable tubular member and
collapsible after expanding the bell portion and a second cone
having a fixed diameter corresponding to the desired diameter of
the mono diameter wellbore casing such that collapsing the first
cone effectively adjusts the effective expansion diameter to the
fixed diameter of the second cone.
[0084] In another embodiment the expansion cone assembly includes
an upper cam assembly coupled to the upper tubular support member
includes a tubular base coupled to the upper tubular support
member; and a plurality of cam arms extending from the tubular base
in a downward longitudinal direction, each cam arm defining an
inclined surface, a plurality of upper expansion cone segments
interleaved with the cam arms of the upper cam assembly and
pivotally coupled to the tubular support member, and each upper
expansion segment movable relative to the inclined surface of one
of the plurality of cam arms to adjust the radial position of an
eternal surface of the segment to adjust the diameter of the
expansion cone assembly, a lower tubular support member defining a
second passage fluidicly coupled to the first passage releasably
coupled to the upper tubular support member, a lower cam assembly
coupled to the lower tubular support member including a tubular
base coupled to the lower tubular support member and a plurality of
cam arms extending from the tubular base in an upward longitudinal
direction, each cam arm defining an inclined surface that mates
with the inclined surface of a corresponding one of the upper
expansion cone segments, wherein the cams arms of the upper cam
assembly are interleaved with and overlap the cam arms of the lower
cam assembly; and a plurality of lower expansion cone segments
interleaved with cam arms of the lower cam assembly, each lower
expansion cone segment pivotally coupled to the lower tubular
support member and mating with the inclined surface of a
corresponding one of the cam arms of the upper cam assembly and
each lower expansion segment movable relative to the inclined
surface of one of the plurality of cam arms to adjust the radial
position of an eternal surface of the segment to adjust the
diameter of the expansion cone assembly, wherein the lower
expansion cone segments interleave and overlap the upper expansion
cone segments and wherein the upper and lower expansion cone
segments each approximate an arcuate spherical external surface for
plastically deforming and radially expanding the expandable tubular
member.
[0085] In another embodiment, an apparatus for radially expanding
and plastically deforming an expandable tubular member, is
disclosed including a tubular support member, a adjustable
expansion cone assembly coupled to the tubular support member, an
expandable tubular member coupled to the adjustable expansion cone
assembly, means for displacing the adjustable expansion cone
assembly relative to the expandable tubular member and means for
adjusting the adjustable expansion cone assembly from one effective
expansion diameter to another effective expansion diameter.
[0086] In another embodiment the tubular support member includes an
upper tubular support member comprising an internal flange and a
lower tubular support member comprising an internal flange, wherein
the expansion cone includes an upper cam assembly coupled to the
upper tubular support member including a tubular base coupled to
the upper support member and a plurality of cam arms extending from
the tubular base in a downward longitudinal direction, each cam arm
defining an inclined surface, a plurality of upper expansion cone
segments interleaved with the cam arms of the upper cam assembly
and pivotally coupled to the internal flange of the upper tubular
support member, a lower cam assembly coupled to the lower tubular
support member including a tubular base coupled to the lower
tubular support member and a plurality of cam arms extending from
the tubular base in an upward longitudinal direction, each cam arm
defining an inclined surface that mates with the inclined surface
of a corresponding one of the upper expansion cone segments,
wherein the cams arms of the upper cam assembly are interleaved
with and overlap the cam arms of the lower cam assembly and a
plurality of lower expansion cone segments interleaved with cam
arms of the lower cam assembly, each lower expansion cone segment
pivotally coupled to the internal flange of the lower tubular
support member and mating with the inclined surface of a
corresponding one of the cam arms of the upper cam assembly; and
wherein the apparatus further includes means for releasably
coupling the upper tubular support member to the lower tubular
support member and means for limiting movement of the upper tubular
support member relative to the lower tubular support member.
[0087] In one alternative embodiment the apparatus for radially
expanding and plastically deforming an expandable tubular member
further includes means for pivoting the upper expansion cone
segments and means for pivoting the lower expansion cone
segments.
[0088] In one alternative embodiment the apparatus for radially
expanding and plastically deforming an expandable tubular member
further includes means for pulling the adjustable expansion cone
assembly through the expandable tubular member.
[0089] A adjustable expansion cone assembly is disclosed, that
includes an upper cam assembly including a tubular base and a
plurality of cam arms extending from the tubular base in a downward
longitudinal direction, each cam arm defining an inclined surface,
a plurality of upper expansion cone segments interleaved with the
cam arms of the upper cam assembly, a lower cam assembly including
a tubular base and a plurality of cam arms extending from the
tubular base in an upward longitudinal direction, each cam arm
defining an inclined surface that mates with the inclined surface
of a corresponding one of the upper expansion cone segments,
wherein the cam arms of the upper cam assembly are interleaved with
and overlap the cam arms of the lower cam assembly, a plurality of
lower expansion cone segments interleaved with cam arms of the
lower cam assembly, each lower expansion cone segment mating with
the inclined surface of a corresponding one of the cam arms of the
upper cam assembly, means for moving the upper cam assembly toward
or away from the lower expansion cone segments to adjust the radial
position of an external surface of the lower expansion cone
segments, and means for moving the lower cam assembly toward or
away from the upper expansion cone segments to adjust the radial
position of an external surface of the upper expansion cone
segments.
[0090] In one embodiment of the adjustable expansion cone assembly,
the upper and lower expansion cone segments together approximate an
arcuate spherical external surface.
[0091] In one embodiment of the adjustable expansion cone assembly,
each upper expansion cone segment comprises an inner portion
defining an arcuate cylindrical upper surface and arcuate
cylindrical lower surfaces, an intermediate portion defining
arcuate cylindrical and spherical upper surfaces and an arcuate
conical lower surface and an outer portion defining arcuate
cylindrical upper and lower surfaces, and wherein each lower
expansion cone segment include an inner portion defining an arcuate
cylindrical upper surface and arcuate cylindrical lower surfaces,
an intermediate portion defining arcuate cylindrical and spherical
upper surfaces and an arcuate conical lower surface and an outer
portion defining arcuate cylindrical upper and lower surfaces.
[0092] In one embodiment of the adjustable expansion cone assembly,
each upper expansion cone segment is tapered in the longitudinal
direction from the intermediate portion to the outer portion and
each lower expansion cone segment is tapered in the longitudinal
direction from the intermediate portion to the outer portion.
[0093] An embodiment of an apparatus for radially expanding and
plastically deforming an expandable tubular member from an initial
inside diameter to a desired diameter of a mono diameter wellbore
casing is disclosed, including an upper tubular support member
defining a first passage, one or more cup seals coupled to the
exterior surface of the upper tubular support member for sealing an
interface between the upper tubular support member and the
expandable tubular member, an expansion assembly coupled to the
upper tubular support member adjustable to one expansion diameter
corresponding to the desired diameter of the bell portion of the
wellbore casing for forming an expanded bell portion in the
expandable tubular member and adjustable to another expansion
diameter corresponding to the desired diameter of the mono diameter
casing for forming the mono diameter wellbore casing, means for
actuating the expandable tubular member to adjust from the one
diameter to the other diameter and an actuator for moving the
expansion assembly through the expandable tubular member a desired
distance with the expansion assembly adjusted to the diameter of
the bell portion and for moving the expansion assembly through the
expandable tubular member for another distance with the expansion
assembly adjusted to the desired diameter of the mono diameter
portion of the expandable tubular member.
[0094] According to one alternative embodiment of an apparatus for
radially expanding and plastically deforming an expandable tubular
member from an initial inside diameter to a desired diameter of a
mono diameter wellbore casing, the expansion assembly includes an
expansion cone device.
[0095] According to another alternative embodiment of an apparatus
for radially expanding and plastically deforming an expandable
tubular member from an initial inside diameter to a desired
diameter of a mono diameter wellbore casing, the expansion assembly
comprises a rotary expansion device.
[0096] According to another alternative embodiment of an apparatus
for radially expanding and plastically deforming an expandable
tubular member from an initial inside diameter to a desired
diameter of a mono diameter wellbore casing, the expansion assembly
comprises compliant expansion device.
[0097] According to another alternative embodiment of an apparatus
for radially expanding and plastically deforming an expandable
tubular member from an initial inside diameter to a desired
diameter of a mono diameter wellbore casing, the expansion assembly
comprises a hydroforming expansion device.
[0098] According to another alternative embodiment of an apparatus
for radially expanding and plastically deforming an expandable
tubular member from an initial inside diameter to a desired
diameter of a mono diameter wellbore casing, the expansion assembly
comprises an adjustable expander device that is adjustable to the
diameter of the bell portion of the expandable tubular member and
wherein the one adjustable expander device is also adjustable to
the diameter corresponding to the desired diameter of the mono
diameter wellbore casing.
[0099] According to another alternative embodiment of an apparatus
for radially expanding and plastically deforming an expandable
tubular member from an initial inside diameter to a desired
diameter of a mono diameter wellbore casing, the expansion assembly
comprises an adjustable expander device that is adjustable to the
diameter of the bell portion of the expandable tubular member and
wherein the one adjustable expander device is also adjustable to
the diameter corresponding to the desired diameter of the mono
diameter wellbore casing and wherein the adjustable expander device
comprises an adjustable expansion cone device
[0100] According to another alternative embodiment of an apparatus
for radially expanding and plastically deforming an expandable
tubular member from an initial inside diameter to a desired
diameter of a mono diameter wellbore casing, the expansion assembly
comprises an adjustable expander device that is adjustable to the
diameter of the bell portion of the expandable tubular member and
wherein the one adjustable expander device is also adjustable, to
the diameter corresponding to the desired diameter of the mono
diameter wellbore casing and wherein the adjustable expander device
includes an adjustable rotary expansion device.
[0101] According to another alternative embodiment of an apparatus
for radially expanding and plastically deforming an expandable
tubular member from an initial inside diameter to a desired
diameter of a mono diameter wellbore casing, the expansion assembly
comprises an adjustable expander device that is adjustable to the
diameter of the bell portion of the expandable tubular member and
wherein the one adjustable expander device is also adjustable to
the diameter corresponding to the desired diameter of the mono
diameter wellbore casing and wherein the adjustable expander device
includes an adjustable compliant expansion device.
[0102] According to another alternative embodiment of an apparatus
for radially expanding and plastically deforming an expandable
tubular member from an initial inside diameter to a desired
diameter of a mono diameter wellbore casing, the expansion assembly
comprises an adjustable expander device that is adjustable to the
diameter of the bell portion of the expandable tubular member and
wherein the one adjustable expander device is also adjustable to
the diameter corresponding to the desired diameter of the mono
diameter wellbore casing and wherein the adjustable expander device
includes an adjustable hydroforming expansion device.
[0103] According to another alternative embodiment of an apparatus
for radially expanding and plastically deforming an expandable
tubular member from an initial inside diameter to a desired
diameter of a mono diameter wellbore casing, wherein the expansion
assembly includes a first adjustable expander device adjustable to
the diameter of the bell portion of the expandable tubular member
and second adjustable expander device adjustable to the diameter
corresponding to the desired diameter of the mono diameter wellbore
casing.
[0104] According to another alternative embodiment of an apparatus
for radially expanding and plastically deforming an expandable
tubular member from an initial inside diameter to a desired
diameter of a mono diameter wellbore casing, wherein the expansion
assembly includes a first adjustable expander device adjustable to
the diameter of the bell portion of the expandable tubular member
and collapsible after expanding the bell portion and a second
expander device having a fixed diameter corresponding to the
desired diameter of the mono diameter wellbore casing such that
collapsing the first adjustable expander device effectively adjusts
the effective expansion diameter to the fixed diameter of the
second expander device.
[0105] A method of forming a mono diameter casing in a wellbore is
disclosed, including supporting a first expandable tubular member
in the wellbore using a tubular support member and an adjustable
expansion assembly having a first diameter smaller than the inside
diameter of the expandable tubular member injecting a fluidic
material into the tubular support member, sensing the operating
pressure of the injected fluidic material within a first interior
portion of the tubular support member, displacing the adjustable
expansion assembly relative to the expandable tubular member and
into the wellbore when the sensed operating pressure of the
injected fluidic material exceeds a predetermined level within the
first interior portion of the tubular support member, sensing the
operating pressure of the injected fluidic material within a second
interior portion of the tubular support member, adjusting the
effective expansion diameter of the adjustable expansion assembly
to a second diameter larger than the inside diameter of the
expandable tubular member when the sensed operating pressure of the
injected fluidic material exceeds a predetermined level within the
second interior portion of the tubular support member, moving the
adjustable expansion assembly having the second diameter a
predetermined distance into the expandable tubular member to
radially expand and plastically deform a first portion of the
expandable tubular member, activating the effective expansion
diameter of the adjustable expansion assembly to adjust to a second
diameter smaller than the first effective expansion diameter and
moving the adjustable expansion assembly through the expandable
tubular member when the adjustable expansion assembly is adjusted
to the third diameter, to thereby radially expand and plastically
deform the remaining portion of the expandable tubular member.
[0106] In an alternative embodiment, the method of forming a mono
diameter wellbore casing as in the paragraph above that further
includes supporting a second expandable tubular member in the
wellbore using a tubular support member and an adjustable expansion
assembly having a first diameter smaller than the inside diameter
of the expandable tubular member, positioning the second expandable
tubular member in the expanded first expandable tubular member with
the first portion thereof overlapping the second expandable tubular
member, injecting a fluidic material into the tubular support
member, sensing the operating pressure of the injected fluidic
material within a first interior portion of the tubular support
member, displacing the adjustable expansion assembly relative to
the second expandable tubular member and into the wellbore when the
sensed operating pressure of the injected fluidic material exceeds
a predetermined level within the first interior portion of the
tubular support member, sensing the operating pressure of the
injected fluidic material within a second interior portion of the
tubular support member, adjusting the effective expansion diameter
of the adjustable expansion assembly to the second diameter when
the sensed operating pressure of the injected fluidic material
exceeds a predetermined level within the second interior portion of
the tubular support member, moving the adjustable expansion
assembly having the second diameter a predetermined distance into
the second expandable tubular member to radially expand and
plastically deform a first portion of the second expandable tubular
member below the first portion of the first expandable tubular
member, activating the effective expansion diameter of the
adjustable expansion assembly to adjust to the second diameter and
moving the adjustable expansion assembly through the second
expandable tubular member and past the portion overlapping with the
first expandable tubular member when the adjustable expansion
assembly is adjusted to the third diameter, and to thereby radially
expand and plastically deform a second portion of the second
expandable tubular member to the same diameter as the expanded
remaining portion of the first expandable tubular member.
[0107] In an alternative embodiment the method includes expanding
the expandable tubular member using an adjustable expansion cone
device
[0108] In an alternative embodiment the method includes expanding
the expandable tubular member using an adjustable a rotary
expansion device.
[0109] In an alternative embodiment the method includes expanding
the expandable tubular member using an adjustable compliant
expansion device.
[0110] In an alternative embodiment the method includes expanding
the expandable tubular member using an adjustable hydroforming
expansion device.
[0111] In an alternative embodiment a method of a casing in a
wellbore, includes inserting an expandable tubular member into the
wellbore, radially expanding and plastically deforming a lower
portion of the expandable tubular member to a first inside
diameter; and radially expanding and plastically deforming an upper
portion of the expandable tubular member to a second inside
diameter, wherein the first inside diameter is larger than the
second inside diameter.
[0112] In an alternative embodiment the method of forming a casing
in a wellbore, as described in the preceding paragraph, further
includes inserting a second expandable tubular member into the
expanded expandable tubular member so that a top portion of the
second expandable tubular member is overlapped by the expanded
lower portion of the expanded expandable tubular member and
expanding the top portion of the second expandable tubular member
to the second diameter of so that the top portion of the second
expandable tubular member is expanded radially outward in the lower
portion of the expanded expandable tubular member.
[0113] In an alternative embodiment of the method of forming a
casing in a wellbore, expanding the lower and upper portions of the
expandable tubular members includes expanding using an expansion
cone device.
[0114] In an alternative embodiment of the method of forming a
casing in a wellbore, expanding the lower and upper portions of the
expandable tubular members includes expanding using a rotary
expansion device.
[0115] In an alternative embodiment of the method of forming a
casing in a wellbore, expanding the lower and upper portions of the
expandable tubular members includes expanding using a compliant
expansion device.
[0116] In an alternative embodiment of the method of forming a
casing in a wellbore, expanding the lower and upper portions of the
expandable tubular members includes expanding using a hydroforming
expansion device.
[0117] An alternative embodiment of the method of forming a mono
diameter casing in a wellbore includes supporting a first
expandable tubular member in the wellbore using a tubular support
member and an adjustable expansion cone assembly having a first
diameter smaller than the inside diameter of the expandable tubular
member, injecting a fluidic material into the tubular support
member, sensing the operating pressure of the injected fluidic
material within a first interior portion of the tubular support
member, displacing the adjustable expansion cone assembly relative
to the expandable tubular member and into the wellbore when the
sensed operating pressure of the injected fluidic material exceeds
a predetermined level within the first interior portion of the
tubular support member, sensing the operating pressure of the
injected fluidic material within a second interior portion of the
tubular support member, adjusting the effective expansion diameter
of the adjustable expansion cone assembly to a second diameter
larger than the inside diameter of the expandable tubular member
when the sensed operating pressure of the injected fluidic material
exceeds a predetermined level within the second interior portion of
the tubular support member, moving the adjustable expansion cone
assembly having the second diameter a predetermined distance into
the expandable tubular member to radially expand and plastically
deform a first portion of the expandable tubular member, activating
the effective expansion diameter of the adjustable expansion cone
assembly to adjust to a second diameter smaller than the first
effective expansion diameter and moving the adjustable expansion
cone assembly through the expandable tubular member when the
adjustable expansion cone assembly is adjusted to the third
diameter, to thereby radially expand and plastically deform the
remaining portion of the expandable tubular member.
[0118] In an alternative embodiment of the method of forming a mono
diameter casing in a wellbore, as described in the preceding
paragraph, further includes supporting a second expandable tubular
member in the wellbore using a tubular support member and an
adjustable expansion cone assembly having a first diameter smaller
than the inside diameter of the expandable tubular member,
positioning the second expandable tubular member in the expanded
first expandable tubular member with the first portion thereof
overlapping the second expandable tubular member, injecting a
fluidic material into the tubular support member, sensing the
operating pressure of the injected fluidic material within a first
interior portion of the tubular support member, displacing the
adjustable expansion cone assembly relative to the second
expandable tubular member and into the wellbore when the sensed
operating pressure of the injected fluidic material exceeds a
predetermined level within the first interior portion of the
tubular support member, sensing the operating pressure of the
injected fluidic material within a second interior portion of the
tubular support member, adjusting the effective expansion diameter
of the adjustable expansion cone assembly to the second diameter
when the sensed operating pressure of the injected fluidic material
exceeds a predetermined level within the second interior portion of
the tubular support member, moving the adjustable expansion cone
assembly having the second diameter a predetermined distance into
the second expandable tubular member to radially expand and
plastically deform a first portion of the second expandable tubular
member below the first portion of the first expandable tubular
member, activating the effective expansion diameter of the
adjustable expansion cone assembly to adjust to the second diameter
and moving the adjustable expansion cone assembly through the
second expandable tubular member and past the portion overlapping
with the first expandable tubular member when the adjustable
expansion cone assembly is adjusted to the third diameter, and to
thereby radially expand and plastically deform a second portion of
the second expandable tubular member to the same diameter as the
expanded remaining portion of the first expandable tubular
member.
[0119] 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.
[0120] 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.
* * * * *