U.S. patent application number 10/551880 was filed with the patent office on 2006-11-02 for apparatus for radially expanding and plastically deforming a tubular member.
Invention is credited to David Paul Brisco, Harold Treece, Brock Wayne Watson.
Application Number | 20060243444 10/551880 |
Document ID | / |
Family ID | 33159687 |
Filed Date | 2006-11-02 |
United States Patent
Application |
20060243444 |
Kind Code |
A1 |
Brisco; David Paul ; et
al. |
November 2, 2006 |
apparatus for radially expanding and plastically deforming a
tubular member
Abstract
An apparatus for radially expanding and plastically deforming a
tubular member.
Inventors: |
Brisco; David Paul; (Duncan,
OK) ; Watson; Brock Wayne; (Carrollton, TX) ;
Treece; Harold; (Duncan, OK) |
Correspondence
Address: |
HAYNES AND BOONE, LLP
901 MAIN STREET, SUITE 3100
DALLAS
TX
75202
US
|
Family ID: |
33159687 |
Appl. No.: |
10/551880 |
Filed: |
April 2, 2004 |
PCT Filed: |
April 2, 2004 |
PCT NO: |
PCT/US04/10317 |
371 Date: |
September 30, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60459776 |
Apr 2, 2003 |
|
|
|
Current U.S.
Class: |
166/298 ;
166/207; 166/380; 166/55 |
Current CPC
Class: |
E21B 21/10 20130101;
E21B 23/06 20130101; E21B 33/129 20130101; E21B 33/14 20130101;
E21B 33/128 20130101; E21B 43/103 20130101; E21B 34/14 20130101;
E21B 29/005 20130101; E21B 33/1291 20130101; E21B 43/105
20130101 |
Class at
Publication: |
166/298 ;
166/380; 166/055; 166/207 |
International
Class: |
E21B 23/02 20060101
E21B023/02; E21B 43/11 20060101 E21B043/11 |
Claims
1. An apparatus for cutting a tubular member, comprising: a support
member; a plurality of movable cutting elements coupled to the
support member: an actuator coupled to the support member for
moving the cutting elements between a first position and a second
position; and a sensor coupled to the support member for sensing
the internal diameter of the tubular member; wherein in the first
position, the cutting elements do not engage the tubular member;
wherein in the second position, the cutting elements engage the
tubular member; wherein the sensor prevents the cutting elements
from being moved to the second position if the internal diameter of
the tubular member is less than a predetermined value.
2. The apparatus of claim 1, wherein the cutting elements comprise:
a first set of cutting elements; a second set of cutting elements;
and wherein the first set of cutting elements are interleaved with
the second set of cutting elements.
3. The apparatus of claim 2, wherein the first position, the first
set of cutting elements are not axially aligned with the second set
of cutting elements.
4. The apparatus of claim 2, wherein in the second position, the
first set of cutting elements are axially aligned with the second
set of cutting elements.
5. An apparatus of claim 3, for gripping a tubular member,
comprising: a plurality of movable gripping elements; wherein the
gripping elements are moveable from a first position to a second
position; wherein in the first position, the gripping elements do
not engage the tubular member; wherein in the second position, the
gripping elements do engage the tubular member; and wherein, during
the movement from the first position to the second position, the
gripping elements move in a radial and an axial direction.
6. The apparatus of claim 5, wherein, in a first axial direction,
the gripping device grips the tubular member; and wherein, in a
second axial direction, the gripping device does not grip the
tubular member.
7. The apparatus of claim 5, further comprising an actuator for
moving the gripping elements.
8. The apparatus of claim 5, a plurality of separate and distinct
gripping elements.
9. A method of radially expanding and plastically deforming a
tubular member, comprising: positioning the tubular member within a
preexisting structure; radially expanding and plastically deforming
a lower portion of the tubular member to form a bell section; and
radially expanding and plastically deforming a portion of the
tubular member above the bell section.
10. The method of claim 9 wherein positioning the tubular member
within a preexisting structure comprises: locking the tubular
member to an expansion device.
11. The method of claim 10, wherein the outside diameter of the
expansion device is less than the inside diameter of the tubular
member.
12. The method of claim 10, wherein the expansion device is
positioned within the tubular member.
13. The method of claim 10, wherein the expansion device comprises
an adjustable expansion device.
14. The method of claim 13, wherein the adjustable expansion device
is adjustable to a plurality of sizes.
15. The method of claim 10, wherein the expansion device comprises
a plurality of expansion devices.
16. The method of claim 15, wherein at least one of the expansion
devices comprises an adjustable expansion device.
17. The method of claim 16, wherein at least one of the adjustable
expansion device is adjustable to a plurality of sizes.
18. The method of claim 9 wherein radially expanding and
plastically deforming a lower portion of the tubular member to form
a bell section comprises: lowering an expansion device out of an
end of the tubular member: and pulling the expansion device through
the end of the tubular member.
19. The method of claim 18, wherein lowering an expansion device
out of an end of the tubular member comprises: lowering the
expansion device out of the end of the tubular member; and
adjusting the size of the expansion device.
20. The method of 19, wherein the adjustable expansion device is
adjustable to a plurality of sizes.
21. The method of claim 19, wherein the expansion device comprises
a plurality of adjustable expansion devices.
22. The method claim 21, wherein at least one of the adjustable
expansion devices is adjustable to a plurality of sizes.
23. The method of claim 18, wherein pulling the expansion device
through the end of the tubular member comprises: gripping the
tubular member; and pulling an expansion device through an end of
the tubular member.
24. The method of claim 24, wherein gripping the tubular member
comprises: permitting axial displacement of the tubular member in a
first direction; and not permitting axial displacement of the
tubular member in a second direction.
25. The method of claim 25, wherein pulling the expansion device
through the end of the tubular member comprises: pulling the
expansion device through the end of the tubular member using an
actuator.
26. The method of claim 9 wherein radially expanding and
plastically deforming a portion of the tubular member above the
bell section comprises: lowering an expansion device out of an end
of the tubular member; and pulling the expansion device through the
end of the tubular member.
27. The method of claim 26, wherein lowering an expansion device
out of an end of the tubular member comprises: lowering the
expansion device out of the end of the tubular member; and
adjusting the size of the expansion device.
28. The method of claim 27, wherein the adjustable expansion device
is adjustable to a plurality of sizes.
29. The method of claim 27, wherein the expansion device comprises
a plurality of adjustable expansion devices.
30. The method of claim 29, wherein at least one of the adjustable
expansion devices is adjustable to a plurality of sizes.
31. The method of claim 26, wherein pulling the expansion device
through the end of the tubular member comprises: gripping the
tubular member: and pulling an expansion device through an end of
the tubular member.
32. The method of claim 31, wherein gripping the tubular member
comprises: permitting axial displacement of the tubular member in a
first direction; and not permitting axial displacement of the
tubular member in a second direction.
33. The method of claim 31, wherein pulling the expansion device
through the end of the tubular member comprises: pulling the
expansion device through the end of the tubular member using an
actuator.
34. The method of claim 26, wherein pulling the expansion device
through the end of the tubular member comprises: pulling the
expansion device through the end of the tubular member using fluid
pressure.
35. The method of claim 34, wherein pulling the expansion device
through the end of the tubular member using fluid pressure
comprises: pressurizing an annulus within the tubular member above
the expansion device.
36. The method of claim 9 wherein radially expanding and
plastically deforming a portion of the tubular member above the
bell section comprises: fluidicly sealing an end of the tubular
member; and pulling the expansion device through the tubular
member.
37. The method of claim 36, wherein the expansion device is
adjustable.
38. The method of claim 37, wherein the expansion device is
adjustable to a plurality of sizes.
39. The method of claim 36, wherein the expansion device comprises
a plurality of adjustable expansion devices.
40. The method of claim 39, wherein at least one of the adjustable
expansion devices is adjustable to a plurality of sizes.
41. The method of claim 36, wherein pulling the expansion device
through the end of the tubular member comprises: gripping the
tubular member: and pulling an expansion device through an end of
the tubular member.
42. The method of claim 41, wherein gripping the tubular member
comprises: permitting axial displacement of the tubular member in a
first direction; and not permitting axial displacement of the
tubular member in a second direction.
43. The method of claim 41, wherein pulling the expansion device
through the end of the tubular member comprises: pulling the
expansion device through the end of the tubular member using an
actuator.
44. The method of claim 36, wherein pulling the expansion device
through the end of the tubular member comprises: pulling the
expansion device through the end of the tubular member using fluid
pressure.
45. The method of claim 44, wherein pulling the expansion device
through the end of the tubular member using fluid pressure
comprises: pressurizing an annulus within the tubular member above
the expansion device.
46. The method of claim 9 wherein radially expanding and
plastically deforming a portion of the tubular member above the
bell section comprises: overlapping the portion of the tubular
member above the bell section with an end of a preexisting tubular
member: and pulling an expansion device through the overlapping
portions of the tubular member and the preexisting tubular
member.
47. The method of claim 46 wherein the expansion device is
adjustable.
48. The method of claim 47 wherein the expansion device is
adjustable to a plurality of sizes.
49. The method of claim 46 wherein expansion device comprises a
plurality of adjustable expansion devices.
50. The method of claim 49, wherein at least one of the adjustable
expansion devices is adjustable to a plurality of sizes.
51. The method of claim 46 wherein pulling the expansion device
through the overlapping portions of the tubular member and the
preexisting tubular member comprises: gripping the tubular member;
and pulling the expansion device through the overlapping portions
of the tubular member and the preexisting tubular member.
52. The method of claim 51, wherein gripping the tubular member
comprises: permitting axial displacement of the tubular member in a
first direction; and not permitting axial displacement of the
tubular member in a second direction.
53. The method of claim 51, wherein pulling the expansion device
through the overlapping portions of the tubular member and the
preexisting tubular member comprises: pulling the expansion device
through the overlapping portions of the tubular member and the
preexisting tubular member using an actuator.
54. The method of claim 46 wherein pulling the expansion device
through the overlapping portions of the tubular member and the
preexisting tubular member comprises: pulling the expansion device
through the overlapping portions of the tubular member and the
preexisting tubular member using fluid pressure.
55. The method of claim 54, wherein pulling the expansion device
through the overlapping portions of the tubular member and the
preexisting tubular member using fluid pressure comprises:
pressurizing an annulus within the tubular member above the
expansion device.
56. The method of claim 46 further comprising: cutting an end of
the portion of the tubular member that overlaps with the
preexisting tubular member.
57. The method of claim 56, further comprising: removing the cut
off end of the expandable tubular member from the preexisting
structure.
58. The method of claim 9 further comprising: injecting a
hardenable fluidic sealing material into an annulus between the
expandable tubular member and the preexisting structure.
59. The method of claim 9, further comprising: cutting off an end
of the expandable tubular member coupled to the support member.
60. The method of claim 59, further comprising: removing the cut
off end of the expandable tubular member from the preexisting
structure.
61. A method of cutting a tubular member, comprising: positioning a
plurality of cutting elements within the tubular member; and
bringing the cutting elements into engagement with the tubular
member.
62. The method of claim 61, wherein the cutting elements comprise:
a first group of cutting elements; and a second group of cutting
elements; wherein the first group of cutting elements are
interleaved with the second group of cutting elements.
63. The method of claim 61, wherein bringing the cutting elements
into engagement with the tubular member comprises: bringing the
cutting elements into axial alignment.
64. The method of claim 63, wherein bringing the cutting elements
into engagement with the tubular member further comprises: pivoting
the cutting elements.
65. The method of claim 63, wherein bringing the cutting elements
into engagement with the tubular member further comprises:
translating the cutting elements.
66. The method of claim 63, wherein bringing the cutting elements
into engagement with the tubular member further comprises: pivoting
the cutting elements; and translating the cutting elements.
67. The method of claim 61, wherein bringing the cutting elements
into engagement with the tubular member comprises: rotating the
cutting elements about a common axis.
68. The method of claim 61, wherein bringing the cutting elements
into engagement with the tubular member comprises: pivoting the
cutting elements about corresponding axes; translating the cutting
elements: and rotating the cutting elements about a common
axis.
69. The method of claim 61, further comprising: preventing the
cutting elements from coming into engagement with the tubular
member if the inside diameter of the tubular member is less than a
predetermined value.
70. The method of claim 69, wherein preventing the cutting elements
from coming into engagement with the tubular member if the inside
diameter of the tubular member is less than a predetermined value
comprises: sensing the inside diameter of the tubular member.
71. A method of gripping a tubular member, comprising: positioning
a plurality of gripping elements within the tubular member; and
bringing the gripping elements into engagement with the tubular
member.
72. The method of claim 71, wherein bringing the gripping elements
into engagement with the tubular member comprises: displacing the
gripping elements in an axial direction: and displacing the
gripping elements in a radial direction.
73. The method of claim 71, further comprising: biasing the
gripping elements against engagement with the tubular member.
74. An apparatus for radially expanding and plastically deforming
an expandable tubular member, comprising: a support member; a
cutting device for cutting the tubular member coupled to the
support member; a gripping device for gripping the tubular member
coupled to the support member; a sealing device for sealing an
interface with the tubular member coupled to the support member; a
locking device for locking the position of the tubular member
relative to the support member; a first adjustable expansion device
for radially expanding and plastically deforming the tubular member
coupled to the support member; a second adjustable expansion device
for radially expanding and plastically deforming the tubular member
coupled to the support member; a packer coupled to the support
member; and an actuator for displacing one or more of the sealing
assembly, first and second adjustable expansion devices, and packer
relative to the support member.
75. An actuator, comprising: a tubular housing; a tubular piston
rod movably coupled to and at least partially positioned within the
housing; a plurality of annular piston chambers defined by the
tubular housing and the tubular piston rod; and a plurality of
tubular pistons coupled to the tubular piston rod, each tubular
piston movably positioned within a corresponding annular piston
chamber.
76. An apparatus for controlling a packer, comprising: a tubular
support member; one or more drag blocks releasably coupled to the
tubular support member; and a tubular stinger coupled to the
tubular support member for engaging the packer.
77. A packer comprising: a support member defining a passage; a
shoe comprising a float valve coupled to an end of the support
member; one or more compressible packer elements movably coupled to
the support member; and a sliding sleeve valve movably positioned
within the passage of the support member.
78. A method of radially expanding and plastically deforming an
expandable tubular member within a borehole having a preexisting
wellbore casing, comprising: positioning the tubular member within
the borehole in overlapping relation to the wellbore casing;
radially expanding and plastically deforming a portion of the
tubular member to form a bell section; and radially expanding and
plastically deforming a portion of the tubular member above the
bell section comprising a portion of the tubular member that
overlaps with the wellbore casing; wherein the inside diameter of
the bell section is greater than the inside diameter of the
radially expanded and plastically deformed portion of the tubular
member above the bell section.
79. A method for forming a mono diameter wellbore casing,
comprising: positioning an adjustable expansion device within a
first expandable tubular member; supporting the first expandable
tubular member and the adjustable expansion device within a
borehole; lowering the adjustable expansion device out of the first
expandable tubular member; increasing the outside dimension of the
adjustable expansion device; displacing the adjustable expansion
device upwardly relative to the first expandable tubular member m
times to radially expand and plastically deform m portions of the
first expandable tubular member within the borehole; positioning
the adjustable expansion device within a second expandable tubular
member; supporting the second expandable tubular member and the
adjustable expansion device within the borehole in overlapping
relation to the first expandable tubular member; lowering the
adjustable expansion device out of the second expandable tubular
member; increasing the outside dimension of the adjustable
expansion device; and displacing the adjustable expansion device
upwardly relative to the second expandable tubular member n times
to radially expand and plastically deform n portions of the second
expandable tubular member within the borehole.
80. A method for radially expanding and plastically deforming an
expandable tubular member within a borehole, comprising:
positioning an adjustable expansion device within the expandable
tubular member; supporting the expandable tubular member and the
adjustable expansion device within the borehole; lowering the
adjustable expansion device out of the expandable tubular member;
increasing the outside dimension of the adjustable expansion
device; displacing the adjustable expansion mandrel upwardly
relative to the expandable tubular member n times to radially
expand and plastically deform n portions of the expandable tubular
member within the borehole; and pressurizing an interior region of
the expandable tubular member above the adjustable expansion device
during the radial expansion and plastic deformation of the
expandable tubular member within the borehole.
81. A method for forming a mono diameter wellbore casing,
comprising: positioning an adjustable expansion device within a
first expandable tubular member; supporting the first expandable
tubular member and the adjustable expansion device within a
borehole; lowering the adjustable expansion device out of the first
expandable tubular member; increasing the outside dimension of the
adjustable expansion device; displacing the adjustable expansion
device upwardly relative to the first expandable tubular member m
times to radially expand and plastically deform m portions of the
first expandable tubular member within the borehole; pressurizing
an interior region of the first expandable tubular member above the
adjustable expansion device during the radial expansion and plastic
deformation of the first expandable tubular member within the
borehole; positioning the adjustable expansion mandrel within a
second expandable tubular member; supporting the second expandable
tubular member and the adjustable expansion mandrel within the
borehole in overlapping relation to the first expandable tubular
member; lowering the adjustable expansion mandrel out of the second
expandable tubular member; increasing the outside dimension of the
adjustable expansion mandrel; displacing the adjustable expansion
mandrel upwardly relative to the second expandable tubular member n
times to radially expand and plastically deform n portions of the
second expandable tubular member within the borehole; and
pressurizing an interior region of the second expandable tubular
member above the adjustable expansion mandrel during the radial
expansion and plastic deformation of the second expandable tubular
member within the borehole.
82. A method for radially expanding and plastically deforming an
expandable tubular member within a borehole, comprising: supporting
the expandable tubular member, an hydraulic actuator, and an
adjustable expansion device within the borehole; increasing the
size of the adjustable expansion device; and displacing the
adjustable expansion device upwardly relative to the expandable
tubular member using the hydraulic actuator to radially expand and
plastically deform a portion of the expandable tubular member.
83. A method for forming a mono diameter wellbore casing within a
borehole that includes a preexisting wellbore casing, comprising:
supporting the expandable tubular member, an hydraulic actuator,
and an adjustable expansion device within the borehole; increasing
the size of the adjustable expansion device; displacing the
adjustable expansion device upwardly relative to the expandable
tubular member using the hydraulic actuator to radially expand and
plastically deform a portion of the expandable tubular member; and
displacing the adjustable expansion device upwardly relative to the
expandable tubular member to radially expand and plastically deform
the remaining portion of the expandable tubular member and a
portion of the preexisting wellbore casing that overlaps with an
end of the remaining portion of the expandable tubular member.
84. A method of radially expanding and plastically deforming a
tubular member, comprising: applying internal pressure
simultaneously to the inside surface of the tubular member at a
plurality of discrete locations separated from one another.
85. A system for radially expanding and plastically deforming an
expandable tubular member within a borehole having a preexisting
wellbore casing, comprising: means for positioning the tubular
member within the borehole in overlapping relation to the wellbore
casing; means for radially expanding and plastically deforming a
portion of the tubular member to form a bell section; and means for
radially expanding and plastically deforming a portion of the
tubular member above the bell section comprising a portion of the
tubular member that overlaps with the wellbore casing; wherein the
inside diameter of the bell section is greater than the inside
diameter of the radially expanded and plastically deformed portion
of the tubular member above the bell section.
86. A system for forming a mono diameter wellbore casing,
comprising: means for positioning an adjustable expansion device
within a first expandable tubular member; means for supporting the
first expandable tubular member and the adjustable expansion device
within a borehole; means for lowering the adjustable expansion
device out of the first expandable tubular member; means for
increasing the outside dimension of the adjustable expansion
device; means for displacing the adjustable expansion device
upwardly relative to the first expandable tubular member m times to
radially expand and plastically deform m portions of the first
expandable tubular member within the borehole; means for
positioning the adjustable expansion device within a second
expandable tubular member; means for supporting the second
expandable tubular member and the adjustable expansion device
within the borehole in overlapping relation to the first expandable
tubular member; means for lowering the adjustable expansion device
out of the second expandable tubular member; means for increasing
the outside dimension of the adjustable expansion device; and means
for displacing the adjustable expansion device upwardly relative to
the second expandable tubular member n times to radially expand and
plastically deform n portions of the second expandable tubular
member within the borehole.
87. A system for radially expanding and plastically deforming an
expandable tubular member within a borehole, comprising: means for
positioning an adjustable expansion device within the expandable
tubular member; means for supporting the expandable tubular member
and the adjustable expansion device within the borehole; means for
lowering the adjustable expansion device out of the expandable
tubular member; means for increasing the outside dimension of the
adjustable expansion device; means for displacing the adjustable
expansion mandrel upwardly relative to the expandable tubular
member n times to radially expand and plastically deform n portions
of the expandable tubular member within the borehole; and means for
pressurizing an interior region of the expandable tubular member
above the adjustable expansion device during the radial expansion
and plastic deformation of the expandable tubular member within the
borehole.
88. A system for forming a mono diameter wellbore casing,
comprising: means for positioning an adjustable expansion device
within a first expandable tubular member; means for supporting the
first expandable tubular member and the adjustable expansion device
within a borehole; means for lowering the adjustable expansion
device out of the first expandable tubular member; means for
increasing the outside dimension of the adjustable expansion
device; means for displacing the adjustable expansion device
upwardly relative to the first expandable tubular member m times to
radially expand and plastically deform m portions of the first
expandable tubular member within the borehole; means for
pressurizing an interior region of the first expandable tubular
member above the adjustable expansion device during the radial
expansion and plastic deformation of the first expandable tubular
member within the borehole; means for positioning the adjustable
expansion mandrel within a second expandable tubular member; means
for supporting the second expandable tubular member and the
adjustable expansion mandrel within the borehole in overlapping
relation to the first expandable tubular member; means for lowering
the adjustable expansion mandrel out of the second expandable
tubular member; means for increasing the outside dimension of the
adjustable expansion mandrel; means for displacing the adjustable
expansion mandrel upwardly relative to the second expandable
tubular member n times to radially expand and plastically deform n
portions of the second expandable tubular member within the
borehole; and means for pressurizing an interior region of the
second expandable tubular member above the adjustable expansion
mandrel during the radial expansion and plastic deformation of the
second expandable tubular member within the borehole.
89. A system for radially expanding and plastically deforming an
expandable tubular member within a borehole, comprising: means for
supporting the expandable tubular member, an hydraulic actuator,
and an adjustable expansion device within the borehole; means for
increasing the size of the adjustable expansion device; and means
for displacing the adjustable expansion device upwardly relative to
the expandable tubular member using the hydraulic actuator to
radially expand and plastically deform a portion of the expandable
tubular member.
90. A system for forming a mono diameter wellbore casing within a
borehole that includes a preexisting wellbore casing, comprising:
means for supporting the expandable tubular member, an hydraulic
actuator, and an adjustable expansion device within the borehole;
means for increasing the size of the adjustable expansion device;
means for displacing the adjustable expansion device upwardly
relative to the expandable tubular member using the hydraulic
actuator to radially expand and plastically deform a portion of the
expandable tubular member; and means for displacing the adjustable
expansion device upwardly relative to the expandable tubular member
to radially expand and plastically deform the remaining portion of
the expandable tubular member and a portion of the preexisting
wellbore casing that overlaps with an end of the remaining portion
of the expandable tubular member.
91. A system for radially expanding and plastically deforming a
tubular member, comprising: means for positioning the tubular
member within a preexisting structure; means for radially expanding
and plastically deforming a lower portion of the tubular member to
form a bell section; and means for radially expanding and
plastically deforming a portion of the tubular member above the
bell section.
92. A system of radially expanding and plastically deforming a
tubular member, comprising: a support member; and means for
applying internal pressure simultaneously to the inside surface of
the tubular member at a plurality of discrete location separated
from one another coupled to the support member.
93. A method of injecting a hardenable fluidic sealing material
into an annulus between a tubular member and a preexisting
structure, comprising: positioning the tubular member into the
preexisting structure; sealing off an end of the tubular member;
operating a valve within the end of the tubular member; and
injecting a hardenable fluidic sealing material through the valve
into the annulus between the tubular member and the preexisting
structure.
94. A system for cutting a tubular member, comprising: means for
positioning a plurality of cutting elements within the tubular
member; and means for bringing the cutting elements into engagement
with the tubular member.
95. An actuator system, comprising: a support member; and means for
pressurizing a plurality of pressure chambers coupled to the
support member.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of the filing
date of U.S. provisional patent application Ser. No. 60/459,776,
attorney docket no. 25791.270, filed on Apr. 2, 2003, the
disclosure of which is incorporated herein by reference.
[0002] The present application is a continuation-in-part of the
following: (1) PCT patent application serial number PCT/US02/36157,
attorney docket number 25791.87.02, filed on Nov. 12, 2002, (2) PCT
patent application serial number PCT/US02/36267, attorney docket
number 25791.88.02, filed on Nov. 12, 2002, (3) PCT patent
application serial number PCT/US03/04837, attorney docket number
25791.95.02, filed on Feb. 29, 2003, (4) PCT patent application
serial number PCT/US03/29859, attorney docket no. 25791.102.02,
filed on Sep. 22, 2003, (5) PCT patent application serial number
PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov.
13, 2003, (6) PCT patent application serial number PCT/US03/18530,
attorney docket number 25791.108.02, filed on Jun. 11, 2003, (7)
PCT patent application serial number PCT/US03/29858, attorney
docket number 25791.112.02, (8) PCT patent application serial
number PCT/US03/29460, attorney docket number 25791.114.02, filed
on Sep. 23, 2003, filed on Sep. 22, 2003, (9) PCT patent
application serial number PCT/US04/______, attorney docket number
25791.253.02, filed on Mar. 11, 2004, and (10) PCT patent
application serial number PCT/US04/______, attorney docket number
25791.260, filed on Mar. 26, 2004, the disclosures of which are
incorporated herein by reference.
This application is related to the following co-pending
applications: (1) U.S. Pat. No. 6,497,289, which was filed as U.S.
patent application Ser. No. 09/454,139, attorney docket no.
25791.03.02, filed on Dec. 3, 1999, which claims priority from
provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S.
patent application Ser. No. 09/510,913, attorney docket no.
25791.7.02, filed on Feb. 23, 2000, which claims priority from
provisional application 60/121,702, filed on Feb. 25, 1999, (3)
U.S. patent application Ser. No. 09/502,350, attorney docket no.
25791.8.02, filed on Feb. 10, 2000, which claims priority from
provisional application 60/119,611, filed on Feb. 11, 1999, (4)
U.S. Pat. No. 6,328,113, which was filed as U.S. patent application
Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on
Nov. 15, 1999, which claims priority from provisional application
60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application
Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul.
1, 2002, which claims priority from provisional application
60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application
Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar.
10, 2000, which claims priority from provisional application
60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471,
which was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent
application Ser. No. 09/511,941, attorney docket no. 25791.16.02,
filed on Feb. 24, 2000, which claims priority from provisional
application 60/121,907, filed on Feb. 26, 1999, (9) U.S. Pat. No.
6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (10) U.S. patent application Ser. No.
09/981,916, attorney docket no. 25791.18, filed on Oct. 18, 2001 as
a continuation-in-part application of U.S. Pat. No. 6,328,113,
which was filed as U.S. patent application Ser. No. 09/440,338,
attorney docket number 25791.9.02, filed on Nov. 15, 1999, which
claims priority from provisional application 60/108,558, filed on
Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed as
application Ser. No. 09/559,122, attorney docket no. 25791.23.02,
filed on Apr. 26, 2000, which claims priority from provisional
application 60/131,106, filed on Apr. 26, 1999, (12) U.S. patent
application Ser. No. 10/030,593, attorney docket no. 25791.25.08,
filed on Jan. 8, 2002, which claims priority from provisional
application 60/146,203, filed on Jul. 29, 1999, (13) U.S.
provisional patent application Ser. No. 60/143,039, attorney docket
no. 25791.26, filed on Jul. 9, 1999, (14) U.S. patent application
Ser. No. 10/111,982, attorney docket no. 25791.27.08, filed on Apr.
30, 2002, which claims priority from provisional patent application
Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1,
1999, (15) U.S. provisional patent application Ser. No. 60/154,047,
attorney docket no. 25791.29, filed on Sep. 16, 1999, (16) U.S.
provisional patent application Ser. No. 60/438,828, attorney docket
no. 25791.31, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875,
which was filed as application Ser. No. 09/679,907, attorney docket
no. 25791.34.02, on Oct. 5, 2000, which claims priority from
provisional patent application Ser. No. 60/159,082, attorney docket
no. 25791.34, filed on Oct. 12, 1999, (18) U.S. patent application
Ser. No. 10/089,419, filed on Mar. 27, 2002, attorney docket no.
25791.36.03, which claims priority from provisional patent
application Ser. No. 60/159,039, attorney docket no. 25791.36,
filed on Oct. 12, 1999, (19) U.S. patent application Ser. No.
09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02,
which claims priority from provisional patent application Ser. No.
60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999,
(20) U.S. patent application Ser. No. 10/303,992, filed on Nov. 22,
2002, attorney docket no. 25791.38.07, which claims priority from
provisional patent application Ser. No. 60/212,359, attorney docket
no. 25791.38, filed on Jun. 19, 2000, (21) U.S. provisional patent
application Ser. No. 60/165,228, attorney docket no. 25791.39,
filed on Nov. 12, 1999, (22) U.S. provisional patent application
Ser. No. 60/455,051, attorney docket no. 25791.40, filed on Mar.
14, 2003, (23) PCT application US02/2477, filed on Jun. 26, 2002,
attorney docket no. 25791.44.02, which claims priority from U.S.
provisional patent application Ser. No. 60/303,711, attorney docket
no. 25791.44, filed on Jul. 6, 2001, (24) U.S. patent application
Ser. No. 10/311,412, filed on Dec. 12, 2002, attorney docket no.
25791.45.07, which claims priority from provisional patent
application Ser. No. 60/221,443, attorney docket no. 25791.45,
filed on Jul. 28, 2000, (25) U.S. patent application Ser. No.
10/______, filed on Dec. 18, 2002, attorney docket no. 25791.46.07,
which claims priority from provisional patent application Ser. No.
60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000,
(26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22,
2003, attorney docket no. 25791.47.03, which claims priority from
provisional patent application Ser. No. 60/233,638, attorney docket
no. 25791.47, filed on Sep. 18, 2000, (27) U.S. patent application
Ser. No. 10/406,648, filed on Mar. 31, 2003, attorney docket no.
25791.48.06, which claims priority from provisional patent
application Ser. No. 60/237,334, attorney docket no. 25791.48,
filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on
Feb. 14, 2002, attorney docket no. 25791.50.02, which claims
priority from U.S. provisional patent application Ser. No.
60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001,
(29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13,
2003, attorney docket no. 25791.51.06, which claims priority from
provisional patent application Ser. No. 60/262,434, attorney docket
no. 25791.51, filed on Jan. 17, 2001, (30) U.S. patent application
Ser. No. 10/465,831, filed on Jun. 13, 2003, attorney docket no.
25791.52.06, which claims priority from U.S. provisional patent
application Ser. No. 60/259,486, attorney docket no. 25791.52,
filed on Jan. 3, 2001, (31) U.S. provisional patent application
Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney docket no.
25791.53, (32) U.S. Pat. No. 6,470,966, which was filed as patent
application Ser. No. 09/850,093, filed on May 7, 2001, attorney
docket no. 25791.55, as a divisional application of U.S. Pat. No.
6,497,289, which was filed as U.S. patent application Ser. No.
09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,
which claims priority from provisional application 60/111,293,
filed on Dec. 7, 1998, (33) U.S. Pat. No. 6,561,227, which was
filed as patent application Ser. No. 09/852,026, filed on May 9,
2001, attorney docket no. 25791.56, as a divisional application of
U.S. Pat. No. 6,497,289, which was filed as U.S. patent application
Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec.
3, 1999, which claims priority from provisional application
60/111,293, filed on Dec. 7, 1998, (34) U.S. patent application
Ser. No. 09/852,027, filed on May 9, 2001, attorney docket no.
25791.57, as a divisional application of U.S. Pat. No. 6,497,289,
which was filed as U.S. patent application Ser. No. 09/454,139,
attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which
claims priority from provisional application 60/111,293, filed on
Dec. 7, 1998, (35) PCT Application US02/25608, attorney docket no.
25791.58.02, filed on Aug. 13, 2002, which claims priority from
provisional application 60/318,021, filed on Sep. 7, 2001, attorney
docket no. 25791.58, (36) PCT Application US02/24399, attorney
docket no. 25791.59.02, filed on Aug. 1, 2002, which claims
priority from U.S. provisional patent application Ser. No.
60/313,453, attorney docket no. 25791.59, filed on Aug. 20, 2001,
(37) PCT Application US02/29856, attorney docket no. 25791.60.02,
filed on Sep. 19, 2002, which claims priority from U.S. provisional
patent application Ser. No. 60/326,886, attorney docket no.
25791.60, filed on Oct. 3, 2001, (38) PCT Application US02/20256,
attorney docket no. 25791.61.02, filed on Jun. 26, 2002, which
claims priority from U.S. provisional patent application Ser. No.
60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001,
(39) U.S. patent application Ser. No. 09/962,469, filed on Sep. 25,
2001, attorney docket no. 25791.62, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (40)
U.S. patent application Ser. No. 09/962,470, filed on Sep. 25,
2001, attorney docket no. 25791.63, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (41)
U.S. patent application Ser. No. 09/962,471, filed on Sep. 25,
2001, attorney docket no. 25791.64, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (42)
U.S. patent application Ser. No. 09/962,467, filed on Sep. 25,
2001, attorney docket no. 25791.65, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (43)
U.S. patent application Ser. No. 09/962,468, filed on Sep. 25,
2001, attorney docket no. 25791.66, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (44)
PCT application US 02/25727, filed on Aug. 14, 2002, attorney
docket no. 25791.67.03, which claims priority from U.S. provisional
patent application Ser. No. 60/317,985, attorney docket no.
25791.67, filed on Sep. 6, 2001, and U.S. provisional patent
application Ser. No. 60/318,386, attorney docket no. 25791.67.02,
filed on Sep. 10, 2001, (45) PCT application US 02/39425, filed on
Dec. 10, 2002, attorney docket no. 25791.68.02, which claims
priority from U.S. provisional patent application Ser. No.
60/343,674, attorney docket no. 25791.68, filed on Dec. 27, 2001,
(46) U.S. utility patent application Ser. No. 09/969,922, attorney
docket no. 25791.69, filed on Oct. 3, 2001, which is a
continuation-in-part application of U.S. Pat. No. 6,328,113, which
was filed as U.S. patent application Ser. No. 09/440,338, attorney
docket number 25791.9.02, filed on Nov. 15, 1999, which claims
priority from provisional application 60/108,558, filed on Nov. 16,
1998, (47) U.S. utility patent application Ser. No. 10/516,467,
attorney docket no. 25791.70, filed on Dec. 10, 2001, which is a
continuation application of U.S. utility patent application Ser.
No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3,
2001, which is a continuation-in-part application of U.S. Pat. No.
6,328,113, which was filed as U.S. patent application Ser. No.
09/440,338, attorney docket number 25791.9.02, filed on Nov. 15,
1999, which claims priority from provisional application
60/108,558, filed on Nov. 16, 1998, (48) PCT application US
03/00609, filed on Jan. 9, 2003, attorney docket no. 25791.71.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/357,372, attorney docket no. 25791.71, filed on Feb. 15,
2002, (49) U.S. patent application Ser. No. 10/074,703, attorney
docket no. 25791.74, filed on Feb. 12, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (50) U.S. patent application
Ser. No. 10/074,244, attorney docket no. 25791.75, filed on Feb.
12, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (51) U.S. patent application Ser. No. 10/076,660, attorney
docket no. 25791.76, filed on Feb. 15, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (52) U.S. patent application
Ser. No. 10/076,661, attorney docket no. 25791.77, filed on Feb.
15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (53) U.S. patent application Ser. No. 10/076,659, attorney
docket no. 25791.78, filed on Feb. 15, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (54) U.S. patent application
Ser. No. 10/078,928, attorney docket no. 25791.79, filed on Feb.
20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (55) U.S. patent application Ser. No. 10/078,922, attorney
docket no. 25791.80, filed on Feb. 20, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (56) U.S. patent application
Ser. No. 10/078,921, attorney docket no. 25791.81, filed on Feb.
20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (57) U.S. patent application Ser. No. 10/261,928, attorney
docket no. 25791.82, filed on Oct. 1, 2002, which is a divisional
of U.S. Pat. No. 6,557,640, which was filed as patent application
Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun.
7, 2000, which claims priority from provisional application
60/137,998, filed on Jun. 7, 1999, (58) U.S. patent application
Ser. No. 10/079,276, attorney docket no. 25791.83, filed on Feb.
20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (59) U.S. patent application Ser. No. 10/262,009, attorney
docket no. 25791.84, filed on Oct. 1, 2002, which is a divisional
of U.S. Pat. No. 6,557,640, which was filed as patent application
Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun.
7, 2000, which claims priority from provisional application
60/137,998, filed on Jun. 7, 1999, (60) U.S. patent application
Ser. No. 10/092,481, attorney docket no. 25791.85, filed on Mar. 7,
2002, which is a divisional of U.S. Pat. No. 6,568,471, which was
filed as patent application Ser. No. 09/512,895, attorney docket
no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from
provisional application 60/121,841, filed on Feb. 26, 1999, (61)
U.S. patent application Ser. No. 10/261,926, attorney docket no.
25791.86, filed on Oct. 1, 2002, which is a divisional of U.S. Pat.
No. 6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (62) PCT application US 02/36157, filed on
Nov. 12, 2002, attorney docket no. 25791.87.02, which claims
priority from U.S. provisional patent application Ser. No.
60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001,
(63) PCT application US 02/36267, filed on Nov. 12, 2002, attorney
docket no. 25791.88.02, which claims priority from U.S. provisional
patent application Ser. No. 60/339,013, attorney docket no.
25791.88, filed on Nov. 12, 2001, (64) PCT application US 03/11765,
filed on Apr. 16, 2003, attorney docket no. 25791.89.02, which
claims priority from U.S. provisional patent application Ser. No.
60/383,917, attorney docket no. 25791.89, filed on May 29, 2002,
(65) PCT application US 03/15020, filed on May 12, 2003, attorney
docket no. 25791.90.02, which claims priority from U.S. provisional
patent application Ser. No. 60/391,703, attorney docket no.
25791.90, filed on Jun. 26, 2002, (66) PCT application US 02/39418,
filed on Dec. 10, 2002, attorney docket no. 25791.92.02, which
claims priority from U.S. provisional patent
application Ser. No. 60/346,309, attorney docket no. 25791.92,
filed on Jan. 7, 2002, (67) PCT application US 03/06544, filed on
Mar. 4, 2003, attorney docket no. 25791.93.02, which claims
priority from U.S. provisional patent application Ser. No.
60/372,048, attorney docket no. 25791.93, filed on Apr. 12, 2002,
(68) U.S. patent application Ser. No. 10/331,718, attorney docket
no. 25791.94, filed on Dec. 30, 2002, which is a divisional U.S.
patent application Ser. No. 09/679,906, filed on Oct. 5, 2000,
attorney docket no. 25791.37.02, which claims priority from
provisional patent application Ser. No. 60/159,033, attorney docket
no. 25791.37, filed on Oct. 12, 1999, (69) PCT application US
03/04837, filed on Feb. 29, 2003, attorney docket no. 25791.95.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13,
2002, (70) U.S. patent application Ser. No. 10/261,927, attorney
docket no. 25791.97, filed on Oct. 1, 2002, which is a divisional
of U.S. Pat. No. 6,557,640, which was filed as patent application
Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun.
7, 2000, which claims priority from provisional application
60/137,998, filed on Jun. 17, 1999, (71) U.S. patent application
Ser. No. 10/262,008, attorney docket no. 25791.98, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 17, 1999, (72)
U.S. patent application Ser. No. 10/261,925, attorney docket no.
25791.99, filed on Oct. 1, 2002, which is a divisional of U.S. Pat.
No. 6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (73) U.S. patent application Ser. No.
10/199,524, attorney docket no. 25791.100, filed on Jul. 19, 2002,
which is a continuation of U.S. Pat. No. 6,497,289, which was filed
as U.S. patent application Ser. No. 09/454,139, attorney docket no.
25791.03.02, filed on Dec. 3, 1999, which claims priority from
provisional application 60/111,293, filed on Dec. 7, 1998, (74) PCT
application US 03/10144, filed on Mar. 28, 2003, attorney docket
no. 25791.101.02, which claims priority from U.S. provisional
patent application Ser. No. 60/372,632, attorney docket no.
25791.101, filed on Apr. 15, 2002, (75) U.S. provisional patent
application Ser. No. 60/412,542, attorney docket no. 25791.102,
filed on Sep. 20, 2002, (76) PCT application US 03/14153, filed on
May 6, 2003, attorney docket no. 25791.104.02, which claims
priority from U.S. provisional patent application Ser. No.
60/380,147, attorney docket no. 25791.104, filed on May 6, 2002,
(77) PCT application US 03/19993, filed on Jun. 24, 2003, attorney
docket no. 25791.106.02, which claims priority from U.S.
provisional patent application Ser. No. 60/397,284, attorney docket
no. 25791.106, filed on Jul. 19, 2002, (78) PCT application US
03/13787, filed on May 5, 2003, attorney docket no. 25791.107.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/387,486, attorney docket no. 25791.107, filed on Jun. 10,
2002, (79) PCT application US 03/18530, filed on Jun. 11, 2003,
attorney docket no. 25791.108.02, which claims priority from U.S.
provisional patent application Ser. No. 60/387,961, attorney docket
no. 25791.108, filed on Jun. 12, 2002, (80) PCT application US
03/20694, filed on Jul. 1, 2003, attorney docket no. 25791.110.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/398,061, attorney docket no. 25791.110, filed on Jul. 24,
2002, (81) PCT application US 03/20870, filed on Jul. 2, 2003,
attorney docket no. 25791.111.02, which claims priority from U.S.
provisional patent application Ser. No. 60/399,240, attorney docket
no. 25791.111, filed on Jul. 29, 2002, (82) U.S. provisional patent
application Ser. No. 60/412,487, attorney docket no. 25791.112,
filed on Sep. 20, 2002, (83) U.S. provisional patent application
Ser. No. 60/412,488, attorney docket no. 25791.114, filed on Sep.
20, 2002, (84) U.S. patent application serial no. 10/280,356,
attorney docket no. 25791.115, filed on Oct. 25, 2002, which is a
continuation of U.S. Pat. No. 6,470,966, which was filed as patent
application Ser. No. 09/850,093, filed on May 7, 2001, attorney
docket no. 25791.55, as a divisional application of U.S. Pat. No.
6,497,289, which was filed as U.S. patent application Ser. No.
09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,
which claims priority from provisional application 60/111,293,
filed on Dec. 7, 1998, (85) U.S. provisional patent application
Ser. No. 60/412,177, attorney docket no. 25791.117, filed on Sep.
20, 2002, (86) U.S. provisional patent application Ser. No.
60/412,653, attorney docket no. 25791.118, filed on Sep. 20, 2002,
(87) U.S. provisional patent application Ser. No. 60/405,610,
attorney docket no. 25791.119, filed on Aug. 23, 2002, (88) U.S.
provisional patent application Ser. No. 60/405,394, attorney docket
no. 25791.120, filed on Aug. 23, 2002, (89) U.S. provisional patent
application Ser. No. 60/412,544, attorney docket no. 25791.121,
filed on Sep. 20, 2002, (90) PCT application US 03/24779, filed on
Aug. 8, 2003, attorney docket no. 25791.125.02, which claims
priority from U.S. provisional patent application Ser. No.
60/407,442, attorney docket no. 25791.125, filed on Aug. 30, 2002,
(91) U.S. provisional patent application Ser. No. 60/423,363,
attorney docket no. 25791.126, filed on Dec. 10, 2002, (92) U.S.
provisional patent application Ser. No. 60/412,196, attorney docket
no. 25791.127, filed on Sep. 20, 2002, (93) U.S. provisional patent
application Ser. No. 60/412,187, attorney docket no. 25791.128,
filed on Sep. 20, 2002, (94) U.S. provisional patent application
Ser. No. 60/412,371, attorney docket no. 25791.129, filed on Sep.
20, 2002, (95) U.S. patent application Ser. No. 10/382,325,
attorney docket no. 25791.145, filed on Mar. 5, 2003, which is a
continuation of U.S. Pat. No. 6,557,640, which was filed as patent
application Ser. No. 09/588,946, attorney docket no. 25791.17.02,
filed on Jun. 7, 2000, which claims priority from provisional
application 60/137,998, filed on Jun. 7, 1999, (96) U.S. patent
application Ser. No. 10/624,842, attorney docket no. 25791.151,
filed on Jul. 22, 2003, which is a divisional of U.S. patent
application Ser. No. 09/502,350, attorney docket no. 25791.8.02,
filed on Feb. 10, 2000, which claims priority from provisional
application 60/119,611, filed on Feb. 11, 1999, (97) U.S.
provisional patent application Ser. No. 60/431,184, attorney docket
no. 25791.157, filed on Dec. 5, 2002, (98) U.S. provisional patent
application Ser. No. 60/448,526, attorney docket no. 25791.185,
filed on Feb. 18, 2003, (99) U.S. provisional patent application
Ser. No. 60/461,539, attorney docket no. 25791.186, filed on Apr.
9, 2003, (100) U.S. provisional patent application Ser. No.
60/462,750, attorney docket no. 25791.193, filed on Apr. 14, 2003,
(101) U.S. provisional patent application Ser. No. 60/436,106,
attorney docket no. 25791.200, filed on Dec. 23, 2002, (102) U.S.
provisional patent application Ser. No. 60/442,942, attorney docket
no. 25791.213, filed on Jan. 27, 2003, (103) U.S. provisional
patent application Ser. No. 60/442,938, attorney docket no.
25791.225, filed on Jan. 27, 2003, (104) U.S. provisional patent
application Ser. No. 60/418,687, attorney docket no. 25791.228,
filed on Apr. 18, 2003, (105) U.S. provisional patent application
Ser. No. 60/454,896, attorney docket no. 25791.236, filed on Mar.
14, 2003, (106) U.S. provisional patent application Ser. No.
60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003,
(107) U.S. provisional patent application Ser. No. 60/451,152,
attorney docket no. 25791.239, filed on Mar. 9, 2003, (108) U.S.
provisional patent application Ser. No. 60/455,124, attorney docket
no. 25791.241, filed on Mar. 17, 2003, (109) U.S. provisional
patent application Ser. No. 60/453,678, attorney docket no.
25791.253, filed on Mar. 11, 2003, (110) U.S. patent application
Ser. No. 10/421,682, attorney docket no. 25791.256, filed on Apr.
23, 2003, which is a continuation of U.S. patent application Ser.
No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10,
2000, which claims priority from provisional application
60/124,042, filed on Mar. 11, 1999, (111) U.S. provisional patent
application Ser. No. 60/457,965, attorney docket no. 25791.260,
filed on Mar. 27, 2003, (112) U.S. provisional patent application
Ser. No. 60/455,718, attorney docket no. 25791.262, filed on Mar.
18, 2003, (113) U.S. Pat. No. 6,550,821, which was filed as patent
application Ser. No. 09/811,734, filed on Mar. 19, 2001, (114) U.S.
patent application Ser. No. 10/436,467, attorney docket no.
25791.268, filed on May 12, 2003, which is a continuation of U.S.
Pat. No. 6,604,763, which was filed as application Ser. No.
09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26,
2000, which claims priority from provisional application
60/131,106, filed on Apr. 26, 1999, (115) U.S. provisional patent
application Ser. No. 60/459,776, attorney docket no. 25791.270,
filed on Apr. 2, 2003, (116) U.S. provisional patent application
Ser. No. 60/461,094, attorney docket no. 25791.272, filed on Apr.
8, 2003, (117) U.S. provisional patent application Ser. No.
60/461,038, attorney docket no. 25791.273, filed on Apr. 7, 2003,
(118) U.S. provisional patent application Ser. No. 60/463,586,
attorney docket no. 25791.277, filed on Apr. 17, 2003, (119) U.S.
provisional patent application Ser. No. 60/472,240, attorney docket
no. 25791.286, filed on May 20, 2003, (120) U.S. patent application
Ser. No. 10/619,285, attorney docket no. 25791.292, filed on Jul.
14, 2003, which is a continuation-in-part of U.S. utility patent
application Ser. No. 09/969,922, attorney docket no. 25791.69,
filed on Oct. 3, 2001, which is a continuation-in-part application
of U.S. Pat. No. 6,328,113, which was filed as U.S. patent
application Ser. No. 09/440,338, attorney docket number 25791.9.02,
filed on Nov. 15, 1999, which claims priority from provisional
application 60/108,558, filed on Nov. 16, 1998, (121) U.S. utility
patent application Ser. No. 10/418,688, attorney docket no.
25791.257, which was filed on Apr. 18, 2003, as a division of U.S.
utility patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (122)
PCT patent application serial no. PCT/US04/06246, attorney docket
no. 25791.238.02, filed on Feb. 26, 2004, (123) PCT patent
application serial number PCT/US04/______, attorney docket number
25791.40.02, filed on Mar. 15, 2004, (124) PCT patent application
serial number PCT/US04/______, attorney docket number 25791.236.02,
filed on Mar. 15, 2004, (125) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.262.02, filed on Mar.
18, 2004, (126) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.253.02, filed on Mar.
11, 2004, and (127) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.260, filed on Mar.
26, 2004, the disclosures of which are incorporated herein by
reference.
[0003] 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.
SUMMARY OF THE INVENTION
[0005] According to one aspect of the present invention, an
apparatus for radially expanding and plastically deforming an
expandable tubular member is provided that includes a support
member, a cutting device for cutting the tubular member coupled to
the support member, and an expansion device for radially expanding
and plastically deforming the tubular member coupled to the support
member.
[0006] According to another aspect of the present invention, an
apparatus for radially expanding and plastically deforming an
expandable tubular member is provided that includes a support
member, an expansion device for radially expanding and plastically
deforming the tubular member coupled to the support member, and an
actuator coupled to the support member for displacing the expansion
device relative to the support member.
[0007] According to another aspect of the present invention, an
apparatus for radially expanding and plastically deforming an
expandable tubular member is provided that includes a support
member; an expansion device for radially expanding and plastically
deforming the tubular member coupled to the support member; and a
sealing assembly for sealing an annulus defined between the support
member and the tubular member.
[0008] According to another aspect of the present invention, an
apparatus for radially expanding and plastically deforming an
expandable tubular member is provided that includes a support
member; a first expansion device for radially expanding and
plastically deforming the tubular member coupled to the support
member; and a second expansion device for radially expanding and
plastically deforming the tubular member coupled to the support
member.
[0009] According to another aspect of the present invention, an
apparatus for radially expanding and plastically deforming an
expandable tubular member is provided that includes a support
member; an expansion device for radially expanding and plastically
deforming the tubular member coupled to the support member; and a
packer coupled to the support member.
[0010] According to another aspect of the present invention, an
apparatus for radially expanding and plastically deforming an
expandable tubular member is provided that includes a support
member; a cutting device for cutting the tubular member coupled to
the support member; a gripping device for gripping the tubular
member coupled to the support member; a sealing device for sealing
an interface with the tubular member coupled to the support member;
a locking device for locking the position of the tubular member
relative to the support member; a first adjustable expansion device
for radially expanding and plastically deforming the tubular member
coupled to the support member; a second adjustable expansion device
for radially expanding and plastically deforming the tubular member
coupled to the support member; a packer coupled to the support
member; and an actuator for displacing one or more of the sealing
assembly, first and second adjustable expansion devices, and packer
relative to the support member.
[0011] According to another aspect of the present invention, an
apparatus for cutting a tubular member is provided that includes a
support member; and a plurality of movable cutting elements coupled
to the support member.
[0012] According to another aspect of the present invention, an
apparatus for engaging a tubular member is provided that includes a
support member; and a plurality of movable elements coupled to the
support member.
[0013] According to another aspect of the present invention, an
apparatus for gripping a tubular member is provided that includes a
plurality of movable gripping elements.
[0014] According to another aspect of the present invention, an
actuator is provided that includes a tubular housing; a tubular
piston rod movably coupled to and at least partially positioned
within the housing; a plurality of annular piston chambers defined
by the tubular housing and the tubular piston rod; and a plurality
of tubular pistons coupled to the tubular piston rod, each tubular
piston movably positioned within a corresponding annular piston
chamber.
[0015] According to another aspect of the present invention, an
apparatus for controlling a packer is provided that includes a
tubular support member; one or more drag blocks releasably coupled
to the tubular support member; and a tubular stinger coupled to the
tubular support member for engaging the packer.
[0016] According to another aspect of the present invention, a
packer is provided that includes a support member defining a
passage; a shoe comprising a float valve coupled to an end of the
support member; one or more compressible packer elements movably
coupled to the support member; and a sliding sleeve valve movably
positioned within the passage of the support member.
[0017] According to another aspect of the present invention, a
method of radially expanding and plastically deforming an
expandable tubular member within a borehole having a preexisting
wellbore casing is provided that includes positioning the tubular
member within the borehole in overlapping relation to the wellbore
casing; radially expanding and plastically deforming a portion of
the tubular member to form a bell section; and radially expanding
and plastically deforming a portion of the tubular member above the
bell section comprising a portion of the tubular member that
overlaps with the wellbore casing; wherein the inside diameter of
the bell section is greater than the inside diameter of the
radially expanded and plastically deformed portion of the tubular
member above the bell section.
[0018] According to another aspect of the present invention, a
method for forming a mono diameter wellbore casing is provided that
includes positioning an adjustable expansion device within a first
expandable tubular member; supporting the first expandable tubular
member and the adjustable expansion device within a borehole;
lowering the adjustable expansion device out of the first
expandable tubular member; increasing the outside dimension of the
adjustable expansion device; displacing the adjustable expansion
device upwardly relative to the first expandable tubular member m
times to radially expand and plastically deform m portions of the
first expandable tubular member within the borehole; positioning
the adjustable expansion device within a second expandable tubular
member; supporting the second expandable tubular member and the
adjustable expansion device within the borehole in overlapping
relation to the first expandable tubular member; lowering the
adjustable expansion device out of the second expandable tubular
member; increasing the outside dimension of the adjustable
expansion device; and displacing the adjustable expansion device
upwardly relative to the second expandable tubular member n times
to radially expand and plastically deform n portions of the second
expandable tubular member within the borehole.
[0019] According to another aspect of the present invention, a
method for radially expanding and plastically deforming an
expandable tubular member within a borehole is provided that
includes positioning an adjustable expansion device within the
expandable tubular member; supporting the expandable tubular member
and the adjustable expansion device within the borehole; lowering
the adjustable expansion device out of the expandable tubular
member; increasing the outside dimension of the adjustable
expansion device; displacing the adjustable expansion mandrel
upwardly relative to the expandable tubular member n times to
radially expand and plastically deform n portions of the expandable
tubular member within the borehole; and pressurizing an interior
region of the expandable tubular member above the adjustable
expansion device during the radial expansion and plastic
deformation of the expandable tubular member within the
borehole.
[0020] According to another aspect of the present invention, a
method for forming a mono diameter wellbore casing is provided that
includes positioning an adjustable expansion device within a first
expandable tubular member; supporting the first expandable tubular
member and the adjustable expansion device within a borehole;
lowering the adjustable expansion device out of the first
expandable tubular member; increasing the outside dimension of the
adjustable expansion device; displacing the adjustable expansion
device upwardly relative to the first expandable tubular member m
times to radially expand and plastically deform m portions of the
first expandable tubular member within the borehole; pressurizing
an interior region of the first expandable tubular member above the
adjustable expansion device during the radial expansion and plastic
deformation of the first expandable tubular member within the
borehole; positioning the adjustable expansion mandrel within a
second expandable tubular member; supporting the second expandable
tubular member and the adjustable expansion mandrel within the
borehole in overlapping relation to the first expandable tubular
member; lowering the adjustable expansion mandrel out of the second
expandable tubular member; increasing the outside dimension of the
adjustable expansion mandrel; displacing the adjustable expansion
mandrel upwardly relative to the second expandable tubular member n
times to radially expand and plastically deform n portions of the
second expandable tubular member within the borehole; and
pressurizing an interior region of the second expandable tubular
member above the adjustable expansion mandrel during the radial
expansion and plastic deformation of the second expandable tubular
member within the borehole.
[0021] According to another aspect of the present invention, a
method for radially expanding and plastically deforming an
expandable tubular member within a borehole is provided that
includes positioning first and second adjustable expansion devices
within the expandable tubular member; supporting the expandable
tubular member and the first and second adjustable expansion
devices within the borehole; lowering the first adjustable
expansion device out of the expandable tubular member; increasing
the outside dimension of the first adjustable expansion device;
displacing the first adjustable expansion device upwardly relative
to the expandable tubular member to radially expand and plastically
deform a lower portion of the expandable tubular member; displacing
the first adjustable expansion device and the second adjustable
expansion device downwardly relative to the expandable tubular
member; decreasing the outside dimension of the first adjustable
expansion device and increasing the outside dimension of the second
adjustable expansion device; displacing the second adjustable
expansion device upwardly relative to the expandable tubular member
to radially expand and plastically deform portions of the
expandable tubular member above the lower portion of the expandable
tubular member; wherein the outside dimension of the first
adjustable expansion device is greater than the outside dimension
of the second adjustable expansion device.
[0022] According to another aspect of the present invention, a
method for forming a mono diameter wellbore casing is provided that
includes positioning first and second adjustable expansion devices
within a first expandable tubular member; supporting the first
expandable tubular member and the first and second adjustable
expansion devices within a borehole; lowering the first adjustable
expansion device out of the first expandable tubular member;
increasing the outside dimension of the first adjustable expansion
device; displacing the first adjustable expansion device upwardly
relative to the first expandable tubular member to radially expand
and plastically deform a lower portion of the first expandable
tubular member; displacing the first adjustable expansion device
and the second adjustable expansion device downwardly relative to
the first expandable tubular member; decreasing the outside
dimension of the first adjustable expansion device and increasing
the outside dimension of the second adjustable expansion device;
displacing the second adjustable expansion device upwardly relative
to the first expandable tubular member to radially expand and
plastically deform portions of the first expandable tubular member
above the lower portion of the expandable tubular member;
positioning first and second adjustable expansion devices within a
second expandable tubular member; supporting the first expandable
tubular member and the first and second adjustable expansion
devices within the borehole in overlapping relation to the first
expandable tubular member; lowering the first adjustable expansion
device out of the second expandable tubular member; increasing the
outside dimension of the first adjustable expansion device;
displacing the first adjustable expansion device upwardly relative
to the second expandable tubular member to radially expand and
plastically deform a lower portion of the second expandable
tubular, member; displacing the first adjustable expansion device
and the second adjustable expansion device downwardly relative to
the second expandable tubular member; decreasing the outside
dimension of the first adjustable expansion device and increasing
the outside dimension of the second adjustable expansion device;
and displacing the second adjustable expansion device upwardly
relative to the second expandable tubular member to radially expand
and plastically deform portions of the second expandable tubular
member above the lower portion of the second expandable tubular
member; wherein the outside dimension of the first adjustable
expansion device is greater than the outside dimension of the
second adjustable expansion device.
[0023] According to another aspect of the present invention, a
method for radially expanding and plastically deforming an
expandable tubular member within a borehole is provided that
includes positioning first and second adjustable expansion devices
within the expandable tubular member; supporting the expandable
tubular member and the first and second adjustable expansion
devices within the borehole; lowering the first adjustable
expansion device out of the expandable tubular member; increasing
the outside dimension of the first adjustable expansion device;
displacing the first adjustable expansion device upwardly relative
to the expandable tubular member to radially expand and plastically
deform a lower portion of the expandable tubular member;
pressurizing an interior region of the expandable tubular member
above the first adjustable expansion device during the radial
expansion of the lower portion of the expandable tubular member by
the first adjustable expansion device; displacing the first
adjustable expansion device and the second adjustable expansion
device downwardly relative to the expandable tubular member;
decreasing the outside dimension of the first adjustable expansion
device and increasing the outside dimension of the second
adjustable expansion device; displacing the second adjustable
expansion device upwardly relative to the expandable tubular member
to radially expand and plastically deform portions of the
expandable tubular member above the lower portion of the expandable
tubular member; and pressurizing an interior region of the
expandable tubular member above the second adjustable expansion
device during the radial expansion of the portions of the
expandable tubular member above the lower portion of the expandable
tubular member by the second adjustable expansion device; wherein
the outside dimension of the first adjustable expansion device is
greater than the outside dimension of the second adjustable
expansion device.
[0024] According to another aspect of the present invention, a
method for forming a mono diameter wellbore casing is provided that
includes positioning first and second adjustable expansion devices
within a first expandable tubular member; supporting the first
expandable tubular member and the first and second adjustable
expansion devices within a borehole; lowering the first adjustable
expansion device out of the first expandable tubular member;
increasing the outside dimension of the first adjustable expansion
device; displacing the first adjustable expansion device upwardly
relative to the first expandable tubular member to radially expand
and plastically deform a lower portion of the first expandable
tubular member; pressurizing an interior region of the first
expandable tubular member above the first adjustable expansion
device during the radial expansion of the lower portion of the
first expandable tubular member by the first adjustable expansion
device; displacing the first adjustable expansion device and the
second adjustable expansion device downwardly relative to the first
expandable tubular member; decreasing the outside dimension of the
first adjustable expansion device and increasing the outside
dimension of the second adjustable expansion device; displacing the
second adjustable expansion device upwardly relative to the first
expandable tubular member to radially expand and plastically deform
portions of the first expandable tubular member above the lower
portion of the expandable tubular member; pressurizing an interior
region of the first expandable tubular member above the second
adjustable expansion device during the radial expansion of the
portions of the first expandable tubular member above the lower
portion of the first expandable tubular member by the second
adjustable expansion device; positioning first and second
adjustable expansion devices within a second expandable tubular
member; supporting the first expandable tubular member and the
first and second adjustable expansion devices within the borehole
in overlapping relation to the first expandable tubular member;
lowering the first adjustable expansion device out of the second
expandable tubular member; increasing the outside dimension of the
first adjustable expansion device; displacing the first adjustable
expansion device upwardly relative to the second expandable tubular
member to radially expand and plastically deform a lower portion of
the second expandable tubular member; pressurizing an interior
region of the second expandable tubular member above the first
adjustable expansion device during the radial expansion of the
lower portion of the second expandable tubular member by the first
adjustable expansion device; displacing the first adjustable
expansion device and the second adjustable expansion device
downwardly relative to the second expandable tubular member;
decreasing the outside dimension of the first adjustable expansion
device and increasing the outside dimension of the second
adjustable expansion device; displacing the second adjustable
expansion device upwardly relative to the second expandable tubular
member to radially expand and plastically deform portions of the
second expandable tubular member above the lower portion of the
second expandable tubular member; and pressurizing an interior
region of the second expandable tubular member above the second
adjustable expansion device during the radial expansion of the
portions of the second expandable tubular member above the lower
portion of the second expandable tubular member by the second
adjustable expansion device; wherein the outside dimension of the
first adjustable expansion device is greater than the outside
dimension of the second adjustable expansion device.
[0025] According to another aspect of the present invention, a
method for radially expanding and plastically deforming an
expandable tubular member within a borehole is provided that
includes supporting the expandable tubular member, an hydraulic
actuator, and an adjustable expansion device within the borehole;
increasing the size of the adjustable expansion device; and
displacing the adjustable expansion device upwardly relative to the
expandable tubular member using the hydraulic actuator to radially
expand and plastically deform a portion of the expandable tubular
member.
[0026] According to another aspect of the present invention, a
method for forming a mono diameter wellbore casing within a
borehole that includes a preexisting wellbore casing is provided
that includes supporting the expandable tubular member, an
hydraulic actuator, and an adjustable expansion device within the
borehole; increasing the size of the adjustable expansion device;
displacing the adjustable expansion device upwardly relative to the
expandable tubular member using the hydraulic actuator to radially
expand and plastically deform a portion of the expandable tubular
member; and displacing the adjustable expansion device upwardly
relative to the expandable tubular member to radially expand and
plastically deform the remaining portion of the expandable tubular
member and a portion of the preexisting wellbore casing that
overlaps with an end of the remaining portion of the expandable
tubular member.
[0027] According to another aspect of the present invention, a
method of radially expanding and plastically deforming a tubular
member is provided that includes positioning the tubular member
within a preexisting structure; radially expanding and plastically
deforming a lower portion of the tubular member to form a bell
section; and radially expanding and plastically deforming a portion
of the tubular member above the bell section.
[0028] According to another aspect of the present invention, a
method of radially expanding and plastically deforming a tubular
member is provided that includes applying internal pressure to the
inside surface of the tubular member at a plurality of discrete
location separated from one another.
[0029] According to another aspect of the present invention, a
system for radially expanding and plastically deforming an
expandable tubular member within a borehole having a preexisting
wellbore casing is provided that includes means for positioning the
tubular member within the borehole in overlapping relation to the
wellbore casing; means for radially expanding and plastically
deforming a portion of the tubular member to form a bell section;
and means for radially expanding and plastically deforming a
portion of the tubular member above the bell section comprising a
portion of the tubular member that overlaps with the wellbore
casing; wherein the inside diameter of the bell section is greater
than the inside diameter of the radially expanded and plastically
deformed portion of the tubular member above the bell section.
[0030] According to another aspect of the present invention, a
system for forming a mono diameter wellbore casing is provided that
includes means for positioning an adjustable expansion device
within a first expandable tubular member; means for supporting the
first expandable tubular member and the adjustable expansion device
within a borehole; means for lowering the adjustable expansion
device out of the first expandable tubular member; means for
increasing the outside dimension of the adjustable expansion
device; means for displacing the adjustable expansion device
upwardly relative to the first expandable tubular member m times to
radially expand and plastically deform m portions of the first
expandable tubular member within the borehole; means for
positioning the adjustable expansion device within a second
expandable tubular member; means for supporting the second
expandable tubular member and the adjustable expansion device
within the borehole in overlapping relation to the first expandable
tubular member; means for lowering the adjustable expansion device
out of the second expandable tubular member; means for increasing
the outside dimension of the adjustable expansion device; and means
for displacing the adjustable expansion device upwardly relative to
the second expandable tubular member n times to radially expand and
plastically deform n portions of the second expandable tubular
member within the borehole.
[0031] According to another aspect of the present invention, a
system for radially expanding and plastically deforming an
expandable tubular member within a borehole is provided that
includes means for positioning an adjustable expansion device
within the expandable tubular member; means for supporting the
expandable tubular member and the adjustable expansion device
within the borehole; means for lowering the adjustable expansion
device out of the expandable tubular member; means for increasing
the outside dimension of the adjustable expansion device; means for
displacing the adjustable expansion mandrel upwardly relative to
the expandable tubular member n times to radially expand and
plastically deform n portions of the expandable tubular member
within the borehole; and means for pressurizing an interior region
of the expandable tubular member above the adjustable expansion
device during the radial expansion and plastic deformation of the
expandable tubular member within the borehole.
[0032] According to another aspect of the present invention, a
system for forming a mono diameter wellbore casing is provided that
includes means for positioning an adjustable expansion device
within a first expandable tubular member; means for supporting the
first expandable tubular member and the adjustable expansion device
within a borehole; means for lowering the adjustable expansion
device out of the first expandable tubular member; means for
increasing the outside dimension of the adjustable expansion
device; means for displacing the adjustable expansion device
upwardly relative to the first expandable tubular member m times to
radially expand and plastically deform m portions of the first
expandable tubular member within the borehole; means for
pressurizing an interior region of the first expandable tubular
member above the adjustable expansion device during the radial
expansion and plastic deformation of the first expandable tubular
member within the borehole; means for positioning the adjustable
expansion mandrel within a second expandable tubular member; means
for supporting the second expandable tubular member and the
adjustable expansion mandrel within the borehole in overlapping
relation to the first expandable tubular member; means for lowering
the adjustable expansion mandrel out of the second expandable
tubular member; means for increasing the outside dimension of the
adjustable expansion mandrel; means for displacing the adjustable
expansion mandrel upwardly relative to the second expandable
tubular member n times to radially expand and plastically deform n
portions of the second expandable tubular member within the
borehole; and means for pressurizing an interior region of the
second expandable tubular member above the adjustable expansion
mandrel during the radial expansion and plastic deformation of the
second expandable tubular member within the borehole.
[0033] According to another aspect of the present invention, a
system for radially expanding and plastically deforming an
expandable tubular member within a borehole is provided that
includes means for positioning first and second adjustable
expansion devices within the expandable tubular member; means for
supporting the expandable tubular member and the first and second
adjustable expansion devices within the borehole; means for
lowering the first adjustable expansion device out of the
expandable tubular member; means for increasing the outside
dimension of the first adjustable expansion device; means for
displacing the first adjustable expansion device upwardly relative
to the expandable tubular member to radially expand and plastically
deform a lower portion of the expandable tubular member; means for
displacing the first adjustable expansion device and the second
adjustable expansion device downwardly relative to the expandable
tubular member; means for decreasing the outside dimension of the
first adjustable expansion device and increasing the outside
dimension of the second adjustable expansion device; means for
displacing the second adjustable expansion device upwardly relative
to the expandable tubular member to radially expand and plastically
deform portions of the expandable tubular member above the lower
portion of the expandable tubular member; wherein the outside
dimension of the first adjustable expansion device is greater than
the outside dimension of the second adjustable expansion
device.
[0034] According to another aspect of the present invention, a
system for forming a mono diameter wellbore casing is provided that
includes means for positioning first and second adjustable
expansion devices within a first expandable tubular member; means
for supporting the first expandable tubular member and the first
and second adjustable expansion devices within a borehole; means
for lowering the first adjustable expansion device out of the first
expandable tubular member; means for increasing the outside
dimension of the first adjustable expansion device; displacing the
first adjustable expansion device upwardly relative to the first
expandable tubular member to radially expand and plastically deform
a lower portion of the first expandable tubular member; means for
displacing the first adjustable expansion device and the second
adjustable expansion device downwardly relative to the first
expandable tubular member; means for decreasing the outside
dimension of the first adjustable expansion device and increasing
the outside dimension of the second adjustable expansion device;
means for displacing the second adjustable expansion device
upwardly relative to the first expandable tubular member to
radially expand and plastically deform portions of the first
expandable tubular member above the lower portion of the expandable
tubular member; means for positioning first and second adjustable
expansion devices within a second expandable tubular member; means
for supporting the first expandable tubular member and the first
and second adjustable expansion devices within the borehole in
overlapping relation to the first expandable tubular member; means
for lowering the first adjustable expansion device out of the
second expandable tubular member; means for increasing the outside
dimension of the first adjustable expansion device; means for
displacing the adjustable expansion device upwardly relative to the
second expandable tubular member to radially expand and plastically
deform a lower portion of the second expandable tubular member;
means for displacing the first adjustable expansion device and the
second adjustable expansion device downwardly relative to the
second expandable tubular member; means for decreasing the outside
dimension of the first adjustable expansion device and increasing
the outside dimension of the second adjustable expansion device;
and means for displacing the second adjustable expansion device
upwardly relative to the second expandable tubular member to
radially expand and plastically deform portions of the second
expandable tubular member above the lower portion of the second
expandable tubular member; wherein the outside dimension of the
first adjustable expansion device is greater than the outside
dimension of the second adjustable expansion device.
[0035] According to another aspect of the present invention, a
system for radially expanding and plastically deforming an
expandable tubular member within a borehole is provided that
includes means for positioning first and second adjustable
expansion devices within the expandable tubular member; means for
supporting the expandable tubular member and the first and second
adjustable expansion devices within the borehole; means for
lowering the first adjustable expansion device out of the
expandable tubular member; means for increasing the outside
dimension of the first adjustable expansion device; means for
displacing the first adjustable expansion device upwardly relative
to the expandable tubular member to radially expand and plastically
deform a lower portion of the expandable tubular member; means for
pressurizing an interior region of the expandable tubular member
above the first adjustable expansion device during the radial
expansion of the lower portion of the expandable tubular member by
the first adjustable expansion device; means for displacing the
first adjustable expansion device and the second adjustable
expansion device downwardly relative to the expandable tubular
member; means for decreasing the outside dimension of the first
adjustable expansion device and increasing the outside dimension of
the second adjustable expansion device; means for displacing the
second adjustable expansion device upwardly relative to the
expandable tubular member to radially expand and plastically deform
portions of the expandable tubular member above the lower portion
of the expandable tubular member; and means for pressurizing an
interior region of the expandable tubular member above the second
adjustable expansion device during the radial expansion of the
portions of the expandable tubular member above the lower portion
of the expandable tubular member by the second adjustable expansion
device; wherein the outside dimension of the first adjustable
expansion device is greater than the outside dimension of the
second adjustable expansion device.
[0036] According to another aspect of the present invention, a
system for forming a mono diameter wellbore casing is provided that
includes means for positioning first and second adjustable
expansion devices within a first expandable tubular member; means
for supporting the first expandable tubular member and the first
and second adjustable expansion devices within a borehole; means
for lowering the first adjustable expansion device out of the first
expandable tubular member; means for increasing the outside
dimension of the first adjustable expansion device; means for
displacing the first adjustable expansion device upwardly relative
to the first expandable tubular member to radially expand and
plastically deform a lower portion of the first expandable tubular
member; means for pressurizing an interior region of the first
expandable tubular member above the first adjustable expansion
device during the radial expansion of the lower portion of the
first expandable tubular member by the first adjustable expansion
device; means for displacing the first adjustable expansion device
and the second adjustable expansion device downwardly relative to
the first expandable tubular member; means for decreasing the
outside dimension of the first adjustable expansion device and
increasing the outside dimension of the second adjustable expansion
device; means for displacing the second adjustable expansion device
upwardly relative to the first expandable tubular member to
radially expand and plastically deform portions of the first
expandable tubular member above the lower portion of the expandable
tubular member; means for pressurizing an interior region of the
first expandable tubular member above the second adjustable
expansion device during the radial expansion of the portions of the
first expandable tubular member above the lower portion of the
first expandable tubular member by the second adjustable expansion
device; means for positioning first and second adjustable expansion
devices within a second expandable tubular member; means for
supporting the first expandable tubular member and the first and
second adjustable expansion devices within the borehole in
overlapping relation to the first expandable tubular member; means
for lowering the first adjustable expansion device out of the
second expandable tubular member; means for increasing the outside
dimension of the first adjustable expansion device; means for
displacing the first adjustable expansion device upwardly relative
to the second expandable tubular member to radially expand and
plastically deform a lower portion of the second expandable tubular
member; means for pressurizing an interior region of the second
expandable tubular member above the first adjustable expansion
device during the radial expansion of the lower portion of the
second expandable tubular member by the first adjustable expansion
device; means for displacing the first adjustable expansion device
and the second adjustable expansion device downwardly relative to
the second expandable tubular member; means for decreasing the
outside dimension of the first adjustable expansion device and
increasing the outside dimension of the second adjustable expansion
device; means for displacing the second adjustable expansion device
upwardly relative to the second expandable tubular member to
radially expand and plastically deform portions of the second
expandable tubular member above the lower portion of the second
expandable tubular member; and means for pressurizing an interior
region of the second expandable tubular member above the second
adjustable expansion device during the radial expansion of the
portions of the second expandable tubular member above the lower
portion of the second expandable tubular member by the second
adjustable expansion device; wherein the outside dimension of the
first adjustable expansion device is greater than the outside
dimension of the second adjustable expansion device.
[0037] According to another aspect of the present invention, a
system for radially expanding and plastically deforming an
expandable tubular member within a borehole is provided that
includes means for supporting the expandable tubular member, an
hydraulic actuator, and an adjustable expansion device within the
borehole; means for increasing the size of the adjustable expansion
device; and means for displacing the adjustable expansion device
upwardly relative to the expandable tubular member using the
hydraulic actuator to radially expand and plastically deform a
portion of the expandable tubular member.
[0038] According to another aspect of the present invention, a
system for forming a mono diameter wellbore casing within a
borehole that includes a preexisting wellbore casing is provided
that includes means for supporting the expandable tubular member,
an hydraulic actuator, and an adjustable expansion device within
the borehole; means for increasing the size of the adjustable
expansion device; means for displacing the adjustable expansion
device upwardly relative to the expandable tubular member using the
hydraulic actuator to radially expand and plastically deform a
portion of the expandable tubular member; and means for displacing
the adjustable expansion device upwardly relative to the expandable
tubular member to radially expand and plastically deform the
remaining portion of the expandable tubular member and a portion of
the preexisting wellbore casing that overlaps with an end of the
remaining portion of the expandable tubular member.
[0039] According to another aspect of the present invention, a
system for radially expanding and plastically deforming a tubular
member is provided that includes means for positioning the tubular
member within a preexisting structure; means for radially expanding
and plastically deforming a lower portion of the tubular member to
form a bell section; and means for radially expanding and
plastically deforming a portion of the tubular member above the
bell section.
[0040] According to another aspect of the present invention, a
system of radially expanding and plastically deforming a tubular
member is provided that includes a support member; and means for
applying internal pressure to the inside surface of the tubular
member at a plurality of discrete location separated from one
another coupled to the support member.
[0041] According to another aspect of the present invention, a
method of cutting a tubular member is provided that includes
positioning a plurality of cutting elements within the tubular
member; and bringing the cutting elements into engagement with the
tubular member.
[0042] According to another aspect of the present invention, a
method of gripping a tubular member is provided that includes
positioning a plurality of gripping elements within the tubular
member; bringing the gripping elements into engagement with the
tubular member. In an exemplary embodiment, bringing the gripping
elements into engagement with the tubular member includes
displacing the gripping elements in an axial direction; and
displacing the gripping elements in a radial direction.
[0043] According to another aspect of the present invention, a
method of operating an actuator is provided that includes
pressurizing a plurality of pressure chamber.
[0044] According to another aspect of the present invention, a
method of injecting a hardenable fluidic sealing material into an
annulus between a tubular member and a preexisting structure is
provided that includes positioning the tubular member into the
preexisting structure; sealing off an end of the tubular member;
operating a valve within the end of the tubular member; and
injecting a hardenable fluidic sealing material through the valve
into the annulus between the tubular member and the preexisting
structure.
[0045] According to another aspect of the present invention, a
system for cutting a tubular member is provided that includes means
for positioning a plurality of cutting elements within the tubular
member; and means for bringing the cutting elements into engagement
with the tubular member.
[0046] According to another aspect of the present invention, a
system for gripping a tubular member is provided that includes
means for positioning a plurality of gripping elements within the
tubular member; and means for bringing the gripping elements into
engagement with the tubular member.
[0047] According to another aspect of the present invention, an
actuator system is provided that includes a support member; and
means for pressurizing a plurality of pressure chambers coupled to
the support member. In an exemplary embodiment, the system further
includes means for transmitting torsional loads.
[0048] According to another aspect of the present invention, a
system for injecting a hardenable fluidic sealing material into an
annulus between a tubular member and a preexisting structure is
provided that includes means for positioning the tubular member
into the preexisting structure; means for sealing off an end of the
tubular member; means for operating a valve within the end of the
tubular member; and means for injecting a hardenable fluidic
sealing material through the valve into the annulus between the
tubular member and the preexisting structure.
[0049] According to another aspect of the present invention, a
method of engaging a tubular member is provided that includes
positioning a plurality of elements within the tubular member; and
bringing the elements into engagement with the tubular member.
[0050] According to another aspect of the present invention, a
system for engaging a tubular member is provided that includes
means for positioning a plurality of elements within the tubular
member; and means for bringing the elements into engagement with
the tubular member. In an exemplary embodiment, the elements
include a first group of elements; and a second group of elements;
wherein the first group of elements are interleaved with the second
group of elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] FIG. 1 is a fragmentary cross-sectional illustration of an
embodiment of a system for radially expanding and plastically
deforming wellbore casing, including a tubular support member, a
casing cutter, a ball gripper for gripping a wellbore casing, a
force multiplier tension actuator, a safety sub, a cup sub, a
casing lock, an extension actuator, a bell section adjustable
expansion cone assembly, a casing section adjustable expansion cone
assembly, a packer setting tool, a packer, a stinger, and an
expandable wellbore casing, during the placement of the system
within a wellbore.
[0052] FIG. 2 is a fragmentary cross-sectional illustration of the
system of FIG. 1 during the subsequent displacement of the bell
section adjustable expansion cone assembly, the casing section
adjustable expansion cone assembly, the packer setting tool, the
packer, and the stinger downwardly out of the end of the expandable
wellbore casing and the expansion of the size of the bell section
adjustable expansion cone assembly and the casing section
adjustable expansion cone assembly.
[0053] FIG. 3 is a fragmentary cross-sectional illustration of the
system of FIG. 2 during the subsequent operation of the tension
actuator to displace the bell section adjustable expansion cone
assembly upwardly into the end of the expandable wellbore casing to
form a bell section in the end of the expandable wellbore
casing.
[0054] FIG. 4 is a fragmentary cross-sectional illustration of the
system of FIG. 3 during the subsequent reduction of the bell
section adjustable expansion cone assembly.
[0055] FIG. 5 is a fragmentary cross-sectional illustration of the
system of FIG. 4 during the subsequent upward displacement of the
expanded casing section adjustable expansion cone assembly to
radially expand the expandable wellbore casing.
[0056] FIG. 6 is a fragmentary cross-sectional illustration of the
system of FIG. 5 during the subsequent lowering of the tubular
support member, casing cutter, ball gripper, a force multiplier
tension actuator, safety sub, cup sub, casing lock, extension
actuator, bell section adjustable expansion cone assembly, casing
section adjustable expansion cone assembly, packer setting tool,
packer, and stinger and subsequent setting of the packer within the
expandable wellbore casing above the bell section.
[0057] FIG. 7 is a fragmentary cross-sectional illustration of the
system of FIG. 6 during the subsequent injection of fluidic
materials into the system to displace the expanded casing section
adjustable expansion cone assembly upwardly through the expandable
wellbore casing to radially expand and plastically deform the
expandable wellbore casing.
[0058] FIG. 8 is a fragmentary cross-sectional illustration of the
system of FIG. 7 during the subsequent injection of fluidic
materials into the system to displace the expanded casing section
adjustable expansion cone assembly upwardly through the expandable
wellbore casing and a surrounding preexisting wellbore casing to
radially expand and plastically deform the overlapping expandable
wellbore casing and the surrounding preexisting wellbore
casing.
[0059] FIG. 9 is a fragmentary cross-sectional illustration of the
system of FIG. 8 during the subsequent operation of the casing
cutter to cut off an end of the expandable wellbore casing.
[0060] FIG. 10 is a fragmentary cross-sectional illustration of the
system of FIG. 9 during the subsequent removal of the cut off end
of the expandable wellbore casing.
[0061] FIGS. 11-1 and 11-2, 11A to 11A2, 11B1 to 11B2, 11C, 11D,
11E, 11F, 11G, 11H, 11I, 11j, 11K, 11L, 11M, 11N, 11O, 11P, 11Q,
11R, 11S, 11T, 11U, 11V, 11W, 11X, 11Y, 11Z1 to 11Z4, 11AA1 to
11AA4, 11AB1 to 11AB4, 11AC1 to 11AC4, 11AD, and 11AE are
fragmentary cross-sectional and perspective illustrations of an
exemplary embodiment of a casing cutter assembly.
[0062] FIGS. 12A1 to 12A4 and 12C1 to 12C4 are fragmentary
cross-sectional illustrations of an exemplary embodiment of a ball
gripper assembly.
[0063] FIG. 12B is a top view of a portion of the ball gripper
assembly of FIGS. 12A1 to 12A4 and 12C1 to 12C4.
[0064] FIGS. 13A1 to 13A8 and 13B1 to 13B7 are fragmentary
cross-sectional illustrations of an exemplary embodiment of a
tension actuator assembly.
[0065] FIG. 14A is a fragmentary cross-sectional illustrations of
an exemplary embodiment of a safety sub assembly.
[0066] FIGS. 14A, 14B and 14C are fragmentary cross-sectional and
perspective illustrations of an exemplary embodiment of a cup seal
assembly.
[0067] FIGS. 15-1 and 15-2, 15A1 to 15A2, 15B to 15B2, 15C, 15D,
15E, 15F, 15G, 15H, 15I, 15j, 15K, 15L, 15M, 15N, 15O, 15P, 15R,
15S, 15T, 15U, 15V, 15W, 15X, 15Y, 15Z1 to 15Z4, 15AA1 to 15AA4,
15AB1 to 15AB4, 15AC1 to 15AC4, 15AD, and 15AE are fragmentary
cross-sectional and perspective illustrations of an exemplary
embodiment of an adjustable bell section expansion cone
assembly.
[0068] FIGS. 16-1 and 16-2, 16A1 to 16A2, 16B1 to 16B2, 16C, 16D,
16E, 16F, 16G, 16H, 16I, 16j, 16K, 16L, 16M, 16N, 16O, 16P, 16R,
16S, 16T, 16U, 16V, 16W, 16X, 16Y, 16Z1-16Z4, 16AA1 to 16AA4, 16AB1
to 16AB4, 16AC1 to 16AC4, 16AD, and 16AE are fragmentary
cross-sectional and perspective illustrations of an exemplary
embodiment of an adjustable casing expansion cone assembly.
[0069] FIGS. 17A to 17C is a fragmentary cross-sectional
illustration of an exemplary embodiment of a packer setting tool
assembly.
[0070] FIGS. 18-1 to 18-5 is a fragmentary cross-sectional
illustration of an exemplary embodiment of a packer assembly.
[0071] FIGS. 19A1 to 19A5, 19B1 to 19B5, 19C1 to 19C5, 19D1 to
19D5, 19E1 to 19E6, 19F1 to 19F6, 19G1 to 19G6, and 19H1 to 19H5,
are fragmentary cross-sectional illustrations of an exemplary
embodiment of the operation of the packer setting tool and the
packer assembly of FIGS. 17A to 17C and 18-1 to 18-5.
[0072] FIGS. 20 and 20A to 20AX are fragmentary perspective and
cross-sectional illustrations of an alternative embodiment of the
packer assembly.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0073] Referring initially to FIGS. 1-10, an exemplary embodiment
of a system 10 for radially expanding and plastically deforming a
wellbore casing includes a conventional tubular support 12 having
an end that is coupled to an end of a casing cutter assembly 14. In
an exemplary embodiment, the casing cutter assembly 14 may be, or
may include elements, of one or more conventional commercially
available casing cutters for cutting wellbore casing, or
equivalents thereof.
[0074] An end of a ball gripper assembly 16 is coupled to another
end of the casing cutter assembly 14. In an exemplary embodiment,
the ball gripper assembly 14 may be, or may include elements, of
one or more conventional commercially available ball grippers, or
other types of gripping devices, for gripping wellbore casing, or
equivalents thereof.
[0075] An end of a tension actuator assembly 18 is coupled to
another end of the ball gripper assembly 16. In an exemplary
embodiment, the tension actuator assembly 18 may be, or may include
elements, of one or more conventional commercially actuators, or
equivalents thereof.
[0076] An end of a safety sub assembly 20 is coupled to another end
of the tension actuator assembly 18. In an exemplary embodiment,
the safety sub assembly 20 may be, or may include elements, of one
or more conventional apparatus that provide quick connection and/or
disconnection of tubular members, or equivalents thereof.
[0077] An end of a sealing cup assembly 22 is coupled to another
end of the safety sub assembly 20. In an exemplary embodiment, the
sealing cup assembly 22 may be, or may include elements, of one or
more conventional sealing cup assemblies, or other types of sealing
assemblies, that sealingly engage the interior surfaces of
surrounding tubular members, or equivalents thereof.
[0078] An end of a casing lock assembly 24 is coupled to another
end of the sealing cup assembly 22. In an exemplary embodiment, the
casing lock assembly 24 may be, or may include elements, of one or
more conventional casing lock assemblies that lock the position of
wellbore casing, or equivalents thereof.
[0079] An end of an extension actuator assembly 26 is coupled to
another end of the casing lock assembly 24. In an exemplary
embodiment, the extension actuator assembly 26 may be, or may
include elements, of one or more conventional actuators, or
equivalents thereof.
[0080] An end of an adjustable bell section expansion cone assembly
28 is coupled to another end of the extension actuator assembly 26.
In an exemplary embodiment, the adjustable bell section expansion
cone assembly 28 may be, or may include elements, of one or more
conventional adjustable expansion devices for radially expanding
and plastically deforming wellbore casing, or equivalents
thereof.
[0081] An end of an adjustable casing expansion cone assembly 30 is
coupled to another end of the adjustable bell section expansion
cone assembly 28. In an exemplary embodiment, the adjustable casing
expansion cone assembly 30 may be, or may include elements, of one
or more conventional adjustable expansion devices for radially
expanding and plastically deforming wellbore casing, or equivalents
thereof.
[0082] An end of a packer setting tool assembly 32 is coupled to
another end of the adjustable casing expansion cone assembly 30. In
an exemplary embodiment, the packer setting tool assembly 32 may
be, or may include elements, of one or more conventional adjustable
expansion devices for controlling the operation of a conventional
packer, or equivalents thereof.
[0083] An end of a stinger assembly 34 is coupled to another end of
the packer setting tool assembly 32. In an exemplary embodiment,
the stinger assembly 34 may be, or may include elements, of one or
more conventional devices for engaging a conventional packer, or
equivalents thereof.
[0084] An end of a packer assembly 36 is coupled to another end of
the stinger assembly 34. In an exemplary embodiment, the packer
assembly 36 may be, or may include elements, of one or more
conventional packers.
[0085] As illustrated in FIG. 1, in an exemplary embodiment, during
operation of the system 10, an expandable wellbore casing 100 is
coupled to and supported by the casing lock assembly 24 of the
system. The system 10 is then positioned within a wellbore 102 that
traverses a subterranean formation 104 and includes a preexisting
wellbore casing 106.
[0086] As illustrated in FIG. 2, in an exemplary embodiment, the
extension actuator assembly 26 is then operated to move the
adjustable bell section expansion cone assembly 28, adjustable
casing expansion cone assembly 30, packer setting tool assembly 32,
stinger assembly 34, packer assembly 36 downwardly in a direction
108 and out of an end of the expandable wellbore casing 100. After
the adjustable bell section expansion cone assembly 28 and
adjustable casing expansion cone assembly 30 have been moved to a
position out of the end of the expandable wellbore casing 100, the
adjustable bell section expansion cone assembly and adjustable
casing expansion cone assembly are then operated to increase the
outside diameters of the expansion cone assemblies. In an exemplary
embodiment, the increased outside diameter of the adjustable bell
section expansion cone assembly 28 is greater than the increased
outside diameter of the adjustable casing expansion cone assembly
30.
[0087] As illustrated in FIG. 3, in an exemplary embodiment, the
ball gripper assembly 16 is then operated to engage and hold the
position of the expandable tubular member 100 stationary relative
to the tubular support member 12. The tension actuator assembly 18
is then operated to move the adjustable bell section expansion cone
assembly 28, adjustable casing expansion cone assembly 30, packer
setting tool assembly 32, stinger assembly 34, packer assembly 36
upwardly in a direction 110 into and through the end of the
expandable wellbore casing 100. As a result, the end of the
expandable wellbore casing 100 is radially expanded and plastically
deformed by the adjustable bell section expansion cone assembly 28
to form a bell section 112. In an exemplary embodiment, during the
operation of the system 10 described above with reference to FIG.
3, the casing lock assembly 24 may or may not be coupled to the
expandable wellbore casing 100.
[0088] In an exemplary embodiment, the length of the end of the
expandable wellbore casing 100 that is radially expanded and
plastically deformed by the adjustable bell section expansion cone
assembly 28 is limited by the stroke length of the tension actuator
assembly 18. In an exemplary embodiment, once the tension actuator
assembly 18 completes a stroke, the ball gripper assembly 16 is
operated to release the expandable tubular member 100, and the
tubular support 12 is moved upwardly to permit the tension actuator
assembly to be re-set. In this manner, the length of the bell
section 112 can be further extended by continuing to stroke and
then re-set the position of the tension actuator assembly 18. Note,
that, during the upward movement of the tubular support 12 to
re-set the position of the tension actuator assembly 18, the
expandable tubular wellbore casing 100 is supported by the
expansion surfaces of the adjustable bell section expansion cone
assembly 28.
[0089] As illustrated in FIG. 4, in an exemplary embodiment, the
casing lock assembly 24 is then operated to engage and maintain the
position of the expandable wellbore casing 100 stationary relative
to the tubular support 12. The adjustable bell section expansion
cone assembly 28, adjustable casing expansion cone assembly 30,
packer setting tool assembly 32, stinger assembly 34, and packer
assembly 36 are displaced downwardly into the bell section 112 in a
direction 114 relative to the expandable wellbore casing 100 by
operating the extension actuator 26 and/or by displacing the system
10 downwardly in the direction 114 relative to the expandable
wellbore casing. After the adjustable bell section expansion cone
assembly 28 and adjustable casing expansion cone assembly 30 have
been moved downwardly in the direction 114 into the bell section
112 of the expandable wellbore casing 100, the adjustable bell
section expansion cone assembly is then operated to decrease the
outside diameter of the adjustable bell section expansion cone
assembly. In an exemplary embodiment, the decreased outside
diameter of the adjustable bell section expansion cone assembly 28
is less than the increased outside diameter of the adjustable
casing expansion cone assembly 30. In an exemplary embodiment,
during the operation of the system illustrated and described above
with reference to FIG. 4, the ball gripper 16 may or may not be
operated to engage the expandable wellbore casing 100.
[0090] As illustrated in FIG. 5, in an exemplary embodiment, the
casing lock assembly 24 is then disengaged from the expandable
wellbore casing 100 and fluidic material 116 is then injected into
the system 10 through the tubular support 12 to thereby pressurize
an annulus 118 defined within the expandable wellbore casing below
the cup sub assembly 22. As a result, a pressure differential is
created across the cup seal assembly 22 that causes the cup seal
assembly to apply a tensile force in the direction 120 to the
system 10. As a result, the system 10 is displaced upwardly in the
direction 120 relative to the expandable wellbore casing 100
thereby pulling the adjustable casing expansion cone assembly 30
upwardly in the direction 120 through the expandable wellbore
casing thereby radially expanding and plastically deforming the
expandable wellbore casing.
[0091] In an exemplary embodiment, the tension actuator assembly 16
may also be operated during the injection of the fluidic material
116 to displace the adjustable casing expansion cone assembly 30
upwardly relative to the tubular support 12. As a result,
additional expansion forces may be applied to the expandable
wellbore casing 100.
[0092] As illustrated in FIG. 6, in an exemplary embodiment, the
radial expansion and plastic deformation of the expandable wellbore
casing using the adjustable casing expansion cone assembly 30
continues until the packer assembly 36 is positioned within a
portion of the expandable tubular member above the bell section
112. The packer assembly 36 may then be operated to engage the
interior surface of the expandable wellbore casing 100 above the
bell section 112.
[0093] In an exemplary embodiment, after the packer assembly 36 is
operated to engage the interior surface of the expandable wellbore
casing 100 above the bell section 112, a hardenable fluidic sealing
material 122 may then be injected into the system 10 through the
tubular support 12 and then out of the system through the packer
assembly to thereby permit the annulus between the expandable
wellbore casing and the wellbore 102 to be filled with the
hardenable fluidic sealing material. The hardenable fluidic sealing
material 122 may then be allowed to cure to form a fluid tight
annulus between the expandable wellbore casing 100 and the wellbore
102, before, during, or after the completion of the radial
expansion and plastic deformation of the expandable wellbore
casing.
[0094] As illustrated in FIG. 7, in an exemplary embodiment, the
fluidic material 116 is then re-injected into the system 10 through
the tubular support 12 to thereby re-pressurize the annulus 118
defined within the expandable wellbore casing below the cup sub
assembly 22. As a result, a pressure differential is once again
created across the cup seal assembly 22 that causes the cup seal
assembly to once again apply a tensile force in the direction 120
to the system 10. As a result, the system 10 is displaced upwardly
in the direction 120 relative to the expandable wellbore casing 100
thereby pulling the adjustable casing expansion cone assembly 30
upwardly in the direction 120 through the expandable wellbore
casing thereby radially expanding and plastically deforming the
expandable wellbore casing and disengaging the stinger assembly 34
from the packer assembly 36. In an exemplary embodiment, during
this operational mode, the packer assembly 36 prevents the flow of
fluidic materials out of the expandable wellbore casing 100. As a
result, the pressurization of the annulus 118 is rapid and
efficient thereby enhancing the operational efficiency of the
subsequent radial expansion and plastic deformation of the
expandable wellbore casing 100.
[0095] In an exemplary embodiment, the tension actuator assembly 16
may also be operated during the re-injection of the fluidic
material 116 to displace the adjustable casing expansion cone
assembly 30 upwardly relative to the tubular support 12. As a
result, additional expansion forces may be applied to the
expandable wellbore casing 100.
[0096] As illustrated in FIG. 8, in an exemplary embodiment, the
radial expansion and plastic deformation of the expandable wellbore
casing using the adjustable casing expansion cone assembly 30
continues until the adjustable casing expansion cone assembly 30
reaches the portion 124 of the expandable wellbore casing 100 that
overlaps with the preexisting wellbore casing 106. At which point,
the system 10 may radially expand the portion 124 of the expandable
wellbore casing 100 that overlaps with the preexisting wellbore
casing 106 and the surrounding portion of the preexisting wellbore
casing. Consequently, in an exemplary embodiment, during the radial
expansion of the portion 124 of the expandable wellbore casing 100
that overlaps with the preexisting wellbore casing 106, the tension
actuator assembly 16 is also operated to displace the adjustable
casing expansion cone assembly 30 upwardly relative to the tubular
support 12. As a result, additional expansion forces may be applied
to the expandable wellbore casing 100 and the preexisting wellbore
casing 106 during the radial expansion of the portion 124 of the
expandable wellbore casing that overlaps with the preexisting
wellbore casing.
[0097] As illustrated in FIG. 9, in an exemplary embodiment, the
entire length of the portion 124 of the expandable wellbore casing
100 that overlaps with the preexisting wellbore casing 106 is not
radially expanded and plastically deformed. Rather, only part of
the portion 124 of the expandable wellbore casing 100 that overlaps
with the preexisting wellbore casing 106 is radially expanded and
plastically deformed. The remaining part of the portion 124 of the
expandable wellbore casing 100 that overlaps with the preexisting
wellbore casing 106 is then cut away by operating the casing cutter
assembly 14.
[0098] As illustrated in FIG. 10, the remaining part of the portion
124 of the expandable wellbore casing 100 that overlaps with the
preexisting wellbore casing 106 that is cut away by operating the
casing cutter assembly 14 is then also carried out of the wellbore
102 using the casing cutter assembly.
[0099] Furthermore, in an exemplary embodiment, the inside diameter
of the expandable wellbore casing 100 above the bell section 112 is
equal to the inside diameter of the portion of the preexisting
wellbore casing 106 that does not overlap with the expandable
wellbore casing 100. As a result, a wellbore casing is constructed
that includes overlapping wellbore casings that together define an
internal passage having a constant cross-sectional area.
[0100] In several exemplary embodiments, the system 10 includes one
or more of the methods and apparatus disclosed in one or more of
the following: (1) U.S. Pat. No. 6,497,289, which was filed as U.S.
patent application Ser. No. 09/454,139, attorney docket no.
25791.03.02, filed on Dec. 3, 1999, which claims priority from
provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S.
patent application Ser. No. 09/510,913, attorney docket no.
25791.7.02, filed on Feb. 23, 2000, which claims priority from
provisional application 60/121,702, filed on Feb. 25, 1999, (3)
U.S. patent application Ser. No. 09/502,350, attorney docket no.
25791.8.02, filed on Feb. 10, 2000, which claims priority from
provisional application 60/119,611, filed on Feb. 11, 1999, (4)
U.S. Pat. No. 6,328,113, which was filed as U.S. patent application
Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on
Nov. 15, 1999, which claims priority from provisional application
60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application
Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul.
1, 2002, which claims priority from provisional application
60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application
Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar.
10, 2000, which claims priority from provisional application
60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471,
which was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent
application Ser. No. 09/511,941, attorney docket no. 25791.16.02,
filed on Feb. 24, 2000, which claims priority from provisional
application 60/121,907, filed on Feb. 26, 1999, (9) U.S. Pat. No.
6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (10) U.S. patent application Ser. No.
09/981,916, attorney docket no. 25791.18, filed on Oct. 18, 2001 as
a continuation-in-part application of U.S. Pat. No. 6,328,113,
which was filed as U.S. patent application Ser. No. 09/440,338,
attorney docket number 25791.9.02, filed on Nov. 15, 1999, which
claims priority from provisional application 60/108,558, filed on
Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed as
application Ser. No. 09/559,122, attorney docket no. 25791.23.02,
filed on Apr. 26, 2000, which claims priority from provisional
application 60/131,106, filed on Apr. 26, 1999, (12) U.S. patent
application Ser. No. 10/030,593, attorney docket no. 25791.25.08,
filed on Jan. 8, 2002, which claims priority from provisional
application 60/146,203, filed on Jul. 29, 1999, (13) U.S.
provisional patent application Ser. No. 60/143,039, attorney docket
no. 25791.26, filed on Jul. 9, 1999, (14) U.S. patent application
Ser. No. 10/111,982, attorney docket no. 25791.27.08, filed on Apr.
30, 2002, which claims priority from provisional patent application
Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1,
1999, (15) U.S. provisional patent application Ser. No. 60/154,047,
attorney docket no. 25791.29, filed on Sep. 16, 1999, (16) U.S.
provisional patent application Ser. No. 60/438,828, attorney docket
no. 25791.31, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875,
which was filed as application Ser. No. 09/679,907, attorney docket
no. 25791.34.02, on Oct. 5, 2000, which claims priority from
provisional patent application Ser. No. 60/159,082, attorney docket
no. 25791.34, filed on Oct. 12, 1999, (18) U.S. patent application
Ser. No. 10/089,419, filed on Mar. 27, 2002, attorney docket no.
25791.36.03, which claims priority from provisional patent
application Ser. No. 60/159,039, attorney docket no. 25791.36,
filed on Oct. 12, 1999, (19) U.S. patent application Ser. No.
09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02,
which claims priority from provisional patent application Ser. No.
60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999,
(20) U.S. patent application Ser. No. 10/303,992, filed on Nov. 22,
2002, attorney docket no. 25791.38.07, which claims priority from
provisional patent application Ser. No. 60/212,359, attorney docket
no. 25791.38, filed on Jun. 19, 2000, (21) U.S. provisional patent
application Ser. No. 60/165,228, attorney docket no. 25791.39,
filed on Nov. 12, 1999, (22) U.S. provisional patent application
Ser. No. 60/455,051, attorney docket no. 25791.40, filed on Mar.
14, 2003, (23) PCT application US02/2477, filed on Jun. 26, 2002,
attorney docket no. 25791.44.02, which claims priority from U.S.
provisional patent application Ser. No. 60/303,711, attorney docket
no. 25791.44, filed on Jul. 6, 2001, (24) U.S. patent application
Ser. No. 10/311,412, filed on Dec. 12, 2002, attorney docket no.
25791.45.07, which claims priority from provisional patent
application Ser. No. 60/221,443, attorney docket no. 25791.45,
filed on Jul. 28, 2000, (25) U.S. patent application Ser. No.
10/______, filed on Dec. 18, 2002, attorney docket no. 25791.46.07,
which claims priority from provisional patent application Ser. No.
60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000,
(26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22,
2003, attorney docket no. 25791.47.03, which claims priority from
provisional patent application Ser. No. 60/233,638, attorney docket
no. 25791.47, filed on Sep. 18, 2000, (27) U.S. patent application
Ser. No. 10/406,648, filed on Mar. 31, 2003, attorney docket no.
25791.48.06, which claims priority from provisional patent
application Ser. No. 60/237,334, attorney docket no. 25791.48,
filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on
Feb. 14, 2002, attorney docket no. 25791.50.02, which claims
priority from U.S. provisional patent application Ser. No.
60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001,
(29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13,
2003, attorney docket no. 25791.51.06, which claims priority from
provisional patent application Ser. No. 60/262,434, attorney docket
no. 25791.51, filed on Jan. 17, 2001, (30) U.S. patent application
Ser. No. 10/465,831, filed on Jun. 13, 2003, attorney docket no.
25791.52.06, which claims priority from U.S. provisional patent
application Ser. No. 60/259,486, attorney docket no. 25791.52,
filed on Jan. 3, 2001, (31) U.S. provisional patent application
Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney docket no.
25791.53, (32) U.S. Pat. No. 6,470,966, which was filed as patent
application Ser. No. 09/850,093, filed on May 7, 2001, attorney
docket no. 25791.55, as a divisional application of U.S. Pat. No.
6,497,289, which was filed as U.S. patent application Ser. No.
09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,
which claims priority from provisional application 60/111,293,
filed on Dec. 7, 1998, (33) U.S. Pat. No. 6,561,227, which was
filed as patent application Ser. No. 09/852,026, filed on May 9,
2001, attorney docket no. 25791.56, as a divisional application of
U.S. Pat. No. 6,497,289, which was filed as U.S. patent application
Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec.
3, 1999, which claims priority from provisional application
60/111,293, filed on Dec. 7, 1998, (34) U.S. patent application
Ser. No. 09/852,027, filed on May 9, 2001, attorney docket no.
25791.57, as a divisional application of U.S. Pat. No. 6,497,289,
which was filed as U.S. patent application Ser. No. 09/454,139,
attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which
claims priority from provisional application 60/111,293, filed on
Dec. 7, 1998, (35) PCT Application US02/25608, attorney docket no.
25791.58.02, filed on Aug. 13, 2002, which claims priority from
provisional application 60/318,021, filed on Sep. 17, 2001,
attorney docket no. 25791.58, (36) PCT Application US02/24399,
attorney docket no. 25791.59.02, filed on Aug. 1, 2002, which
claims priority from U.S. provisional patent application Ser. No.
60/313,453, attorney docket no. 25791.59, filed on Aug. 20, 2001,
(37) PCT Application US02/29856, attorney docket no. 25791.60.02,
filed on Sep. 19, 2002, which claims priority from U.S. provisional
patent application Ser. No. 60/326,886, attorney docket no.
25791.60, filed on Oct. 3, 2001, (38) PCT Application US02/20256,
attorney docket no. 25791.61.02, filed on Jun. 26, 2002, which
claims priority from U.S. provisional patent application Ser. No.
60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001,
(39) U.S. patent application Ser. No. 09/962,469, filed on 9/25/01,
attorney docket no. 25791.62, which is a divisional of U.S. patent
application Ser. No. 09/523,468, attorney docket no. 25791.11.02,
filed on Mar. 10, 2000, which claims priority from provisional
application 60/124,042, filed on Mar. 11, 1999, (40) U.S. patent
application Ser. No. 09/962,470, filed on Sep. 25, 2001, attorney
docket no. 25791.63, which is a divisional of U.S. patent
application Ser. No. 09/523,468, attorney docket no. 25791.11.02,
filed on Mar. 10, 2000, which claims priority from provisional
application 60/124,042, filed on Mar. 11, 1999, (41) U.S. patent
application Ser. No. 09/962,471, filed on Sep. 25, 2001, attorney
docket no. 25791.64, which is a divisional of U.S. patent
application Ser. No. 09/523,468, attorney docket no. 25791.11.02,
filed on Mar. 10, 2000, which claims priority from provisional
application 60/124,042, filed on Mar. 11, 1999, (42) U.S. patent
application Ser. No. 09/962,467, filed on Sep. 25, 2001, attorney
docket no. 25791.65, which is a divisional of U.S. patent
application Ser. No. 09/523,468, attorney docket no. 25791.11.02,
filed on Mar. 10, 2000, which claims priority from provisional
application 60/124,042, filed on Mar. 11, 1999, (43) U.S. patent
application Ser. No. 09/962,468, filed on Sep. 25, 2001, attorney
docket no. 25791.66, which is a divisional of U.S. patent
application Ser. No. 09/523,468, attorney docket no. 25791.11.02,
filed on Mar. 10, 2000, which claims priority from provisional
application 60/124,042, filed on Mar. 11, 1999, (44) PCT
application US 02/25727, filed on Aug. 14, 2002, attorney docket
no. 25791.67.03, which claims priority from U.S. provisional patent
application Ser. No. 60/317,985, attorney docket no. 25791.67,
filed on Sep. 6, 2001, and U.S. provisional patent application Ser.
No. 60/318,386, attorney docket no. 25791.67.02, filed on Sep. 10,
2001, (45) PCT application US 02/39425, filed on Dec. 10, 2002,
attorney docket no. 25791.68.02, which claims priority from U.S.
provisional patent application Ser. No. 60/343,674, attorney docket
no. 25791.68, filed on Dec. 27, 2001, (46) U.S. utility patent
application Ser. No. 09/969,922, attorney docket no. 25791.69,
filed on Oct. 3, 2001, which is a continuation-in-part application
of U.S. Pat. No. 6,328,113, which was filed as U.S. patent
application Ser. No. 09/440,338, attorney docket number 25791.9.02,
filed on Nov. 15, 1999, which claims priority from provisional
application 60/108,558, filed on Nov. 16, 1998, (47) U.S. utility
patent application Ser. No. 10/516,467, attorney docket no.
25791.70, filed on Dec. 10, 2001, which is a continuation
application of U.S. utility patent application Ser. No. 09/969,922,
attorney docket no. 25791.69, filed on Oct. 3, 2001, which is a
continuation-in-part application of U.S. Pat. No. 6,328,113, which
was filed as U.S. patent application Ser. No. 09/440,338, attorney
docket number 25791.9.02, filed on Nov. 15, 1999, which claims
priority from provisional application 60/108,558, filed on Nov. 16,
1998, (48) PCT application US 03/00609, filed on Jan. 9, 2003,
attorney docket no. 25791.71.02, which claims priority from U.S.
provisional patent application Ser. No. 60/357,372, attorney docket
no. 25791.71, filed on Feb. 15, 2002, (49) U.S. patent application
Ser. No. 10/074,703, attorney docket no. 25791.74, filed on Feb.
12, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (50) U.S. patent application Ser. No. 10/074,244, attorney
docket no. 25791.75, filed on Feb. 12, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (51) U.S. patent application
Ser. No. 10/076,660, attorney docket no. 25791.76, filed on Feb.
15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (52) U.S. patent application Ser. No. 10/076,661, attorney
docket no. 25791.77, filed on Feb. 15, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (53) U.S. patent application
Ser. No. 10/076,659, attorney docket no. 25791.78, filed on Feb.
15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (54) U.S. patent application Ser. No. 10/078,928, attorney
docket no. 25791.79, filed on Feb. 20, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (55) U.S. patent application
Ser. No. 10/078,922, attorney docket no. 25791.80, filed on Feb.
20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (56) U.S. patent application Ser. No. 10/078,921, attorney
docket no. 25791.81, filed on Feb. 20, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (57) U.S. patent application
Ser. No. 10/261,928, attorney docket no. 25791.82, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (58)
U.S. patent application Ser. No. 10/079,276, attorney docket no.
25791.83, filed on Feb. 20, 2002, which is a divisional of U.S.
Pat. No. 6,568,471, which was filed as patent application Ser. No.
09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,
2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (59) U.S. patent application
Ser. No. 10/262,009, attorney docket no. 25791.84, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (60)
U.S. patent application Ser. No. 10/092,481, attorney docket no.
25791.85, filed on Mar. 7, 2002, which is a divisional of U.S. Pat.
No. 6,568,471, which was filed as patent application Ser. No.
09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,
2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (61) U.S. patent application
Ser. No. 10/261,926, attorney docket no. 25791.86, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (62) PCT
application US 02/36157, filed on Nov. 12, 2002, attorney docket
no. 25791.87.02, which claims priority from U.S. provisional patent
application Ser. No. 60/338,996, attorney docket no. 25791.87,
filed on Nov. 12, 2001, (63) PCT application US 02/36267, filed on
Nov. 12, 2002, attorney docket no. 25791.88.02, which claims
priority from U.S. provisional patent application Ser. No.
60/339,013, attorney docket no. 25791.88, filed on Nov. 12, 2001,
(64) PCT application US 03/11765, filed on Apr. 16, 2003, attorney
docket no. 25791.89.02, which claims priority from U.S. provisional
patent application Ser. No. 60/383,917, attorney docket no.
25791.89, filed on May 29, 2002, (65) PCT application US 03/15020,
filed on May 12, 2003, attorney docket no. 25791.90.02, which
claims priority from U.S. provisional patent application Ser. No.
60/391,703, attorney docket no. 25791.90, filed on Jun. 26, 2002,
(66) PCT application US 02/39418, filed on Dec. 10, 2002, attorney
docket no.
25791.92.02, which claims priority from U.S. provisional patent
application Ser. No. 60/346,309, attorney docket no. 25791.92,
filed on Jan. 7, 2002, (67) PCT application US 03/06544, filed on
Mar. 4, 2003, attorney docket no. 25791.93.02, which claims
priority from U.S. provisional patent application Ser. No.
60/372,048, attorney docket no. 25791.93, filed on Apr. 12, 2002,
(68) U.S. patent application Ser. No. 10/331,718, attorney docket
no. 25791.94, filed on Dec. 30, 2002, which is a divisional U.S.
patent application Ser. No. 09/679,906, filed on Oct. 5, 2000,
attorney docket no. 25791.37.02, which claims priority from
provisional patent application Ser. No. 60/159,033, attorney docket
no. 25791.37, filed on Oct. 12, 1999, (69) PCT application US
03/04837, filed on Feb. 29, 2003, attorney docket no. 25791.95.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13,
2002, (70) U.S. patent application Ser. No. 10/261,927, attorney
docket no. 25791.97, filed on Oct. 1, 2002, which is a divisional
of U.S. Pat. No. 6,557,640, which was filed as patent application
Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun.
7, 2000, which claims priority from provisional application
60/137,998, filed on Jun. 7, 1999 (71) U.S. patent application Ser.
No. 10/262,008, attorney docket no. 25791.98, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (72)
U.S. patent application Ser. No. 10/261,925, attorney docket no.
25791.99, filed on Oct. 1, 2002, which is a divisional of U.S. Pat.
No. 6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (73) U.S. patent application Ser. No.
10/199,524, attorney docket no. 25791.100, filed on Jul. 19, 2002,
which is a continuation of U.S. Pat. No. 6,497,289, which was filed
as U.S. patent application Ser. No. 09/454,139, attorney docket no.
25791.03.02, filed on Dec. 3, 1999, which claims priority from
provisional application 60/111,293, filed on Dec. 7, 1998, (74) PCT
application US 03/10144, filed on Mar. 28, 2003, attorney docket
no. 25791.101.02, which claims priority from U.S. provisional
patent application Ser. No. 60/372,632, attorney docket no.
25791.101, filed on Apr. 15, 2002, (75) U.S. provisional patent
application Ser. No. 60/412,542, attorney docket no. 25791.102,
filed on Sep. 20, 2002, (76) PCT application US 03/14153, filed on
May 6, 2003, attorney docket no. 25791.104.02, which claims
priority from U.S. provisional patent application Ser. No.
60/380,147, attorney docket no. 25791.104, filed on May 6, 2002,
(77) PCT application US 03/19993, filed on Jun. 24, 2003, attorney
docket no. 25791.106.02, which claims priority from U.S.
provisional patent application Ser. No. 60/397,284, attorney docket
no. 25791.106, filed on Jul. 19, 2002, (78) PCT application US
03/13787, filed on May 5, 2003, attorney docket no. 25791.107.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/387,486, attorney docket no. 25791.107, filed on Jun. 10,
2002, (79) PCT application US 03/18530, filed on Jun. 11, 2003,
attorney docket no. 25791.108.02, which claims priority from U.S.
provisional patent application Ser. No. 60/387,961, attorney docket
no. 25791.108, filed on Jun. 12, 2002, (80) PCT application US
03/20694, filed on Jul. 1, 2003, attorney docket no. 25791.110.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/398,061, attorney docket no. 25791.110, filed on Jul. 24,
2002, (81) PCT application US 03/20870, filed on Jul. 2, 2003,
attorney docket no. 25791.111.02, which claims priority from U.S.
provisional patent application Ser. No. 60/399,240, attorney docket
no. 25791.111, filed on Jul. 29, 2002, (82) U.S. provisional patent
application Ser. No. 60/412,487, attorney docket no. 25791.112,
filed on Sep. 20, 2002, (83) U.S. provisional patent application
Ser. No. 60/412,488, attorney docket no. 25791.114, filed on Sep.
20, 2002, (84) U.S. patent application Ser. No. 10/280,356,
attorney docket no. 25791.115, filed on Oct. 25, 2002, which is a
continuation of U.S. Pat. No. 6,470,966, which was filed as patent
application Ser. No. 09/850,093, filed on May 7, 2001, attorney
docket no. 25791.55, as a divisional application of U.S. Pat. No.
6,497,289, which was filed as U.S. patent application Ser. No.
09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,
which claims priority from provisional application 60/111,293,
filed on Dec. 7, 1998, (85) U.S. provisional patent application
Ser. No. 60/412,177, attorney docket no. 25791.117, filed on Sep.
20, 2002, (86) U.S. provisional patent application Ser. No.
60/412,653, attorney docket no. 25791.118, filed on Sep. 20, 2002,
(87) U.S. provisional patent application Ser. No. 60/405,610,
attorney docket no. 25791.119, filed on Aug. 23, 2002, (88) U.S.
provisional patent application Ser. No. 60/405,394, attorney docket
no. 25791.120, filed on Aug. 23, 2002, (89) U.S. provisional patent
application Ser. No. 60/412,544, attorney docket no. 25791.121,
filed on Sep. 20, 2002, (90) PCT application US 03/24779, filed on
Aug. 8, 2003, attorney docket no. 25791.125.02, which claims
priority from U.S. provisional patent application Ser. No.
60/407,442, attorney docket no. 25791.125, filed on Aug. 30, 2002,
(91) U.S. provisional patent application Ser. No. 60/423,363,
attorney docket no. 25791.126, filed on Dec. 10, 2002, (92) U.S.
provisional patent application Ser. No. 60/412,196, attorney docket
no. 25791.127, filed on Sep. 20, 2002, (93) U.S. provisional patent
application Ser. No. 60/412,187, attorney docket no. 25791.128,
filed on Sep. 20, 2002, (94) U.S. provisional patent application
Ser. No. 60/412,371, attorney docket no. 25791.129, filed on Sep.
20, 2002, (95) U.S. patent application Ser. No. 10/382,325,
attorney docket no. 25791.145, filed on Mar. 5, 2003, which is a
continuation of U.S. Pat. No. 6,557,640, which was filed as patent
application Ser. No. 09/588,946, attorney docket no. 25791.17.02,
filed on Jun. 7, 2000, which claims priority from provisional
application 60/137,998, filed on Jun. 7, 1999, (96) U.S. patent
application Ser. No. 10/624,842, attorney docket no. 25791.151,
filed on Jul. 22, 2003, which is a divisional of U.S. patent
application Ser. No. 09/502,350, attorney docket no. 25791.8.02,
filed on Feb. 10, 2000, which claims priority from provisional
application 60/119,611, filed on Feb. 11, 1999, (97) U.S.
provisional patent application Ser. No. 60/431,184, attorney docket
no. 25791.157, filed on Dec. 5, 2002, (98) U.S. provisional patent
application Ser. No. 60/448,526, attorney docket no. 25791.185,
filed on Feb. 18, 2003, (99) U.S. provisional patent application
Ser. No. 60/461,539, attorney docket no. 25791.186, filed on Apr.
9, 2003, (100) U.S. provisional patent application Ser. No.
60/462,750, attorney docket no. 25791.193, filed on Apr. 14, 2003,
(101) U.S. provisional patent application Ser. No. 60/436,106,
attorney docket no. 25791.200, filed on Dec. 23, 2002, (102) U.S.
provisional patent application Ser. No. 60/442,942, attorney docket
no. 25791.213, filed on Jan. 27, 2003, (103) U.S. provisional
patent application Ser. No. 60/442,938, attorney docket no.
25791.225, filed on Jan. 27, 2003, (104) U.S. provisional patent
application Ser. No. 60/418,687, attorney docket no. 25791.228,
filed on Apr. 18, 2003, (105) U.S. provisional patent application
Ser. No. 60/454,896, attorney docket no. 25791.236, filed on Mar.
14, 2003, (106) U.S. provisional patent application Ser. No.
60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003,
(107) U.S. provisional patent application Ser. No. 60/451,152,
attorney docket no. 25791.239, filed on Mar. 9, 2003, (108) U.S.
provisional patent application Ser. No. 60/455,124, attorney docket
no. 25791.241, filed on Mar. 17, 2003, (109) U.S. provisional
patent application Ser. No. 60/453,678, attorney docket no.
25791.253, filed on Mar. 11, 2003, (110) U.S. patent application
Ser. No. 10/421,682, attorney docket no. 25791.256, filed on Apr.
23, 2003, which is a continuation of U.S. patent application Ser.
No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10,
2000, which claims priority from provisional application
60/124,042, filed on Mar. 11, 1999, (111) U.S. provisional patent
application Ser. No. 60/457,965, attorney docket no. 25791.260,
filed on Mar. 27, 2003, (112) U.S. provisional patent application
Ser. No. 60/455,718, attorney docket no. 25791.262, filed on Mar.
18, 2003, (113) U.S. Pat. No. 6,550,821, which was filed as patent
application Ser. No. 09/811,734, filed on Mar. 19, 2001, (114) U.S.
patent application Ser. No. 10/436,467, attorney docket no.
25791.268, filed on May 12, 2003, which is a continuation of U.S.
Pat. No. 6,604,763, which was filed as application Ser. No.
09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26,
2000, which claims priority from provisional application
60/131,106, filed on Apr. 26, 1999, (115) U.S. provisional patent
application Ser. No. 60/459,776, attorney docket no. 25791.270,
filed on Apr. 12, 2003, (116) U.S. provisional patent application
Ser. No. 60/461,094, attorney docket no. 25791.272, filed on Apr.
8, 2003, (117) U.S. provisional patent application Ser. No.
60/461,038, attorney docket no. 25791.273, filed on Apr. 7, 2003,
(118) U.S. provisional patent application Ser. No. 60/463,586,
attorney docket no. 25791.277, filed on Apr. 17, 2003, (119) U.S.
provisional patent application Ser. No. 60/472,240, attorney docket
no. 25791.286, filed on May 20, 2003, (120) U.S. patent application
Ser. No. 10/619,285, attorney docket no. 25791.292, filed on Jul.
14, 2003, which is a continuation-in-part of U.S. utility patent
application Ser. No. 09/969,922, attorney docket no. 25791.69,
filed on Oct. 3, 2001, which is a continuation-in-part application
of U.S. Pat. No. 6,328,113, which was filed as U.S. patent
application Ser. No. 09/440,338, attorney docket number 25791.9.02,
filed on Nov. 15, 1999, which claims priority from provisional
application 60/108,558, filed on Nov. 16, 1998, (121) U.S. utility
patent application Ser. No. 10/418,688, attorney docket no.
25791.257, which was filed on Apr. 18, 2003, as a division of U.S.
utility patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (122)
PCT patent application serial no. PCT/US04/06246, attorney docket
no. 25791.238.02, filed on Feb. 26, 2004, (123) PCT patent
application serial number PCT/US04/______, attorney docket number
25791.40.02, filed on Mar. 15, 2004, (124) PCT patent application
serial number PCT/US04/______, attorney docket number 25791.236.02,
filed on Mar. 15, 2004, (125) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.262.02, filed on Mar.
18, 2004, (126) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.253.02, filed on Mar.
11, 2004, and (127) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.260, filed on Mar.
26, 2004, the disclosures of which are incorporated herein by
reference.
[0101] In an exemplary embodiment, the casing cutter assembly 14 is
provided and operates substantially, at least in part, as disclosed
in one or more of the following: (1) PCT patent application serial
number PCT/US03/29858, attorney docket number 25791.112.02, filed
on Sep. 22, 2003, and/or (2) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.253.02, filed on Mar.
11, 2004, and/or (3) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.260, filed on Mar.
26, 2004, the disclosures of which are incorporated herein by
reference.
[0102] In an exemplary embodiment, as illustrated in FIGS. 11-1 and
11-2, 11A1 to 11A2, 11B1 to 11B2, 11C, 11D, 11E, 11F, 11G, 11H,
11I, 11j, 11K, 11L, 11M, 11N, 11O, 11P, 11Q, 11R, 11S, 11T, 11U,
11V, 11W, 11X, 11Y, 11Z1 to 11Z4, 11AA1 to 11AA4, 11AB1 to 11AB4,
11AC1 to 11AC4, 11AD, and 11AE, the casing cutter assembly 14
includes an upper tubular tool joint 14002 that defines a
longitudinal passage 14002a and mounting holes, 14002b and 14002c,
and includes an internal threaded connection 14002d, an inner
annular recess 14002e, an inner annular recess 14002f, and an
internal threaded connection 14002g. A tubular torque plate 14004
that defines a longitudinal passage 14004a and includes
circumferentially spaced apart teeth 14004b is received within,
mates with, and is coupled to the internal annular recess 14002e of
the upper tubular tool joint 14002.
[0103] Circumferentially spaced apart teeth 14006a of an end of a
tubular lower mandrel 14006 that defines a longitudinal passage
14006b, a radial passage 14006ba, and a radial passage 14006bb and
includes an external threaded connection 14006c, an external flange
14006d, an external annular recess 14006e having a step 14006f at
one end, an external annular recess 14006g, external teeth 14006h,
an external threaded connection 14006i, and an external annular
recess 14006j engage the circumferentially spaced apart teeth
14004b of the tubular torque plate 14004. An internal threaded
connection 14008a of an end of a tubular toggle bushing 14008 that
defines a longitudinal passage 14008b, an upper longitudinal slot
14008c, a lower longitudinal slot 14008d, mounting holes, 14008e,
14008f, 14008g, 14008h, 14008i, 14008j, 14008k, 14008l, 14008m,
14008n, 14008o, 14008p, 14008q, 14008r, 14008s, 14008t, 14008u,
14008v, 14008w, 14008x, 14008xa, and 14008xb, and includes an
external annular recess 14008y, internal annular recess 14008z,
external annular recess 14008aa, and an external annular recess
14008ab receives and is coupled to the external threaded connection
14006c of the tubular lower mandrel 14006.
[0104] A sealing element 14010 is received within the external
annular recess 14008y of the tubular toggle bushing 14008 for
sealing the interface between the tubular toggle bushing and the
upper tubular tool joint 14002. A sealing element 14012 is received
within the internal annular recess 14008z of the tubular toggle
bushing 14008 for sealing the interface between the tubular toggle
bushing and the tubular lower mandrel 14006.
[0105] Mounting screws, 14014a and 14014b, mounted within and
coupled to the mounting holes, 14008w and 14008x, respectively, of
the tubular toggle bushing 14008 are also received within the
mounting holes, 14002b and 14002c, of the upper tubular tool joint
14002. Mounting pins, 14016a, 14016b, 14016c, 14016d, and 14016e,
are mounted within the mounting holes, 14008e, 14008f, 14008g,
14008h, and 14008i, respectively. Mounting pins, 14018a, 14018b,
14018c, 14018d, and 14018e, are mounted within the mounting holes,
14008t, 14008s, 14008r, 14008q, and 14008p, respectively. Mounting
screws, 14020a and 14020b, are mounted within the mounting holes,
14008u and 14008v, respectively.
[0106] A first upper toggle link 14022 defines mounting holes,
14022a and 14022b, for receiving the mounting pins, 14016a and
14016b, and includes a mounting pin 14022c at one end. A first
lower toggle link 14024 defines mounting holes, 14024a, 14024b, and
14024c, for receiving the mounting pins, 14022c, 14016c, and
14016d, respectively and includes an engagement arm 14024d. A first
trigger 14026 defines a mounting hole 14026a for receiving the
mounting pin 14016e and includes an engagement arm 14026b at one
end, an engagement member 14026c, and an engagement arm 14026d at
another end.
[0107] A second upper toggle link 14028 defines mounting holes,
14028a and 14028b, for receiving the mounting pins, 14018a and
14018b, and includes a mounting pin 14028c at one end. A second
lower toggle link 14030 defines mounting holes, 14030a, 14030b, and
14030c, for receiving the mounting pins, 14028c, 14018c, and
14018d, respectively and includes an engagement arm 14030d. A
second trigger 14032 defines a mounting hole 14032a for receiving
the mounting pin 14018e and includes an engagement arm 14032b at
one end, an engagement member 14032c, and an engagement arm 14032d
at another end.
[0108] An end of a tubular spring housing 14034 that defines a
longitudinal passage 14034a, mounting holes, 14034b and 14034c, and
mounting holes, 14034ba and 14034ca, and includes an internal
flange 14034d and an internal annular recess 14034e at one end, and
an internal flange 14034f, an internal annular recess 14034g, an
internal annular recess 14034h, and an external threaded connection
14034i at another end receives and mates with the end of the
tubular toggle bushing 14008. Mounting screws, 14035a and 14035b,
are mounted within and coupled to the mounting holes, 14008xb and
14008xa, respectively, of the tubular toggle bushing 14008 and are
received within the mounting holes, 14034ba and 14034ca,
respectively, of the tubular spring housing 14034.
[0109] A tubular retracting spring ring 14036 that defines mounting
holes, 14036a and 14036b, receives and mates with a portion of the
tubular lower mandrel 14006 and is received within and mates with a
portion of the tubular spring housing 14034. Mounting screws,
14038a and 14038b, are mounted within and coupled to the mounting
holes, 14036a and 14036b, respectively, of the tubular retracting
spring ring 14036 and extend into the mounting holes, 14034b and
14034c, respectively, of the tubular spring housing 14034.
[0110] Casing diameter sensor springs, 14040a and 14040b, are
positioned within the longitudinal slots, 14008c and 1408d,
respectively, of the tubular toggle bushing 14008 that engage the
engagement members, 14026c and 14032c, and engagement arms, 14026d
and 14032d, of the first and second triggers, 14026 and 14032,
respectively. An inner flange 14042a of an end of a tubular spring
washer 14042 mates with and receives a portion of the tubular lower
mandrel 14006 and an end face of the inner flange of the tubular
spring washer is positioned proximate and end face of the external
flange 14006d of the tubular lower mandrel. The tubular spring
washer 14042 is further received within the longitudinal passage
14034a of the tubular spring housing 14034.
[0111] An end of a retracting spring 14044 that receives the
tubular lower mandrel 14006 is positioned within the tubular spring
washer 14042 in contact with the internal flange 14042a of the
tubular spring washer and the other end of the retracting spring is
positioned in contact with an end face of the tubular retracting
spring ring 14036.
[0112] A sealing element 14046 is received within the external
annular recess 14006j of the tubular lower mandrel 14006 for
sealing the interface between the tubular lower mandrel and the
tubular spring housing 14034. A sealing element 14048 is received
within the internal annular recess 14034h of the tubular spring
housing 14034 for sealing the interface between the tubular spring
housing and the tubular lower mandrel 14006.
[0113] An internal threaded connection 14050a of an end of a
tubular upper hinge sleeve 14050 that includes an internal flange
14050b and an internal pivot 14050c receives and is coupled to the
external threaded connection 14034i of the end of the tubular
spring housing 14034.
[0114] An external flange 14052a of a base member 14052b of an
upper cam assembly 14052, that is mounted upon and receives the
lower tubular mandrel 14006, that includes an internal flange
14052c that is received within the external annular recess 14006e
of the lower tubular mandrel 14006 and a plurality of
circumferentially spaced apart cam arms 14052d extending from the
base member mates with and is received within the tubular upper
hinge sleeve 14050. The base member 14052b of the upper cam
assembly 14052 further includes a plurality of circumferentially
spaced apart teeth 14052f that mate with and are received within a
plurality of circumferentially spaced apart teeth 14034j provided
on the end face of the tubular spring housing 14034 and an end face
of the external flange 14052a of the base member of the upper cam
assembly is positioned in opposing relation to an end face of the
internal flange 14050b of the tubular upper hinge sleeve 14050.
Each of the cam arms 14052d of the upper cam assembly 14052 include
external cam surfaces 14052e. In an exemplary embodiment, the teeth
14052f of the base member 14052b of the upper cam assembly 14052
and the teeth 14034j provided on the end face of the tubular spring
housing 14034 permit torsional loads to be transmitted between the
tubular spring housing and the upper cam assembly.
[0115] A plurality of circumferentially spaced apart upper casing
cutter segments 14054 are mounted upon and receive the lower
tubular mandrel 14006 and each include an external pivot recess
14054a for mating with and receiving the internal pivot 14050c of
the tubular upper hinge sleeve 14050 and an external flange 14054b
and are pivotally mounted within the tubular upper hinge sleeve and
are interleaved with the circumferentially spaced apart cam arms
14052d of the upper cam assembly 14052. A casing cutter element
14056 is coupled to and supported by the upper surface of each
upper casing cutter segments 14054 proximate the external flange
14054b.
[0116] A plurality of circumferentially spaced apart lower casing
cutter segments 14058 are mounted upon and receive the lower
tubular mandrel 14006, are interleaved among the upper casing
cutter segments 14054, are oriented in the opposite direction to
the upper casing cutter segments 14054, each include an external
pivot recess 14058a, and are positioned in opposing relation to
corresponding circumferentially spaced apart cam arms 14052d of the
upper cam assembly 14052.
[0117] A lower cam assembly 14060 is mounted upon and receives the
lower tubular mandrel 14006 that includes a base member 14060a
having an external flange 14060b, a plurality of circumferentially
spaced apart cam arms 14060d that extend from the base member that
each include external cam surfaces 14060e and define mounting holes
14060f and 14060g. The base member 14060a of the lower cam assembly
14060 further includes a plurality of circumferentially spaced
apart teeth 14060h. The circumferentially spaced apart cam arms
14060d of the lower cam assembly 14060 are interleaved among the
lower casing cutter segments 14058 and the circumferentially spaced
apart cam arms 14052d of the upper cam assembly 14052 and
positioned in opposing relation to corresponding upper casing
cutter segments 14054.
[0118] Mounting screws, 14062a, 14062b, 14062c, and 14062e, are
mounted within the corresponding mounting holes, 14060f and 14060g,
of the lower cam assembly 14060 and are received within the
external annular recess 14006g of the lower cam assembly 14060.
[0119] A tubular lower hinge sleeve 14064 that receives the lower
casing cutter segments 14058 and the lower cam assembly 14060
includes an internal flange 14064a for engaging the external flange
14060b of the base member of the lower cam assembly 14060, an
internal pivot 14064b for engaging and receiving the external pivot
recess 14058a of the lower casing cutter segments 14058 thereby
pivotally mounting the lower casing cutter segments within the
tubular lower hinge sleeve, and an internal threaded connection
14064c.
[0120] An external threaded connection 14066a of an end of a
tubular sleeve 14066 that defines mounting holes, 14066b and
14066c, and includes an internal annular recess 14066d having a
shoulder 14066e, an internal flange 14066f, and an internal
threaded connection 14066g at another end is received within and
coupled to the internal threaded connection 14064c of the tubular
lower hinge sleeve 14064. An external threaded connection 14068a of
an end of a tubular member 14068 that defines a longitudinal
passage 14068b and mounting holes, 14068c and 14068d, and includes
an external annular recess 14068e, and an external threaded
connection 14068f at another end is received within and is coupled
to the internal threaded connection 14066g of the tubular sleeve
14066.
[0121] Mounting screws, 14070a and 14070b, are mounted in and
coupled to the mounting holes, 14068c and 14068d, respectively, of
the tubular member 14068 that also extend into the mounting holes,
14066b and 14066c, respectively, of the tubular sleeve 14066. A
sealing element 14072 is received within the external annular
recess 14068e of the tubular member 14068 for sealing the interface
between the tubular member and the tubular sleeve 14066.
[0122] An internal threaded connection 14074a of a tubular
retracting piston 14074 that defines a longitudinal passage 14074b
and includes an internal annular recess 14074c and an external
annular recess 14074d receives and is coupled to the external
threaded connection 14006i of the tubular lower mandrel 14006. A
sealing element 14076 is received within the external annular
recess 14074d of the tubular retracting piston 14074 for sealing
the interface between the tubular retracting piston and the tubular
sleeve 14066. A sealing element 14078 is received within the
internal annular recess 14074c of the tubular retracting piston
14074 for sealing the interface between the tubular retracting
piston and the tubular lower mandrel 14006.
[0123] Locking dogs 14080 mate with and receive the external teeth
14006h of the tubular lower mandrel 14006. A spacer ring 14082 is
positioned between an end face of the locking dogs 14080 and an end
face of the lower cam assembly 14060. A release piston 14084
mounted upon the tubular lower mandrel 14006 defines a radial
passage 14084a for mounting a burst disk 14086 includes sealing
elements, 14084b, 14084c, and 14084d. The sealing elements, 14084b
and 14084d, sealing the interface between the release piston 14084
and the tubular lower mandrel 14006. An end face of the release
piston 14084 is positioned in opposing relation to an end face of
the locking dogs 14080.
[0124] A release sleeve 14088 that receives and is mounted upon the
locking dogs 14080 and the release piston 14084 includes an
internal flange 14088a at one end that sealingly engages the
tubular lower mandrel 14006. A bypass sleeve 14090 that receives
and is mounted upon the release sleeve 14088 includes an internal
flange 14090a at one end.
[0125] In an exemplary embodiment, during operation of the casing
cutter assembly 14, the retracting spring 14044 is compressed and
thereby applies a biasing spring force in a direction 14092 from
the lower tubular mandrel 14006 to the tubular spring housing 14034
that, in the absence of other forces, moves and/or maintains the
upper cam assembly 14052 and the upper casing cutter segments 14054
out of engagement with the lower casing cutter segments 14058 and
the lower cam assembly 14060. In an exemplary embodiment, during
operation of the casing cutter assembly 14, an external threaded
connection 12a of an end of the tubular support member 12 is
coupled to the internal threaded connection 14002d of the upper
tubular tool joint 14002 and an internal threaded connection 16a of
an end of the ball gripper assembly 16 is coupled to the external
threaded connection 14068f of the tubular member 14068.
[0126] The upper cam assembly 14052 and the upper casing cutter
segments 14054 may be brought into engagement with the lower casing
cutter segments 14058 and the lower cam assembly 14060 by
pressurizing an annulus 14094 defined between the lower tubular
mandrel 14006 and the tubular spring housing 14034. In particular,
injection of fluidic materials into the cam cutter assembly 14
through the longitudinal passage 14006b of the lower tubular
mandrel 14006 and into the radial passage 14006ba may pressurize
the annulus 14094 thereby creating sufficient operating pressure to
generate a force in a direction 14096 sufficient to overcome the
biasing force of the retracting spring 14044. As a result, the
spring housing 14034 may be displaced in the direction 14096
relative to the lower tubular mandrel 14006 thereby displacing the
tubular upper hinge sleeve 14050, upper cam assembly 14052, and
upper casing cutter segments 14054 in the direction 14096.
[0127] In an exemplary embodiment, as illustrated in FIGS. 11P, 11Q
and 11R, the displacement of the upper cam assembly 14052 and upper
casing cutter segments 14054 in the direction 14096 will cause the
lower casing cutter segments 14058 to ride up the cam surfaces of
the cam arms of the upper cam assembly 14052 while also pivoting
about the lower tubular hinge segment 14064, and will also cause
the upper casing cutter segments 14054 to ride up the cam surfaces
of the cam arms of the lower cam assembly 14060 while also pivoting
about the upper tubular hinge segment 14050.
[0128] In an exemplary embodiment, during the operation of the
casing cutter assembly 14, when the upper and lower casing cutter
segments, 14054 and 14058, brought into axial alignment in a
radially expanded position, the casing cutter elements of the
casing cutter segments are brought into intimate contact with the
interior surface of a pre-selected portion of the expandable
wellbore casing 100. The casing cutter assembly 14 may then be
rotated to thereby cause the casing cutter elements to cut through
the expandable wellbore casing. The portion of the expandable
wellbore casing 100 cut away from the remaining portion on the
expandable wellbore casing may then be carried out of the wellbore
102 with the cut away portion of the expandable wellbore casing
supported by the casing cutter elements.
[0129] In an exemplary embodiment, the upper cam assembly 14052 and
the upper casing cutter segments 14054 may be moved out of
engagement with the lower casing cutter segments 14058 and the
lower cam assembly 14060 by reducing the operating pressure within
the annulus 14094.
[0130] In an alternative embodiment, as illustrated in FIGS. 11S,
11T, 11U and 11V, during operation of the casing cutter assembly
14, the upper cam assembly 14052 and the upper casing cutter
segments 14054 may also be moved out of engagement with the lower
casing cutter segments 14058 and the lower cam assembly 14060 by
sensing the operating pressure within the longitudinal passage
14006b of the lower tubular mandrel 14006. In particular, as
illustrated in FIG. 11T, if the operating pressure within the
longitudinal passage 14006b and radial passage 14006bb of the lower
tubular mandrel 14006 exceeds a predetermined value, the burst disc
14086 will open the passage 14084a thereby pressurizing the
interior of the tubular release sleeve 14088 thereby displacing the
tubular release sleeve 14088 downwardly in a direction 14092 away
from engagement with the locking dogs 14080.
[0131] As a result, as illustrated in FIG. 11U, the locking dogs
14080 are displaced outwardly in the radial directed and thereby
released from engagement with the lower tubular mandrel 14006
thereby permitting the lower casing cutter segments 14058 and the
lower cam assembly 14060 to be displaced downwardly relative to the
lower tubular mandrel.
[0132] As a result, as illustrated in FIG. 11V, the operating
pressure within the lower tubular mandrel 14066 may then cause the
lower tubular mandrel to be displaced downwardly in the direction
14094 relative to the tubular lower mandrel 14006 and the
retracting piston 14074. As a result, the lower tubular mandrel
14066, the lower casing cutter segments 14058, the lower cam
assembly 14060, and tubular lower hinge sleeve 14064 are displaced
downwardly in the direction 14094 relative to the tubular spring
housing 14034 thereby moving the lower casing cutter segments 14058
and the lower cam assembly 14060 out of engagement with the upper
cam assembly 14052 and the upper casing cutter segments 14054.
[0133] In an exemplary embodiment, as illustrated in FIGS. 11W,
11X, and 11Y, during operation of the casing cutter assembly 14,
the casing cutter assembly 14 senses the diameter of the expandable
wellbore casing 100 using the upper toggle links, 14022 and 14028,
lower toggle links, 14024 and 14030, and triggers, 14026 and 14032,
and then prevents the engagement of the upper cam assembly 14052
and the upper casing cutter segments 14054 with the lower casing
cutter segments 14058 and the lower cam assembly 14060.
[0134] In particular, as illustrated in FIG. 11W, anytime the upper
toggle links, 14022 and 14028, and lower toggle links, 14024 and
14030, are positioned within a portion of the expandable wellbore
casing 100 that has been radially expanded and plastically deformed
by the system 10, the triggers, 14026 and 14032, will be pivoted by
the engagement arms, 14024d and 14030d, of the lower toggle links,
14024 and 14030, to a position in which the triggers will no longer
engage the internal flange 14034d of the end of the tubular spring
housing 14034 thereby permitting the displacement of the tubular
spring housing in the direction 14096. As a result, the upper cam
assembly 14052 and the upper casing cutter segments 14054 can be
brought into engagement with the lower casing cutter segments 14058
and the lower cam assembly 14060. In an exemplary embodiment, the
upper toggle links, 14022 and 14028, and the lower toggle links,
14024 and 14030, are spring biased towards the position illustrated
in FIG. 11W.
[0135] Conversely, as illustrated in FIG. 11X, anytime the upper
toggle links, 14022 and 14028, and lower toggle links, 14024 and
14030, are positioned within a portion of the expandable wellbore
casing 100 that has not been radially expanded and plastically
deformed by the system 10, the triggers, 14026 and 14032, will be
maintained in a position in which the triggers will engage the
internal flange 14034d of the end of the tubular spring housing
14034 thereby preventing the displacement of the tubular spring
housing in the direction 14096. As a result, the upper cam assembly
14052 and the upper casing cutter segments 14054 cannot be brought
into engagement with the lower casing cutter segments 14058 and the
lower cam assembly 14060. In an exemplary embodiment, the triggers,
14026 and 14032, are spring biased towards the position illustrated
in FIG. 11X.
[0136] In an exemplary embodiment, as illustrated in FIG. 11Y, the
tubular spring housing 14034 may be displaced upwardly in the
direction 14098 even if the upper toggle links, 14022 and 14028,
and lower toggle links, 14024 and 14030, are positioned within a
portion of the expandable wellbore casing 100 that has not been
radially expanded and plastically deformed by the system 10.
[0137] In an exemplary embodiment, as illustrated in FIGS. 11Z1 to
11Z4, 11AA1 to 11AA4, 11AB1 to 11AB4, 11AC1 to 11AC4, 11AD, and
11AE, the tubular spring housing 14034 of the casing cutter
assembly 14 defines internal annular recesses 14034k and 14034l,
spaced apart by an internal flange 14034m, the tubular toggle
bushing 14008 defines an external annular recess 14008ac, and the
casing cutter assembly further includes pins, 14100a and 14100b and
14102a and 14102b, mounted in holes 14008j and 14008o and 14008k
and 14008n, respectively, of the tubular toggle bushing, and a
one-shot deactivation device 14104 mounted on the tubular toggle
bushing between the pins, 14100a and 14100b and 14102a and
14102b.
[0138] The one-shot deactivation device 14104 includes a tubular
body 14104a that defines radial holes, 14104b and 14014c, and
includes an external annular recess 14104d at one end, a centrally
positioned external flange 14104e, a centrally positioned internal
annular recess 14104f, and an external annular recess 14104g at
another end. An engagement member 14106 that includes a base member
14106a having a tapered end 14106b and a key member 14106c having a
tapered end 14106d is received within a portion of the internal
annular recess 14104f of the tubular body 14104a and an engagement
member 14108 that includes a base member 14108a having a tapered
end 14108b and a key member 14108c having a tapered end 14108d is
received within an opposite portion of the internal annular recess
14104f of the tubular body 14104a. Spring members, 14110 and 14112,
are received within the annular recess 14104f of the tubular body
14104a for biasing the base members, base member 14106a and 14108a,
of the engagement members, 14106 and 14108, respectively, radially
inwardly relative to the tubular body 14104a.
[0139] In an exemplary embodiment, during operation of the casing
cutter assembly 14, as illustrated in FIGS. 11Z1 to 11Z4, the
one-shot deactivation device 14104 are positioned proximate and in
intimate contact with the pins, 14102a and 14102b, with the tapered
ends, 14106b and 14108b, of the base members, 14106a and 14108a, of
the engagement members, 14106 and 14108, received within the
external annular recess 14008ac of the tubular toggle bushing
14008. When the one-shot deactivation device 14104 is positioned as
illustrated in FIG. 11Z, the external annular recess 14104d of the
tubular body 14104a of the one-shot deactivation device is moved
out of engagement with the engagement arms, 14026d and 14032d, of
the triggers, 14026 and 14032, respectively. As a result, the
triggers, 14026 and 14032, may operate normally as described above
with reference to FIGS. 11W, 11X, and 11Y.
[0140] Conversely, in an exemplary embodiment, during operation of
the casing cutter assembly 14, as illustrated in FIGS. 11AA1 to
11AA4, the one-shot deactivation device 14104 are positioned
proximate and in intimate contact with the pins, 14100a and 14100b,
with the tapered ends, 14106b and 14108b, of the base members,
14106a and 14108a, of the engagement members, 14106 and 14108, not
received within the external annular recess 14008ac of the tubular
toggle bushing 14008. When the one-shot deactivation device 14104
is positioned as illustrated in FIGS. 11AA1 to 11AA4, the external
annular recess 14104d of the tubular body 14104a of the one-shot
deactivation device is moved into engagement with the engagement
arms, 14026d and 14032d, of the triggers, 14026 and 14032,
respectively. As a result, the triggers, 14026 and 14032, are
deactivated and may not operate normally as described above with
reference to FIGS. 11W, 11X, and 11Y.
[0141] In an alternative embodiment, the elements of the casing
cutter assembly 14 that sense the diameter of the expandable
wellbore casing 100 may be disabled or omitted or adjusted to sense
any pre-selected internal diameter of the expandable wellbore
casing.
[0142] In an exemplary embodiment, the ball gripper assembly 16 is
provided and operates substantially, at least in part, as disclosed
in one or more of the following: (1) PCT patent application serial
number PCT/US03/29859, attorney docket no. 25791.102.02, filed on
Sep. 22, 2003, (2) PCT patent application serial number
PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov.
13, 2003, and/or (3) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.253.02, filed on Mar.
11, 2004, and/or (4) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.260, filed on Mar.
26, 2004, the disclosures of which are incorporated herein by
reference.
[0143] In an exemplary embodiment, as illustrated in FIGS. 12A1 to
12A4, 12B and 12C1 to 12C4, the ball gripper assembly 16 includes
an upper mandrel 1602 that defines a longitudinal passage 1602a and
a radial passage 1602b and includes an internal threaded connection
1602c at one end, an external flange 1602d at an intermediate
portion that includes an external annular recess 1602e having a
shoulder 1602f and an external radial hole 1602g, an external
annular recess 1602h, an external annular recess 1602i, an external
annular recess 1602j having a tapered end 1602k including an
external annular recess 1602ka, an external annular recess 16021,
and an external annular recess 1602m, and an external annular
recess 1602n, an external radial hole 1602o, an external annular
recess 1602p, and an external annular recess 1602q at another
end.
[0144] An upper tubular bushing 1604 defines an internally threaded
radial opening 1604a and includes an external flange 1604b having
an external annular recess 1604c and an internal annular recess
1604d mates with and receives the external flange 1602d of the
upper mandrel 1602. In particular, the internal annular recess
1604d of the upper tubular bushing 1604 mates with the shoulder
1602f of the external annular recess 1602e of the upper mandrel
1602. A screw 1606 that is threadably coupled to the internally
threaded radial opening 1604a of the upper tubular bushing 1604
extends into the external radial hole 1602g of the external flange
1602d of the upper mandrel 1602.
[0145] A deactivation tubular sleeve 1608 defines a radial passage
1608a and includes an internal annular recess 1608b that mates with
and receives an end of the external annular recess 1604c of the
external flange 1604b of the upper tubular bushing 1604, an
internal annular recess 1608c that mates with and receives the
external flange 1602d of the upper mandrel 1602, an internal
annular recess 1608d, an internal annular recess 1608e, and an
internal annular recess 1608f. A deactivation spring 1610 is
received within an annulus 1612 defined between the internal
annular recess 1608b of the deactivation tubular sleeve 1608, an
end face of the external annular recess 1604c of the external
flange 1604b of the upper tubular bushing 1604, and the external
annular recess 1602h of the external flange 1602d of the upper
mandrel 1602.
[0146] A sealing member 1614 is received with the external annular
recess 1602i of the external flange 1602d of the upper mandrel 1602
for sealing the interface between the upper mandrel and the
deactivation tubular sleeve 1608. An annular spacer element 1616 is
received within the external annular recess 1602ka of the tapered
end 1602k of the external annular recess 1602j of the upper mandrel
1602.
[0147] One or more inner engagement elements 1618a of a tubular
coglet 1618 engage and are received within the external annular
recess 1602ka of the tapered end 1602k of the external annular
recess 1602j of the upper mandrel 1602 and one or more outer
engagement elements 1618b of the coglet engage and are received
within the internal annular recess 1608d of the deactivation
tubular sleeve 1608.
[0148] An external annular recess 1620a of an end of a tubular
coglet prop 1620 that includes an inner flange 1620b receives and
mates with the inner surfaces of the outer engagement elements
1618b of the coglet 1618. The end of the tubular coglet prop 1620
further receives and mates with the external annular recess 1602j
of the external flange 1602d of the upper mandrel 1602. A sealing
element 1622 is received within the external annular recess 16021
of the upper mandrel 1602 for sealing the interface between the
upper mandrel and the tubular coglet prop 1620.
[0149] An end of a tubular bumper sleeve 1624 that includes
internal and external flanges, 1624a and 1624b, and a hole 1624c at
another end mates with and receives the external annular recess
1602m of the external flange 1602d of the upper mandrel 1602. A
coglet spring 1626 is received within an annulus 1628 defined
between the external annular recess 1602m of the external flange
1602d of the upper mandrel 1602, the tubular coglet prop 1620, the
inner flange 1620b of the tubular coglet prop, an end face of the
tubular bumper sleeve 1624, and the internal annular recess 1608c
of the deactivation tubular sleeve 1608.
[0150] A tubular ball race 1628 that defines a plurality of tapered
annular recesses 1628a and an internally threaded radial opening
1628b and includes one or more axial engagement elements 1628c at
one end and one or more axial engagement elements 1628d at another
end receives and mates with the other end of the upper mandrel
1602. In an exemplary embodiment, the axial engagement elements
1628c of the tubular ball race 1628 are received within and are
coupled to the hole 1624c of the tubular bumper sleeve 1624. An end
of a tubular activation sleeve 1630 that defines a plurality of
radial openings 1630a, a radial opening 1630b, a radial opening
1630c, and includes an internal annular recess 1630d receives and
mates with the tubular ball race 1628. In an exemplary embodiment,
an end face of an end of the tubular activation sleeve 1630 is
positioned proximate and in opposing relation to an end face of an
end of the deactivation sleeve 1608. In an exemplary embodiment,
the radial openings 1630a are aligned with and positioned in
opposing relation to corresponding of tapered annular recesses
1628a of the tubular ball race 1628, and the radial openings are
also narrowed in cross section in the radial direction for reasons
to be described.
[0151] Balls 1632 are received within each of the of tapered
annular recesses 1628a and corresponding radial openings 1630a of
the tubular ball race 1628 and tubular activation sleeve 1630,
respectively. In an exemplary embodiment, the narrowed cross
sections of the radial openings 1630a of the tubular activation
sleeve 1630 will permit the balls 1632 to be displaced outwardly in
the radial direction until at least a portion of the balls extends
beyond the outer perimeter of the tubular activation sleeve to
thereby permit engagement of the balls with an outer structure such
as, for example, a wellbore casing.
[0152] A lower mandrel 1634 that defines a longitudinal passage
1634a and an internally threaded radial passage 1634b at one end
and includes internal annular recesses, 1634c and 1634d, for
receiving and mating with the external annular recesses, 1602p and
1602q, of the upper mandrel 1602, an internal annular recess 1634e,
an external flange 1634f, and an externally threaded connection
1634g at another end. In an exemplary embodiment, as illustrated in
FIG. 12B, the end of the lower mandrel 1634 further includes
longitudinal recesses 1634h for receiving and mating with
corresponding axial engagement elements 1628d of the tubular ball
race 1628. A sealing element 1635 is received within the internal
annular recess 1634d of the lower mandrel 1634 for sealing an
interface between the lower mandrel and the external annular recess
1602p of the upper mandrel 1602.
[0153] A tubular spring retainer 1636 that defines a radial passage
1636a and includes an external annular recess 1636b at one end
mates with and receives the end of the lower mandrel 1634 and is
positioned proximate an end face of the external flange 1634f of
the lower mandrel. A tubular spring retainer 1638 receives and
mates with the end of the lower mandrel 1634 and is received and
mates with the internal annular recess 1630d of the tubular
activation sleeve 1630.
[0154] An activation spring 1640 is received within an annulus 1642
defined an end face of the tubular spring retainer 1638, an end
face of the spring retainer 1636, the internal annular recess 1630d
of the tubular activation sleeve 1630, and the end of the lower
mandrel 1634. A retainer screw 1642 is received within and is
threadably coupled to the internally threaded radial opening 1634b
of the lower mandrel 1634 that also extends into the external
radial hole 1602o of the upper mandrel 1602.
[0155] During operation of the ball gripper assembly 16, in an
exemplary embodiment, as illustrated in FIGS. 12A1 to 12A4, the
ball gripper assembly may be positioned within the expandable
wellbore casing 100 and the internally threaded connection 1602c of
the upper mandrel 1602 may be coupled to an externally threaded
connection 14a of an end of the casing cutter assembly 14 and the
externally threaded connection 1634g of the lower mandrel 1634 may
be coupled to an internally threaded connection 18a of an end of
the tension actuator assembly 18.
[0156] In an alternative embodiment, the internally threaded
connection 1602c of the upper mandrel 1602 may be coupled to an
externally threaded connection of an end of the tension actuator
assembly 18 and the externally threaded connection 1634g of the
lower mandrel 1634 may be coupled to an internally threaded
connection of an end of casing cutter assembly 14.
[0157] In an exemplary embodiment, the deactivation spring 1610 has
a greater spring rate than the activation spring 1640. As a result,
in an initial operating mode, as illustrated in FIGS. 12A1 to 12A4,
a biasing spring force is applied to the deactivation sleeve 1608
and activation sleeve 1630 in a direction 1644 that maintains the
activation sleeve in a position relative to the tubular ball race
1628 that maintains the balls 1632 within the radially inward
portions of the corresponding tapered annular recesses 1628a of the
tubular ball race such that the balls do not extend beyond the
perimeter of the activation sleeve to engage the expandable
wellbore casing 100.
[0158] As illustrated in FIGS. 12C1 to 12C4, in an exemplary
embodiment, the ball gripper 16 may be operated to engage the
interior surface of the expandable wellbore casing 100 by injecting
a fluidic material 1650 into the ball gripper assembly through the
longitudinal passages 1602a and 1634aa, of the upper and lower
mandrels, 1602 and 1634, respectively.
[0159] In particular, when the longitudinal and radial passages,
1602a and 1602b, respectively, of the upper mandrel 1602 are
pressurized by the injection of the fluidic material 1650, the
internal annular recess 1608c of the deactivation tubular sleeve
1608 is pressurized. When the operating pressure of the fluidic
material 1650 within the internal annular recess 1608c of the
deactivation tubular sleeve 1608 is sufficient to overcome the
biasing spring force of the deactivation spring 1610, the
deactivation tubular sleeve is displaced in a direction 1652. As a
result, the spring force provided by the activation spring 1640
then may displace the activation tubular sleeve 1630 in the
direction 1652 thereby moving the balls 1632 on the corresponding
tapered annular recesses 1628a of the tubular ball race 1628
outwardly in a radial direction into engagement with the interior
surface of the expandable wellbore casing 100. In an exemplary
embodiment, the operating pressure of the fluidic material 1650
sufficient to overcome the biasing spring force of the deactivation
spring 1610 was about 100 psi.
[0160] In an exemplary embodiment, when the operating pressure of
the fluidic material 1650 is reduced, the operating pressure of the
fluidic material 1650 within the internal annular recess 1608c of
the deactivation tubular sleeve 1608 is no longer sufficient to
overcome the biasing spring force of the deactivation spring 1610,
and the deactivation tubular sleeve and the activation tubular
sleeve 1630 are displaced in a direction opposite to the direction
1652 thereby moving the balls 1632 radially inwardly and out of
engagement with the interior surface of the expandable wellbore
casing 100.
[0161] In an exemplary embodiment, the ball gripper assembly 16 is
operated to engage the interior surface of the expandable wellbore
casing 100 in combination with the operation of the tension
actuator assembly 18 to apply an upward tensile force to one or
more elements of the system 10 coupled to and positioned below the
tension actuator assembly. As a result, a reaction force comprising
a downward tensile force is applied to the lower mandrel 1634 of
the ball gripper assembly 16 in a direction opposite to the
direction 1652 during the operation of the tension actuator
assembly 18. Consequently, due to the geometry of the tapered 1628a
of the tubular ball race 1628, the balls 1632 are driven up the
tapered annular recesses 1628a of the tubular ball race 1628 with
increased force and the contact force between the balls 1632 and
the interior surface of the expandable wellbore casing 100 is
significantly increased thereby correspondingly increasing the
gripping force and effect of the ball gripper assembly.
[0162] In an exemplary embodiment, the ball gripper assembly 16 may
be operated to radially expand and plastically deform discrete
portions of the expandable wellbore casing 100 by controlling the
amount of contact force applied to the interior surface of the
expandable wellbore casing by the balls 1632 of the ball gripper
assembly. In an experimental test of an exemplary embodiment of the
ball gripper assembly 16, an expandable wellbore casing was
radially expanded and plastically deformed. This was an unexpected
result.
[0163] In an exemplary embodiment, the tension actuator assembly 18
operates and is provided substantially, at least in part, as
disclosed in one or more of the following: (1) PCT patent
application serial number PCT/US02/36267, attorney docket number
25791.88.02, filed on Nov. 12, 2002, (2) PCT patent application
serial number PCT/US03/29859, attorney docket no. 25791.102.02,
filed on Sep. 22, 2003, (3) PCT patent application serial number
PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov.
13, 2003, (4) PCT patent application serial number PCT/US03/29460,
attorney docket number 25791.114.02, filed on Sep. 23, 2003, and/or
(5) PCT patent application serial number PCT/US04/______, attorney
docket number 25791.253.02, filed on Mar. 11, 2004, and/or (6) PCT
patent application serial number PCT/US04/______, attorney docket
number 25791.260, filed on Mar. 26, 2004, the disclosures of which
are incorporated herein by reference.
[0164] In an exemplary embodiment, as illustrated in FIGS. 13A1 to
13A8 and 13B1 to 13B7, the tension actuator assembly 18 includes an
upper tubular support member 18002 that defines a longitudinal
passage 18002a, and external internally threaded radial openings,
18002b and 18002c, and an external annular recess 18002d and
includes an internally threaded connection 18002e at one end and an
external flange 18002f, an external annular recess 18002g having an
externally threaded connection, and an internal annular recess
18002h having an internally threaded connection at another end. An
end of a tubular actuator barrel 18004 that defines radial
passages, 18004a and 18004b, at one end and radial passages, 18004c
and 18004d, includes an internally threaded connection 18004e at
one end that mates with, receives, and is threadably coupled to the
external annular recess 18002g of the upper tubular support member
18002 and abuts and end face of the external flange 18002f of the
upper tubular support member and an internally threaded connection
18004f at another end.
[0165] Torsional locking pins, 18006a and 18006b, are coupled to
and mounted within the external radial mounting holes, 18002b and
18002c, respectively, of the upper tubular support member and
received within the radial passages, 18004a and 18004b, of the end
of the tubular actuator barrel 18004. The other end of the tubular
actuator barrel 18004 receives and is threadably coupled to an end
of a tubular barrel connector 18008 that defines an internal
annular recess 18008a, external radial mounting holes, 18008b and
18008c, radial passages, 18008d and 18008e, and external radial
mounting holes, 18008f and 18008g and includes circumferentially
spaced apart teeth 18008h at one end. A sealing cartridge 18010 is
received within and coupled to the internal annular recess 18008a
of the tubular barrel connector 18008 for fluidicly sealing the
interface between the tubular barrel connector and the sealing
cartridge. Torsional locking pins, 18012a and 18012b, are coupled
to and mounted within the external radial mounting holes, 18008b
and 18008c, respectively, of the tubular barrel connector 18008 and
received within the radial passages, 18004c and 18004d, of the
tubular actuator barrel 18004.
[0166] A tubular member 18014 that defines a longitudinal passage
18014a having one or more internal splines 18014b at one end and
circumferentially spaced apart teeth 18014c at another end for
engaging the circumferentially spaced apart teeth 18008h of the
tubular barrel connector 18008 mates with and is received within
the actuator barrel 18004 and the one end of the tubular member
abuts an end face of the other end of the upper tubular support
member 18002 and at another end abuts and end face of the tubular
barrel connector 18008. A tubular guide member 18016 that defines a
longitudinal passage 18016a having a tapered opening 18016aa, and
radial passages, 18016b and 18016c, includes an external flange
18016d having an externally threaded connection at one end that is
received within and coupled to the internal annular recess 18002h
of the upper tubular support member 18002.
[0167] The other end of the tubular barrel connector 18008 is
threadably coupled to and is received within an end of a tubular
actuator barrel 18018 that defines a longitudinal passage 18018a,
radial passages, 18018b and 18018c, and radial passages, 18018d and
18018e. Torsional locking pins, 18020a and 18020b, are coupled to
and mounted within the external radial mounting holes, 18008f and
18008g, respectively, of the tubular barrel connector 18008 and
received within the radial passages, 18018b and 18018c, of the
tubular actuator barrel 18018. The other end of the tubular
actuator barrel 18018 receives and is threadably coupled to an end
of a tubular barrel connector 18022 that defines an internal
annular recess 18022a, external radial mounting holes, 18022b and
18022c, radial passages, 18022d and 18022e, and external radial
mounting holes, 18022f and 18022g. A sealing cartridge 18024 is
received within and coupled to the internal annular recess 18022a
of the tubular barrel connector 18022 for fluidicly sealing the
interface between the tubular barrel connector and the sealing
cartridge. Torsional locking pins, 18024a and 18024b, are coupled
to and mounted within the external radial mounting holes, 18022b
and 18022c, respectively, of the barrel connector 18022 and
received within the radial passages, 18018d and 18018e, of the
tubular actuator barrel 18018.
[0168] The other end of the tubular barrel connector 18022 is
threadably coupled to and is received within an end of a tubular
actuator barrel 18026 that defines a longitudinal passage 18026a,
radial passages, 18026b and 18026c, and radial passages, 18026d and
18026e. Torsional locking pins, 18028a and 18028b, are coupled to
and mounted within the external radial mounting holes, 18022f and
18022g, respectively, of the tubular barrel connector 18022 and
received within the radial passages, 18026b and 18026c, of the
tubular actuator barrel 18026. The other end of the tubular
actuator barrel 18026 receives and is threadably coupled to an end
of a tubular barrel connector 18030 that defines an internal
annular recess 18030a, external radial mounting holes, 18030b and
18030c, radial passages, 18030d and 18030e, and external radial
mounting holes, 18030f and 18030g. A sealing cartridge 18032 is
received within and coupled to the internal annular recess 18030a
of the tubular barrel connector 18030 for fluidicly sealing the
interface between the tubular barrel connector and the sealing
cartridge. Torsional locking pins, 18034a and 18034b, are coupled
to and mounted within the external radial mounting holes, 18030b
and 18030c, respectively, of the tubular barrel connector 18030 and
received within the radial passages, 18026d and 18026e, of the
tubular actuator barrel 18026.
[0169] The other end of the tubular barrel connector 18030 is
threadably coupled to and is received within an end of a tubular
actuator barrel 18036 that defines a longitudinal passage 18036a,
radial passages, 18036b and 18036c, and radial passages, 18036d and
18036e. Torsional locking pins, 18038a and 18038b, are coupled to
and mounted within the external radial mounting holes, 18030f and
18030g, respectively, of the tubular barrel connector 18030 and
received within the radial passages, 18036b and 18036c, of the
tubular actuator barrel 18036. The other end of the tubular
actuator barrel 18036 receives and is threadably coupled to an end
of a tubular barrel connector 18040 that defines an internal
annular recess 18040a, external radial mounting holes, 18040b and
18040c, radial passages, 18040d and 18040e, and external radial
mounting holes, 18040f and 18040g. A sealing cartridge 18042 is
received within and coupled to the internal annular recess 18040a
of the tubular barrel connector 18040 for fluidicly sealing the
interface between the tubular barrel connector and the sealing
cartridge. Torsional locking pins, 18044a and 18044b, are coupled
to and mounted within the external radial mounting holes, 18040b
and 18040c, respectively, of the tubular barrel connector 18040 and
received within the radial passages, 18036d and 18036e, of the
tubular actuator barrel 18036.
[0170] The other end of the tubular barrel connector 18040 is
threadably coupled to and is received within an end of a tubular
actuator barrel 18046 that defines a longitudinal passage 18046a,
radial passages, 18046b and 18046c, and radial passages, 18046d and
18046e. Torsional locking pins, 18048a and 18048b, are coupled to
and mounted within the external radial mounting holes, 18040f and
18040g, respectively, of the tubular barrel connector 18040 and
received within the radial passages, 18046b and 18046c, of the
tubular actuator barrel 18046. The other end of the tubular
actuator barrel 18046 receives and is threadably coupled to an end
of a tubular barrel connector 18050 that defines an internal
annular recess 18050a, external radial mounting holes, 18050b and
18050c, radial passages, 18050d and 18050e, and external radial
mounting holes, 18050f and 18050g. A sealing cartridge 18052 is
received within and coupled to the internal annular recess 18050a
of the tubular barrel connector 18050 for fluidicly sealing the
interface between the tubular barrel connector and the sealing
cartridge. Torsional locking pins, 18054a and 18054b, are coupled
to and mounted within the external radial mounting holes, 18050b
and 18050c, respectively, of the tubular barrel connector 18050 and
received within the radial passages, 18046d and 18046e, of the
tubular actuator barrel 18046.
[0171] The other end of the tubular barrel connector 18050 is
threadably coupled to and is received within an end of a tubular
actuator barrel 18056 that defines a longitudinal passage 18056a,
radial passages, 18056b and 18056c, and radial passages, 18056d and
18056e. Torsional locking pins, 18058a and 18058b, are coupled to
and mounted within the external radial mounting holes, 18050f and
18050g, respectively, of the tubular barrel connector 18050 and
received within the radial passages, 18056b and 18056c, of the
tubular actuator barrel 18056. The other end of the tubular
actuator barrel 18056 receives and is threadably coupled to an end
of a tubular lower stop 18060 that defines an internal annular
recess 18060a, external radial mounting holes, 18060b and 18060c,
and an internal annular recess 18060d that includes one or more
circumferentially spaced apart locking teeth 18060e at one end and
one or more circumferentially spaced apart locking teeth 18060f at
the other end. A sealing cartridge 18062 is received within and
coupled to the internal annular recess 18060a of the tubular lower
stop 18060 for fluidicly sealing the interface between the tubular
lower stop and the sealing cartridge. Torsional locking pins,
18064a and 18064b, are coupled to and mounted within the external
radial mounting holes, 18060b and 18060c, respectively, of the
tubular lower stop 18060 and received within the radial passages,
18056d and 18056e, of the tubular actuator barrel 18056.
[0172] A connector tube 18066 that defines a longitudinal passage
18066a and radial mounting holes, 18066b and 18066c, and includes
external splines 18066d at one end for engaging the internal
splines 18014b of the tubular member 18014 and radial mounting
holes, 18066e and 18066f, at another end is received within and
sealingly and movably engages the interior surface of the sealing
cartridge 18010 mounted within the annular recess 18008a of the
tubular barrel connector 18008. In this manner, during longitudinal
displacement of the connector tube 18066 relative to the tubular
barrel connector 18008, a fluidic seal is maintained between the
exterior surface of the connector tube and the interior surface of
the tubular barrel connector. An end of the connector tube 18066
also receives and mates with the other end of the tubular guide
member 18016. Mounting screws, 18068a and 18068b, are coupled to
and received within the radial mounting holes, 18066b and 18066c,
respectively of the connector tube 18066.
[0173] The other end of the connector tube 18066 is received within
and threadably coupled to an end of a tubular piston 18070 that
defines a longitudinal passage 18070a, radial mounting holes,
18070b and 18070c, radial passages, 18070d and 18070e, and radial
mounting holes, 18070f and 18070g, that includes a flange 18070h at
one end. A sealing cartridge 18072 is mounted onto and sealingly
coupled to the exterior of the tubular piston 18070 proximate the
flange 18070h. The sealing cartridge 18072 also mates with and
sealingly engages the interior surface of the tubular actuator
barrel 18018. In this manner, during longitudinal displacement of
the tubular piston 18070 relative to the actuator barrel 18018, a
fluidic seal is maintained between the exterior surface of the
piston and the interior surface of the actuator barrel. Mounting
screws, 18074a and 18074b, are coupled to and mounted within the
external radial mounting holes, 18070b and 18070c, respectively, of
the tubular piston 18070 and received within the radial passages,
18066e and 18066f, of the connector tube 18066.
[0174] The other end of the tubular piston 18070 receives and is
threadably coupled to an end of a connector tube 18076 that defines
a longitudinal passage 18076a, radial mounting holes, 18076b and
18076c, at one end and radial mounting holes, 18076d and 18076e, at
another end. The connector tube 18076 is received within and
sealingly and movably engages the interior surface of the sealing
cartridge 18024 mounted within the annular recess 18022a of the
tubular barrel connector 18022. In this manner, during longitudinal
displacement of the connector tube 18076 relative to the tubular
barrel connector 18022, a fluidic seal is maintained between the
exterior surface of the connector tube and the interior surface of
the barrel connector. Mounting screws, 18078a and 18078b, are
coupled to and mounted within the external radial mounting holes,
18070f and 18070g, respectively, of the tubular piston 18070 and
received within the radial passages, 18076b and 18076c, of the
connector tube 18076.
[0175] The other end of the connector tube 18076 is received within
and threadably coupled to an end of a tubular piston 18080 that
defines a longitudinal passage 18080a, radial mounting holes,
18080b and 18080c, radial passages, 18080d and 18080e, and radial
mounting holes, 18080f and 18080g, that includes a flange 18080h at
one end. A sealing cartridge 18082 is mounted onto and sealingly
coupled to the exterior of the tubular piston 18080 proximate the
flange 18080h. The sealing cartridge 18082 also mates with and
sealingly engages the interior surface of the tubular actuator
barrel 18026. In this manner, during longitudinal displacement of
the tubular piston 18080 relative to the tubular actuator barrel
18026, a fluidic seal is maintained between the exterior surface of
the piston and the interior surface of the actuator barrel.
Mounting screws, 18084a and 18084b, are coupled to and mounted
within the external radial mounting holes, 18080b and 18080c,
respectively, of the tubular piston 18080 and received within the
radial passages, 18076e and 18076f, of the connector tube
18076.
[0176] The other end of the tubular piston 18080 receives and is
threadably coupled to an end of a connector tube 18086 that defines
a longitudinal passage 18086a, radial mounting holes, 18086b and
18086c, at one end and radial mounting holes, 18086d and 18086e, at
another end. The connector tube 18086 is received within and
sealingly and movably engages the interior surface of the sealing
cartridge 18032 mounted within the annular recess 18030a of the
tubular barrel connector 18030. In this manner, during longitudinal
displacement of the connector tube 18086 relative to the tubular
barrel connector 18030, a fluidic seal is maintained between the
exterior surface of the connector tube and the interior surface of
the barrel connector. Mounting screws, 18088a and 18088b, are
coupled to and mounted within the external radial mounting holes,
18080f and 18080g, respectively, of the tubular piston 18080 and
received within the radial passages, 18086b and 18086c, of the
connector tube 18086.
[0177] The other end of the connector tube 18086 is received within
and threadably coupled to an end of a tubular piston 18090 that
defines a longitudinal passage 18090a, radial mounting holes,
18090b and 18090c, radial passages, 18090d and 18090e, and radial
mounting holes, 18090f and 18090g, that includes a flange 18090h at
one end. A sealing cartridge 18092 is mounted onto and sealingly
coupled to the exterior of the tubular piston 18090 proximate the
flange 18090h. The sealing cartridge 18092 also mates with and
sealingly engages the interior surface of the tubular actuator
barrel 18036. In this manner, during longitudinal displacement of
the tubular piston 18090 relative to the tubular actuator barrel
18036, a fluidic seal is maintained between the exterior surface of
the piston and the interior surface of the actuator barrel.
Mounting screws, 18094a and 18094b, are coupled to and mounted
within the external radial mounting holes, 18090b and 18090c,
respectively, of the tubular piston 18090 and received within the
radial passages, 18086e and 18086f, of the connector tube
18086.
[0178] The other end of the tubular piston 18090 receives and is
threadably coupled to an end of a connector tube 18096 that defines
a longitudinal passage 18096a, radial mounting holes, 18096b and
18096c, at one end and radial mounting holes, 18096d and 18096e, at
another end. The connector tube 18096 is received within and
sealingly and movably engages the interior surface of the sealing
cartridge 18042 mounted within the annular recess 18040a of the
tubular barrel connector 18040. In this manner, during longitudinal
displacement of the connector tube 18096 relative to the tubular
barrel connector 18040, a fluidic seal is maintained between the
exterior surface of the connector tube and the interior surface of
the barrel connector. Mounting screws, 18098a and 18098b, are
coupled to and mounted within the external radial mounting holes,
18090f and 18090g, respectively, of the tubular piston 18090 and
received within the radial passages, 18096b and 18096c, of the
connector tube 18096.
[0179] The other end of the connector tube 18096 is received within
and threadably coupled to an end of a tubular piston 18100 that
defines a longitudinal passage 18100a, radial mounting holes,
18100b and 18100c, radial passages, 18100d and 18100e, and radial
mounting holes, 18100f and 18100g, that includes a flange 18100h at
one end. A sealing cartridge 18102 is mounted onto and sealingly
coupled to the exterior of the tubular piston 18100 proximate the
flange 18100h. The sealing cartridge 18102 also mates with and
sealingly engages the interior surface of the tubular actuator
barrel 18046. In this manner, during longitudinal displacement of
the tubular piston 18100 relative to the tubular actuator barrel
18046, a fluidic seal is maintained between the exterior surface of
the piston and the interior surface of the actuator barrel.
Mounting screws, 18104a and 18104b, are coupled to and mounted
within the external radial mounting holes, 18100b and 18100c,
respectively, of the tubular piston 18100 and received within the
radial passages, 18096e and 18096f, of the connector tube
18096.
[0180] The other end of the tubular piston 18100 receives and is
threadably coupled to an end of a connector tube 18106 that defines
a longitudinal passage 18106a, radial mounting holes, 18106b and
18106c, at one end and radial mounting holes, 18106d and 18106e, at
another end. The connector tube 18106 is received within and
sealingly and movably engages the interior surface of the sealing
cartridge 18052 mounted within the annular recess 18050a of the
tubular barrel connector 18050. In this manner, during longitudinal
displacement of the connector tube 18106 relative to the tubular
barrel connector 18050, a fluidic seal is maintained between the
exterior surface of the connector tube and the interior surface of
the barrel connector. Mounting screws, 18108a and 18108b, are
coupled to and mounted within the external radial mounting holes,
18100f and 18100g, respectively, of the tubular piston 18100 and
received within the radial passages, 18106b and 18106c, of the
connector tube 18106.
[0181] The other end of the connector tube 18106 is received within
and threadably coupled to an end of a tubular piston 18110 that
defines a longitudinal passage 18110a, radial mounting holes,
18110b and 18110c, radial passages, 18110d and 18110e, radial
mounting holes, 18110f and 18110g, that includes a flange 18110h at
one end and circumferentially spaced teeth 18110i at another end
for engaging the one or more circumferentially spaced apart locking
teeth 18060e of the tubular lower stop 18060. A sealing cartridge
18112 is mounted onto and sealingly coupled to the exterior of the
tubular piston 18110 proximate the flange 18110h. The sealing
cartridge 18112 also mates with and sealingly engages the interior
surface of the actuator barrel 18056. In this manner, during
longitudinal displacement of the tubular piston 18110 relative to
the actuator barrel 18056, a fluidic seal is maintained between the
exterior surface of the piston and the interior surface of the
actuator barrel. Mounting screws, 18114a and 18114b, are coupled to
and mounted within the external radial mounting holes, 18110b and
18110c, respectively, of the tubular piston 18110 and received
within the radial passages, 18106d and 18106e, of the connector
tube 18106.
[0182] The other end of the tubular piston 18110 receives and is
threadably coupled to an end of a connector tube 18116 that defines
a longitudinal passage 18116a, radial mounting holes, 18116b and
18116c, at one end and radial mounting holes, 18116d and 18116e, at
another end that includes an external flange 18116f that includes
circumferentially spaced apart teeth 18116g that extend from an end
face of the external flange for engaging the teeth 18060f of the
tubular lower stop 18060, and an externally threaded connection
18116h at another end. The connector tube 18116 is received within
and sealingly and movably engages the interior surface of the
sealing cartridge 18062 mounted within the annular recess 18060a of
the lower tubular stop 18060. In this manner, during longitudinal
displacement of the connector tube 18116 relative to the lower
tubular stop 18060, a fluidic seal is maintained between the
exterior surface of the connector tube and the interior surface of
the lower tubular stop. Mounting screws, 18118a and 18118b, are
coupled to and mounted within the external radial mounting holes,
18110f and 18110g, respectively, of the tubular piston 18110 and
received within the radial passages, 18116b and 18116c, of the
connector tube 18116.
[0183] In an exemplary embodiment, as illustrated in FIGS. 13A1 to
13A8, the internally threaded connection 18002e of the upper
tubular support member 18002 receives and is coupled to the
externally threaded connection 1234g of the lower mandrel 1234 of
the ball grabber assembly 16 and the externally threaded connection
18116h of the connector tube 18116 is received within and is
coupled to an internally threaded connection 20a of an end of the
safety sub assembly 20.
[0184] In an exemplary embodiment, as illustrated in FIGS. 13A1 to
13A8, during operation of the tension actuator assembly 18, the
tension actuator assembly is positioned within the expandable
wellbore casing 100 and fluidic material 18200 is injected into the
tension actuator assembly through the passages 18002a, 18016a,
18066a, 18070a, 18076a, 18080a, 18086a, 18090a, 18096a, 18100a,
18106a, 18110a, and 18116a. The injected fluidic material 18200
will also pass through the radial passages, 18070d and 18070e,
18080d and 18080e, 18090d and 18090e, 18100d and 18100e, 18110d and
18110e, of the tubular pistons, 18070, 18080, 18090, 18100, and
18110, respectively, into annular piston chambers, 18202, 18204,
18206, 18208, 18208, and 18210.
[0185] As illustrated in FIGS. 13B1 to 13B7, the operating pressure
of the fluidic material 18200 may then be increased by, for
example, controllably blocking or limiting the flow of the fluidic
material through the passage 18116a and/or increasing the operating
pressure of the outlet of a pumping device for injecting the
fluidic material 18200 into the tension actuator assembly 18. As a
result, of the increased operating pressure of the fluidic material
18200 within the tension actuator assembly 18, the operating
pressures of the annular piston chambers, 18202, 18204, 18206,
18208, 18208, and 18210, will be increased sufficiently to displace
the tubular pistons, 18070, 18080, 18090, 18100, and 18110,
upwardly in the direction 18212 thereby also displacing the
connector tube 18116. As a result, a upward tensile force is
applied to all elements of the system 10 coupled to and positioned
below the connector tube 18116. In an exemplary embodiment, during
the upward displacement of the tubular pistons, 18070, 18080,
18090, 18100, and 18110, fluidic materials displaced by the tubular
pistons within discharge annular chambers, 18214, 18216, 18218,
18220, and 18222 are exhausted out of the tension actuator assembly
18 through the radial passages, 18008d and 18008e, 18022d and
18022e, 18030d and 18030e, 18040d and 18040e, 18050d and 18050e,
respectively. Furthermore, in an exemplary embodiment, the upward
displacement of the tubular pistons, 18070, 18080, 18090, 18100,
and 18110, further causes the external splines 18066d of the
connector tube 18066 to engage the internal splines 18014b of the
tubular member 18014 and the circumferentially spaced apart teeth
18116g of the connector tube 18116 to engage the circumferentially
spaced teeth 18060f of the tubular lower stop 18060. As a result of
the interaction of the external splines 18066d of the connector
tube 18066 to engage the internal splines 18014b of the tubular
member 18014 and the circumferentially spaced apart teeth 18116g of
the connector tube 18116 to engage the circumferentially spaced
teeth 18060f of the tubular lower stop 18060, torsional loads may
be transmitted through the tension actuator assembly 18.
[0186] In an exemplary embodiment, as illustrated in FIG. 14A, the
safety sub assembly 20 includes a tubular body 200a that defines a
longitudinal passage 200b and includes an external flange 200c and
an internal annular recess 200d at one end, and external annular
recesses, 200e, 200f, 200g, and 200h at another end. A sealing
member 202 is positioned within the external annular recess 200h at
the other end of the tubular body 200a.
[0187] In an exemplary embodiment, as illustrated in FIGS. 14A, 14B
and 14C, the sealing cup assembly 22 includes an upper tubular
mandrel 2202 that defines a longitudinal passage 2202a and
internally threaded radial mounting holes, 2202b and 2202c, and
includes an internal annular recess 2202d at one end, an internal
annular recess 2202e, an internal annular recess 2202f, an internal
annular recess 2202g, and an internally threaded internal annular
recess 2202h and an external flange 2202i at another end. The
internal annular recesses, 2202d, 2202e, and 2202f, of the upper
tubular mandrel 2202 of the sealing cup assembly 22 receive, mate
with, and are coupled to the other end of the tubular body 200a of
the safety sub assembly 20.
[0188] An externally threaded end of a lower tubular mandrel 2204
that defines a longitudinal passage 2204a and includes an external
annular recess 2204b at one end, an external annular recess 2204c,
an external flange 2204d, an external annular recess 2204e, an
externally threaded external flange 2204f, and an external annular
recess 2204g at another end mates with, is received within, and is
coupled to the internal annular recesses, 2202g and 2202h, of the
other end of the upper tubular mandrel 2202.
[0189] Mounting screws, 2250a and 2205b, are received within and
coupled to the mounting holes, 2202c and 2202b, respectively, of
the tubular mandrel 2202 that extend into and engage the external
annular recess 2204c of the lower tubular mandrel 2204.
[0190] A tubular cup seal spacer 2206 receives and is mounted upon
the lower tubular mandrel 2204 proximate the external flange 2202i
of the upper tubular mandrel 2202. A tubular cup seal retainer 2208
that includes an internal flange 2208a at one end receives and is
mounted upon the lower tubular mandrel 2204 proximate the tubular
cup seal spacer 2206. A tubular cup seal retainer 2210 that
includes an internal flange 2210a at one end receives and is
mounted upon the lower tubular mandrel 2204 proximate the other end
of the tubular cup seal retainer 2208. In an exemplary embodiment,
the tubular cup seal retainer 2210 is nested within the other end
of the tubular cup seal retainer 2208. A tubular cup seal 2212 that
includes an internal flange 2212a at one end receives and is
mounted upon the lower tubular mandrel 2204 proximate the other end
of the tubular cup seal retainer 2210. In an exemplary embodiment,
the tubular cup seal 2212 is nested within the other end of the
tubular cup seal retainer 2210.
[0191] A sealing member 2211 is received within the external
annular recess 2204b of the lower tubular mandrel 2204 for sealing
the interface between the lower tubular mandrel and the upper
tubular mandrel 2202.
[0192] A tubular spacer 2214 receives and is mounted upon the lower
tubular mandrel 2204 proximate the other end of the tubular cup
seal 2212.
[0193] A tubular cup seal spacer 2216 receives and is mounted upon
the lower tubular mandrel 2204 proximate the other end of the
tubular spacer 2214. A tubular cup seal retainer 2218 that includes
an internal flange 2218a at one end receives and is mounted upon
the lower tubular mandrel 2204 proximate the other end of the
tubular cup seal spacer 2216. A tubular cup seal retainer 2220 that
includes an internal flange 2220a at one end receives and is
mounted upon the lower tubular mandrel 2204 proximate the other end
of the tubular cup seal retainer 2218. In an exemplary embodiment,
the tubular cup seal retainer 2220 is nested within the other end
of the tubular cup seal retainer 2218. A tubular cup seal 2222 that
includes an internal flange 2222a at one end receives and is
mounted upon the lower tubular mandrel 2204 proximate the other end
of the tubular cup seal retainer 2220. In an exemplary embodiment,
the tubular cup seal 2222 is nested within the other end of the
tubular cup seal retainer 2220.
[0194] A tubular spacer 2224 receives and is mounted upon the lower
tubular mandrel 2204 proximate the other end of the tubular cup
seal 2222 at one end and proximate the external flange 2204d of the
lower tubular mandrel at another end. A retaining ring 2226
receives and is mounted upon the other end of the tubular spacer
2224 proximate the external flange 2204d of the lower tubular
mandrel 2204.
[0195] In an exemplary embodiment, during operation of the system
10, the end of the tubular body 200a of the safety sub assembly 20
is coupled to and receives and is coupled to an end of the tension
actuator assembly 18 and the other end of the lower tubular mandrel
2204 of the sealing cup assembly 22 is received within and is
coupled to an end of the casing lock assembly 24.
[0196] In an exemplary embodiment, during operation of the system
10, the tubular cup seals, 2212 and/or 2222, sealingly engage the
interior surface of the expandable tubular member 100. In this
manner, when an annulus defined between the system 10 and the
expandable wellbore casing 10, below the tubular cup seals, 2212
and/or 2222, is pressurized, the resulting pressure differential
across the tubular cup seals applies an upward tensile force to the
system thereby pulling the adjustable bell section expansion cone
assembly 28 and/or the adjustable casing expansion cone assembly 30
through the expandable wellbore casing. In this manner, the
adjustable bell section expansion cone assembly 28 and/or the
adjustable casing expansion cone assembly 30, if either or both are
adjusted to an outside diameter suitable for a radial expansion
operation, may radially expand and plastically deform the
expandable wellbore casing 100.
[0197] In an exemplary embodiment, the sealing cup assembly 22
operates and is provided substantially, at least in part, as
disclosed in one or more of the following: (1) PCT patent
application serial number PCT/US02/36157, attorney docket number
25791.87.02, filed on Nov. 12, 2002, (2) PCT patent application
serial number PCT/US02/36267, attorney docket number 25791.88.02,
filed on Nov. 12, 2002, (3) PCT patent application serial number
PCT/US03/04837, attorney docket number 25791.95.02, filed on Feb.
29, 2003, (4) PCT patent application serial number PCT/US03/29859,
attorney docket no. 25791.102.02, filed on Sep. 22, 2003, (5) PCT
patent application serial number PCT/US03/14153, attorney docket
number 25791.104.02, filed on Nov. 13, 2003, (6) PCT patent
application serial number PCT/US03/18530, attorney docket number
25791.108.02, filed on Jun. 11, 2003, and/or (7) PCT patent
application serial number PCT/US04/______, attorney docket number
25791.253.02, filed on Mar. 11, 2004, and/or (8) PCT patent
application serial number PCT/US04/______, attorney docket number
25791.260, filed on Mar. 26, 2004, the disclosures of which are
incorporated herein by reference.
[0198] In an exemplary embodiment, the casing lock assembly 24
operates and is provided substantially, at least in part, as
disclosed in one or more of the following: (1) PCT patent
application serial number PCT/US02/36267, attorney docket number
25791.88.02, filed on Nov. 12, 2002, (2) PCT patent application
serial number PCT/US03/29859, attorney docket no. 25791.102.02,
filed on Sep. 22, 2003, (3) PCT patent application serial number
PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov.
13, 2003, and/or (4) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.253.02, filed on Mar.
11, 2004, and/or (5) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.260, filed on Mar.
26, 2004, the disclosures of which are incorporated herein by
reference.
[0199] In an exemplary embodiment, the extension actuator assembly
26 operates and is provided substantially, at least in part, as
disclosed in one or more of the following: (1) PCT patent
application serial number PCT/US02/36267, attorney docket number
25791.88.02, filed on Nov, 12, 2002, and/or (2) PCT patent
application serial number PCT/US03/29859, attorney docket no.
25791.102.02, filed on Sep. 22, 2003, and/or (3) PCT patent
application serial number PCT/US/______, attorney docket number
25791.107.02, filed on ______, and/or (4) PCT patent application
serial number PCT/US______, attorney docket number 25791.114.02,
filed on ______, and/or (5) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.253.02, filed on Mar.
11, 2004, and/or (6) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.260, filed on Mar.
26, 2004, the disclosures of which are incorporated herein by
reference.
[0200] In an exemplary embodiment, the adjustable bell section
expansion cone assembly 28 operates and is provided substantially,
at least in part, as disclosed in one or more of the following: (1)
PCT patent application serial number PCT/US02/36157, attorney
docket number 25791.87.02, filed on Nov. 12, 2002, (2) PCT patent
application serial number PCT/US02/36267, attorney docket number
25791.88.02, filed on Nov. 12, 2002, (3) PCT patent application
serial number PCT/US03/04837, attorney docket number 25791.95.02,
filed on Feb. 29, 2003, (4) PCT patent application serial number
PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22,
2003, (5) PCT patent application serial number PCT/US03/14153,
attorney docket number 25791.104.02, filed on Nov. 13, 2003, (6)
PCT patent application serial number PCT/US03/18530, attorney
docket number 25791.108.02, filed on Jun. 11, 2003, and/or (7) PCT
patent application serial number PCT/US04/______, attorney docket
number 25791.253.02, filed on Mar. 11, 2004, and/or (8) PCT patent
application serial number PCT/US04/______, attorney docket number
25791.260, filed on Mar. 26, 2004, the disclosures of which are
incorporated herein by reference.
[0201] In an exemplary embodiment, as illustrated in FIGS. 15-1 and
15-2, 15A1 to 15A2, 15B1 to 15B2, 15C, 15D, 15E, 15F, 15G, 15H,
151, 15j, 15K, 15L, 15M, 15N, 150, 15P, 15R, 15S, 15T, 15U, 15V,
15W, 15X, 15Y, 15Z1 to 15Z4, 15AA1 to 15AA4, 15AB1 to 15AB4, 15AC1
to 15AC4, 15AD, and 15AE, the adjustable bell section expansion
cone assembly 28 includes an upper tubular tool joint 28002 that
defines a longitudinal passage 28002a and mounting holes, 28002b
and 28002c, and includes an internal threaded connection 28002d, an
inner annular recess 28002e, an inner annular recess 28002f, and an
internal threaded connection 28002g. A tubular torque plate 28004
that defines a longitudinal passage 28004a and includes
circumferentially spaced apart teeth 28004b is received within,
mates with, and is coupled to the internal annular recess 28002e of
the upper tubular tool joint 28002.
[0202] Circumferentially spaced apart teeth 28006a of an end of a
tubular lower mandrel 28006 that defines a longitudinal passage
28006b, a radial passage 28006ba, and a radial passage 28006bb and
includes an external threaded connection 28006c, an external flange
28006d, an external annular recess 28006e having a step 28006f at
one end, an external annular recess 28006g, external teeth 28006h,
an external threaded connection 28006i, and an external annular
recess 28006j engage the circumferentially spaced apart teeth
28004b of the tubular torque plate 28004. An internal threaded
connection 28008a of an end of a tubular toggle bushing 28008 that
defines a longitudinal passage 28008b, an upper longitudinal slot
28008c, a lower longitudinal slot 28008d, mounting holes, 28008e,
28008f, 28008g, 28008h, 28008i, 28008j, 28008k, 28008l, 28008m,
28008n, 28008o, 28008p, 28008q, 28008r, 28008s, 28008t, 28008u,
28008v, 28008w, 28008x, 28008xa, and 28008xb, and includes an
external annular recess 28008y, internal annular recess 28008z,
external annular recess 28008aa, and an external annular recess
28008ab receives and is coupled to the external threaded connection
28006c of the tubular lower mandrel 28006.
[0203] A sealing element 28010 is received within the external
annular recess 28008y of the tubular toggle bushing 28008 for
sealing the interface between the tubular toggle bushing and the
upper tubular tool joint 28002. A sealing element 28012 is received
within the internal annular recess 28008z of the tubular toggle
bushing 28008 for sealing the interface between the tubular toggle
bushing and the tubular lower mandrel 28006.
[0204] Mounting screws, 28014a and 28014b, mounted within and
coupled to the mounting holes, 28008w and 28008x, respectively, of
the tubular toggle bushing 28008 are also received within the
mounting holes, 28002b and 28002c, of the upper tubular tool joint
28002. Mounting pins, 28016a, 28016b, 28016c, 28016d, and 28016e,
are mounted within the mounting holes, 28008e, 28008f, 28008g,
28008h, and 28008i, respectively. Mounting pins, 28018a, 28018b,
28018c, 28018d, and 28018e, are mounted within the mounting holes,
28008t, 28008s, 28008r, 28008q, and 28008p, respectively. Mounting
screws, 28020a and 28020b, are mounted within the mounting holes,
28008u and 28008v, respectively.
[0205] A first upper toggle link 28022 defines mounting holes,
28022a and 28022b, for receiving the mounting pins, 28016a and
28016b, and includes a mounting pin 28022c at one end. A first
lower toggle link 28024 defines mounting holes, 28024a, 28024b, and
28024c, for receiving the mounting pins, 28022c, 28016c, and
28016d, respectively and includes an engagement arm 28024d. A first
trigger 28026 defines a mounting hole 28026a for receiving the
mounting pin 28016e and includes an engagement arm 28026b at one
end, an engagement member 28026c, and an engagement arm 28026d at
another end.
[0206] A second upper toggle link 28028 defines mounting holes,
28028a and 28028b, for receiving the mounting pins, 28018a and
28018b, and includes a mounting pin 28028c at one end. A second
lower toggle link 28030 defines mounting holes, 28030a, 28030b, and
28030c, for receiving the mounting pins, 28028c, 28018c, and
28018d, respectively and includes an engagement arm 28030d. A
second trigger 28032 defines a mounting hole 28032a for receiving
the mounting pin 28018e and includes an engagement arm 28032b at
one end, an engagement member 28032c, and an engagement arm 28032d
at another end.
[0207] An end of a tubular spring housing 28034 that defines a
longitudinal passage 28034a, mounting holes, 28034b and 28034c, and
mounting holes, 28034ba and 28034ca, and includes an internal
flange 28034d and an internal annular recess 28034e at one end, and
an internal flange 28034f, an internal annular recess 28034g, an
internal annular recess 28034h, and an external threaded connection
28034i at another end receives and mates with the end of the
tubular toggle bushing 28008. Mounting screws, 28035a and 28035b,
are mounted within and coupled to the mounting holes, 28008xb and
28008xa, respectively, of the tubular toggle bushing 28008 and are
received within the mounting holes, 28034ba and 28034ca,
respectively, of the tubular spring housing 28034.
[0208] A tubular retracting spring ring 28036 that defines mounting
holes, 28036a and 28036b, receives and mates with a portion of the
tubular lower mandrel 28006 and is received within and mates with a
portion of the tubular spring housing 28034. Mounting screws,
28038a and 28038b, are mounted within and coupled to the mounting
holes, 28036a and 28036b, respectively, of the tubular retracting
spring ring 28036 and extend into the mounting holes, 28034b and
28034c, respectively, of the tubular spring housing 28034.
[0209] Casing diameter sensor springs, 28040a and 28040b, are
positioned within the longitudinal slots, 28008c and 2808d,
respectively, of the tubular toggle bushing 28008 that engage the
engagement members, 28026c and 28032c, and engagement arms, 28026d
and 28032d, of the first and second triggers, 28026 and 28032,
respectively. An inner flange 28042a of an end of a tubular spring
washer 28042 mates with and receives a portion of the tubular lower
mandrel 28006 and an end face of the inner flange of the tubular
spring washer is positioned proximate and end face of the external
flange 28006d of the tubular lower mandrel. The tubular spring
washer 28042 is further received within the longitudinal passage
28034a of the tubular spring housing 28034.
[0210] An end of a retracting spring 28044 that receives the
tubular lower mandrel 28006 is positioned within the tubular spring
washer 28042 in contact with the internal flange 28042a of the
tubular spring washer and the other end of the retracting spring is
positioned in contact with an end face of the tubular retracting
spring ring 28036.
[0211] A sealing element 28046 is received within the external
annular recess 28006j of the tubular lower mandrel 28006 for
sealing the interface between the tubular lower mandrel and the
tubular spring housing 28034. A sealing element 28048 is received
within the internal annular recess 28034h of the tubular spring
housing 28034 for sealing the interface between the tubular spring
housing and the tubular lower mandrel 28006.
[0212] An internal threaded connection 28050a of an end of a
tubular upper hinge sleeve 28050 that includes an internal flange
28050b and an internal pivot 28050c receives and is coupled to the
external threaded connection 28034i of the end of the tubular
spring housing 28034.
[0213] An external flange 28052a of a base member 28052b of an
upper cam assembly 28052, that is mounted upon and receives the
lower tubular mandrel 28006, that includes an internal flange
28052c that is received within the external annular recess 28006e
of the lower tubular mandrel 28006 and a plurality of
circumferentially spaced apart tapered cam arms 28052d extending
from the base member mates with and is received within the tubular
upper hinge sleeve 28050. The base member 28052b of the upper cam
assembly 28052 further includes a plurality of circumferentially
spaced apart teeth 28052f that mate with and are received within a
plurality of circumferentially spaced apart teeth 28034j provided
on the end face of the tubular spring housing 28034 and an end face
of the external flange 28052a of the base member of the upper cam
assembly is positioned in opposing relation to an end face of the
internal flange 28050b of the tubular upper hinge sleeve 28050.
Each of the cam arms 28052d of the upper cam assembly 28052 include
external cam surfaces 28052e. In an exemplary embodiment, the teeth
28052f of the base member 28052b of the upper cam assembly 28052
and the teeth 28034j provided on the end face of the tubular spring
housing 28034 permit torsional loads to be transmitted between the
tubular spring housing and the upper cam assembly.
[0214] A plurality of circumferentially spaced apart upper
expansion segments 28054 are mounted upon and receive the lower
tubular mandrel 28006 and each include an external pivot recess
28054a at one end for mating with and receiving the internal pivot
28050c of the tubular upper hinge sleeve 28050 and an external
tapered expansion surface 28054b at another end and are pivotally
mounted within the tubular upper hinge sleeve and are interleaved
with the circumferentially spaced apart cam arms 28052d of the
upper cam assembly 28052. The upper expansion segments 28054 are
interleaved among the cam arms 28052d of the upper cam assembly
28052.
[0215] A plurality of circumferentially spaced apart lower
expansion segments 28058 are mounted upon and receive the lower
tubular mandrel 28006, are interleaved among the upper expansion
segments 28054, are oriented in the opposite direction to the upper
expansion segments 28054, each include an external pivot recess
28058a at one end and an external tapered expansion surface 28054b
at another end and are positioned in opposing relation to
corresponding circumferentially spaced apart cam arms 28052d of the
upper cam assembly 28052.
[0216] A lower cam assembly 28060 is mounted upon and receives the
lower tubular mandrel 28006 that includes a base member 28060a
having an external flange 28060b, a plurality of circumferentially
spaced apart cam arms 28060d that extend from the base member that
each include external cam surfaces 28060e and define mounting holes
28060f and 28060g. The base member 28060a of the lower cam assembly
28060 further includes a plurality of circumferentially spaced
apart teeth 28060h. The circumferentially spaced apart cam arms
28060d of the lower cam assembly 28060 are interleaved among the
lower expansion segments 28058 and the circumferentially spaced
apart cam arms 28052d of the upper cam assembly 28052 and
positioned in opposing relation to corresponding upper expansion
segments 28054.
[0217] Mounting screws, 28062a, 28062b, 28062c, and 28062e, are
mounted within the corresponding mounting holes, 28060f and 28060g,
of the lower cam assembly 28060 and are received within the
external annular recess 28006g of the lower cam assembly 28060.
[0218] A tubular lower hinge sleeve 28064 that receives the lower
expansion segments 28058 and the lower cam assembly 28060 includes
an internal flange 28064a for engaging the external flange 28060b
of the base member of the lower cam assembly 28060, an internal
pivot 28064b for engaging and receiving the external pivot recess
28058a of the lower expansion segments 28058 thereby pivotally
mounting the lower expansion segments within the tubular lower
hinge sleeve, and an internal threaded connection 28064c.
[0219] An external threaded connection 28066a of an end of a
tubular sleeve 28066 that defines mounting holes, 28066b and
28066c, and includes an internal annular recess 28066d having a
shoulder 28066e, an internal flange 28066f, and an internal
threaded connection 28066g at another end is received within and
coupled to the internal threaded connection 28064c of the tubular
lower hinge sleeve 28064. An external threaded connection 28068a of
an end of a tubular member 28068 that defines a longitudinal
passage 28068b and mounting holes, 28068c and 28068d, and includes
an external annular recess 28068e, and an external threaded
connection 28068f at another end is received within and is coupled
to the internal threaded connection 28066g of the tubular sleeve
28066.
[0220] Mounting screws, 28070a and 28070b, are mounted in and
coupled to the mounting holes, 28068c and 28068d, respectively, of
the tubular member 28068 that also extend into the mounting holes,
28066b and 28066c, respectively, of the tubular sleeve 28066. A
sealing element 28072 is received within the external annular
recess 28068e of the tubular member 28068 for sealing the interface
between the tubular member and the tubular sleeve 28066.
[0221] An internal threaded connection 28074a of a tubular
retracting piston 28074 that defines a longitudinal passage 28074b
and includes an internal annular recess 28074c and an external
annular recess 28074d receives and is coupled to the external
threaded connection 28006i of the tubular lower mandrel 28006. A
sealing element 28076 is received within the external annular
recess 28074d of the tubular retracting piston 28074 for sealing
the interface between the tubular retracting piston and the tubular
sleeve 28066. A sealing element 28078 is received within the
internal annular recess 28074c of the tubular retracting piston
28074 for sealing the interface between the tubular retracting
piston and the tubular lower mandrel 28006.
[0222] Locking dogs 28080 mate with and receive the external teeth
28006h of the tubular lower mandrel 28006. A spacer ring 28082 is
positioned between an end face of the locking dogs 28080 and an end
face of the lower cam assembly 28060. A release piston 28084
mounted upon the tubular lower mandrel 28006 defines a radial
passage 28084a for mounting a burst disk 28086 includes sealing
elements, 28084b, 28084c, and 28084d. The sealing elements, 28084b
and 28084d, sealing the interface between the release piston 28084
and the tubular lower mandrel 28006. An end face of the release
piston 28084 is positioned in opposing relation to an end face of
the locking dogs 28080.
[0223] A release sleeve 28088 that receives and is mounted upon the
locking dogs 28080 and the release piston 28084 includes an
internal flange 28088a at one end that sealingly engages the
tubular lower mandrel 28006. A bypass sleeve 28090 that receives
and is mounted upon the release sleeve 28088 includes an internal
flange 28090a at one end.
[0224] In an exemplary embodiment, during operation of the
adjustable bell section expansion cone assembly 28, the retracting
spring 28044 is compressed and thereby applies a biasing spring
force in a direction 28092 from the lower tubular mandrel 28006 to
the tubular spring housing 28034 that, in the absence of other
forces, moves and/or maintains the upper cam assembly 28052 and the
upper expansion segments 28054 out of engagement with the lower
expansion segments 28058 and the lower cam assembly 28060. In an
exemplary embodiment, during operation of the adjustable bell
section expansion cone assembly 28, an external threaded connection
20a of an end of the sealing cup assembly 20 is coupled to the
internal threaded connection 28002d of the upper tubular tool joint
28002 and an internal threaded connection 30a of an end of the
adjustable casing expansion cone assembly 30 is coupled to the
external threaded connection 28068f of the tubular member
28068.
[0225] The upper cam assembly 28052 and the upper expansion
segments 28054 may be brought into engagement with the lower
expansion segments 28058 and the lower cam assembly 28060 by
pressurizing an annulus 28094 defined between the lower tubular
mandrel 28006 and the tubular spring housing 28034. In particular,
injection of fluidic materials into the adjustable bell section
expansion cone assembly 28 through the longitudinal passage 28006b
of the lower tubular mandrel 28006 and into the radial passage
28006ba may pressurize the annulus 28094 thereby creating
sufficient operating pressure to generate a force in a direction
28096 sufficient to overcome the biasing force of the retracting
spring 28044. As a result, the spring housing 28034 may be
displaced in the direction 28096 relative to the lower tubular
mandrel 28006 thereby displacing the tubular upper hinge sleeve
28050, upper cam assembly 28052, and upper expansion segments 28054
in the direction 28096.
[0226] In an exemplary embodiment, as illustrated in FIGS. 15P and
15R, the displacement of the upper cam assembly 28052 and upper
expansion segments 28054 in the direction 28096 will cause the
lower expansion segments 28058 to ride up the cam surfaces 28052e
of the cam arms 28052d of the upper cam assembly 28052 while also
pivoting about the lower tubular hinge segment 28064, and will also
cause the upper expansion segments 28054 to ride up the cam
surfaces 28060e of the cam arms 28060d of the lower cam assembly
28060 while also pivoting about the upper tubular hinge segment
28050. In an exemplary embodiment, when the upper and lower
expansion segments, 28054 and 28058, are brought into axial
alignment, they define an outer expansion surface that is
approximately contiguous in a circumferential direction and which
provides an outer expansion surface that at least approximates a
conical surface.
[0227] In an exemplary embodiment, during the operation of the
adjustable bell section expansion cone assembly 28, when the upper
and lower expansion segments, 28054 and 28058, brought into axial
alignment into a radially expanded position, the upper and lower
expansion segments, 28054 and 28058, are displaced relative to the
expandable wellbore casing 100 to thereby radially expand and
plastically deform at least a portion of the expandable wellbore
casing. In an exemplary embodiment, during the radial expansion and
plastic deformation of the expandable wellbore casing 100, the
adjustable bell section expansion cone assembly 28 may then be
rotated relative to the expandable wellbore casing to enhance
and/or modify the rate at which the expandable wellbore casing is
radially expanded and plastically deformed.
[0228] In an exemplary embodiment, the upper cam assembly 28052 and
the upper expansion segments 28054 may be moved out of engagement
with the lower expansion segments 28058 and the lower cam assembly
28060 by reducing the operating pressure within the annulus
28094.
[0229] In an alternative embodiment, as illustrated in FIGS. 15S,
15T, 15U and 15V, during operation of the adjustable bell section
expansion cone assembly 28, the upper cam assembly 28052 and the
upper expansion segments 28054 may also be moved out of engagement
with the lower expansion segments 28058 and the lower cam assembly
28060 by sensing the operating pressure within the longitudinal
passage 28006b of the lower tubular mandrel 28006. In particular,
as illustrated in FIG. 15T, if the operating pressure within the
longitudinal passage 28006b and radial passage 28006bb of the lower
tubular mandrel 28006 exceeds a predetermined value, the burst disc
28086 will open the passage 28084a thereby pressurizing the
interior of the tubular release sleeve 28088 thereby displacing the
tubular release sleeve 28088 downwardly in a direction 28092 away
from engagement with the locking dogs 28080.
[0230] As a result, as illustrated in FIG. 15U, the locking dogs
28080 are displaced outwardly in the radial directed and thereby
released from engagement with the lower tubular mandrel 28006
thereby permitting the lower expansion segments 28058 and the lower
cam assembly 28060 to be displaced downwardly relative to the lower
tubular mandrel.
[0231] As a result, as illustrated in FIG. 15V, the operating
pressure within the lower tubular mandrel 28066 may then cause the
lower tubular mandrel to be displaced downwardly in the direction
28094 relative to the tubular lower mandrel 28006 and the
retracting piston 28074. As a result, the lower tubular mandrel
28066, the lower expansion segments 28058, the lower cam assembly
28060, and tubular lower hinge sleeve 28064 are displaced
downwardly in the direction 28094 relative to the tubular spring
housing 28034 thereby moving the lower expansion segments 28058 and
the lower cam assembly 28060 out of engagement with the upper cam
assembly 28052 and the upper expansion segments 28054.
[0232] In an exemplary embodiment, as illustrated in FIGS. 15W,
15X, and 15Y, during operation of the adjustable bell section
expansion cone assembly 28, the adjustable bell section expansion
cone assembly senses the diameter of the expandable wellbore casing
100 using the upper toggle links, 28022 and 28028, lower toggle
links, 28024 and 28030, and triggers, 28026 and 28032, and then
prevents the engagement of the upper cam assembly 28052 and the
upper expansion segments 28054 with the lower expansion segments
28058 and the lower cam assembly 28060.
[0233] In particular, as illustrated in FIG. 15W, anytime the upper
toggle links, 28022 and 28028, and lower toggle links, 28024 and
28030, are positioned within a portion of the expandable wellbore
casing 100 that has been radially expanded and plastically deformed
by the system 10, the triggers, 28026 and 28032, will be pivoted by
the engagement arms, 28024d and 28030d, of the lower toggle links,
28024 and 28030, to a position in which the triggers will no longer
engage the internal flange 28034d of the end of the tubular spring
housing 28034 thereby permitting the displacement of the tubular
spring housing in the direction 28096. As a result, the upper cam
assembly 28052 and the upper expansion segments 28054 can be
brought into engagement with the lower expansion segments 28058 and
the lower cam assembly 28060. In an exemplary embodiment, the upper
toggle links, 28022 and 28028, and the lower toggle links, 28024
and 28030, are spring biased towards the position illustrated in
FIG. 15W.
[0234] Conversely, as illustrated in FIG. 15X, anytime the upper
toggle links, 28022 and 28028, and lower toggle links, 28024 and
28030, are positioned within a portion of the expandable wellbore
casing 100 that has not been radially expanded and plastically
deformed by the system 10, the triggers, 28026 and 28032, will be
maintained in a position in which the triggers will engage the
internal flange 28034d of the end of the tubular spring housing
28034 thereby preventing the displacement of the tubular spring
housing in the direction 28096. As a result, the upper cam assembly
28052 and the upper expansion segments 28054 cannot be brought into
engagement with the lower expansion segments 28058 and the lower
cam assembly 28060. In an exemplary embodiment, the triggers, 28026
and 28032, are spring biased towards the position illustrated in
FIG. 15X.
[0235] In an exemplary embodiment, as illustrated in FIG. 15Y, the
tubular spring housing 28034 may be displaced upwardly in the
direction 28098 even if the upper toggle links, 28022 and 28028,
and lower toggle links, 28024 and 28030, are positioned within a
portion of the expandable wellbore casing 100 that has not been
radially expanded and plastically deformed by the system 10.
[0236] In an exemplary embodiment, as illustrated in FIGS. 15Z1 to
15Z4, 15AA1 to 15AA4, 15AB1 to 15AB4, 15AC1 to 15AC4, 15AD, and
15AE, the tubular spring housing 28034 of the adjustable bell
section expansion cone assembly 28 defines internal annular
recesses 28034k and 28034l, spaced apart by an internal flange
28034m, the tubular toggle bushing 28008 defines an external
annular recess 28008ac, and the adjustable bell section expansion
cone assembly further includes pins, 28100a and 28100b and 28102a
and 28102b, mounted in holes 28008j and 28008o and 28008k and
28008n, respectively, of the tubular toggle bushing, and a one-shot
deactivation device 28104 mounted on the tubular toggle bushing
between the pins, 28100a and 28100b and 28102a and 28102b.
[0237] The one-shot deactivation device 28104 includes a tubular
body 28104a that defines radial holes, 28104b and 28014c, and
includes an external annular recess 28104d at one end, a centrally
positioned external flange 28104e, a centrally positioned internal
annular recess 28104f, and an external annular recess 28104g at
another end. An engagement member 28106 that includes a base member
28106a having a tapered end 28106b and a key member 28106c having a
tapered end 28106d is received within a portion of the internal
annular recess 28104f of the tubular body 28104a and an engagement
member 28108 that includes a base member 28108a having a tapered
end 28108b and a key member 28108c having a tapered end 28108d is
received within an opposite portion of the internal annular recess
28104f of the tubular body 28104a. Spring members, 28110 and 28112,
are received within the annular recess 28104f of the tubular body
28104a for biasing the base members, base member 28106a and 28108a,
of the engagement members, 28106 and 28108, respectively, radially
inwardly relative to the tubular body 28104a.
[0238] In an exemplary embodiment, during operation of the
adjustable bell section expansion cone assembly 28, as illustrated
in FIGS. 15Z1 to 15Z4, the one-shot deactivation device 28104 are
positioned proximate and in intimate contact with the pins, 28102a
and 28102b, with the tapered ends, 28106b and 28108b, of the base
members, 28106a and 28108a, of the engagement members, 28106 and
28108, received within the external annular recess 28008ac of the
tubular toggle bushing 28008. When the one-shot deactivation device
28104 is positioned as illustrated in FIGS. 15Z1 to 15Z4, the
external annular recess 28104d of the tubular body 28104a of the
one-shot deactivation device is moved out of engagement with the
engagement arms, 28026d and 28032d, of the triggers, 28026 and
28032, respectively. As a result, the triggers, 28026 and 28032,
may operate normally as described above with reference to FIGS.
15W, 15X, and 15Y.
[0239] Conversely, in an exemplary embodiment, during operation of
the adjustable bell section expansion cone assembly 28, as
illustrated in FIGS. 15AA1 to 15AA4, the one-shot deactivation
device 28104 are positioned proximate and in intimate contact with
the pins, 28100a and 28100b, with the tapered ends, 28106b and
28108b, of the base members, 28106a and 28108a, of the engagement
members, 28106 and 28108, not received within the external annular
recess 28008ac of the tubular toggle bushing 28008. When the
one-shot deactivation device 28104 is positioned as illustrated in
FIG. 15AA, the external annular recess 28104d of the tubular body
28104a of the one-shot deactivation device is moved into engagement
with the engagement arms, 28026d and 28032d, of the triggers, 28026
and 28032, respectively. As a result, the triggers, 28026 and
28032, are deactivated and may not operate normally as described
above with reference to FIGS. 15W, 15X, and 15Y.
[0240] In an alternative embodiment, the elements of the adjustable
bell section expansion cone assembly 28 that sense the diameter of
the expandable wellbore casing 100 may be disabled or omitted or
adjusted to sense any pre-selected internal diameter of the
expandable wellbore casing.
[0241] In an exemplary embodiment, the adjustable casing expansion
cone assembly 30 operates and is provided substantially, at least
in part, as disclosed in one or more of the following: (1) PCT
patent application serial number PCT/US02/36157, attorney docket
number 25791.87.02, filed on Nov. 12, 2002, (2) PCT patent
application serial number PCT/US02/36267, attorney docket number
25791.88.02, filed on Nov. 12, 2002, (3) PCT patent application
serial number PCT/US03/04837, attorney docket number 25791.95.02,
filed on Feb. 29, 2003, (4) PCT patent application serial number
PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22,
2003, (5) PCT patent application serial number PCT/US03/14153,
attorney docket number 25791.104.02, filed on Nov. 13, 2003, (6)
PCT patent application serial number PCT/US03/18530, attorney
docket number 25791.108.02, filed on Jun. 11, 2003, and/or (7) PCT
patent application serial number PCT/US04/______, attorney docket
number 25791.253.02, filed on Mar. 11, 2004, and/or (8) PCT patent
application serial number PCT/US04/______, attorney docket number
25791.260, filed on Mar. 26, 2004, the disclosures of which are
incorporated herein by reference.
[0242] In an exemplary embodiment, as illustrated in FIGS. 16-1 and
16-2, 16A1 to 16A2, 16B1 to 16B2, 16C, 16D, 16E, 16F, 16G, 16H,
16I, 16j, 16K, 16L, 16M, 16N, 16O, 16P, 16R, 16S, 16T, 16U, 16V,
16W, 16X, 16Y, 16Z1-16Z4, 16AA1 to 16AA4, 16AB1 to 16AB4, 16AC1 to
16AC4, 16AD, and 16AE, the adjustable casing expansion cone
assembly 30 includes an upper tubular tool joint 30002 that defines
a longitudinal passage 30002a and mounting holes, 30002b and
30002c, and includes an internal threaded connection 30002d, an
inner annular recess 30002e, an inner annular recess 30002f, and an
internal threaded connection 30002g. A tubular torque plate 30004
that defines a longitudinal passage 30004a and includes
circumferentially spaced apart teeth 30004b is received within,
mates with, and is coupled to the internal annular recess 30002e of
the upper tubular tool joint 30002.
[0243] Circumferentially spaced apart teeth 30006a of an end of a
tubular lower mandrel 30006 that defines a longitudinal passage
30006b, a radial passage 30006ba, and a radial passage 30006bb and
includes an external threaded connection 30006c, an external flange
30006d, an external annular recess 30006e having a step 30006f at
one end, an external annular recess 30006g, external teeth 30006h,
an external threaded connection 30006i, and an external annular
recess 30006j engage the circumferentially spaced apart teeth
30004b of the tubular torque plate 30004. An internal threaded
connection 30008a of an end of a tubular toggle bushing 30008 that
defines a longitudinal passage 30008b, an upper longitudinal slot
30008c, a lower longitudinal slot 30008d, mounting holes, 30008e,
30008f, 30008g, 30008h, 30008i, 30008j, 30008k, 30008l, 30008m,
30008n, 30008o, 30008p, 30008q, 30008r, 30008s, 30008t, 30008u,
30008v, 30008w, 30008x, 30008xa, and 30008xb, and includes an
external annular recess 30008y, internal annular recess 30008z,
external annular recess 30008aa, and an external annular recess
30008ab receives and is coupled to the external threaded connection
30006c of the tubular lower mandrel 30006.
[0244] A sealing element 30010 is received within the external
annular recess 30008y of the tubular toggle bushing 30008 for
sealing the interface between the tubular toggle bushing and the
upper tubular tool joint 30002. A sealing element 30012 is received
within the internal annular recess 30008z of the tubular toggle
bushing 30008 for sealing the interface between the tubular toggle
bushing and the tubular lower mandrel 30006.
[0245] Mounting screws, 30014a and 30014b, mounted within and
coupled to the mounting holes, 30008w and 30008x, respectively, of
the tubular toggle bushing 30008 are also received within the
mounting holes, 30002b and 30002c, of the upper tubular tool joint
30002. Mounting pins, 30016a, 30016b, 30016c, 30016d, and 30016e,
are mounted within the mounting holes, 30008e, 30008f, 30008g,
30008h, and 30008i, respectively. Mounting pins, 30018a, 30018b,
30018c, 30018d, and 30018e, are mounted within the mounting holes,
30008t, 30008s, 30008r, 30008q, and 30008p, respectively. Mounting
screws, 30020a and 30020b, are mounted within the mounting holes,
30008u and 30008v, respectively.
[0246] A first upper toggle link 30022 defines mounting holes,
30022a and 30022b, for receiving the mounting pins, 30016a and
30016b, and includes a mounting pin 30022c at one end. A first
lower toggle link 30024 defines mounting holes, 30024a, 30024b, and
30024c, for receiving the mounting pins, 30022c, 30016c, and
30016d, respectively and includes an engagement arm 30024d. A first
trigger 30026 defines a mounting hole 30026a for receiving the
mounting pin 30016e and includes an engagement arm 30026b at one
end, an engagement member 30026c, and an engagement arm 30026d at
another end.
[0247] A second upper toggle link 30028 defines mounting holes,
30028a and 30028b, for receiving the mounting pins, 30018a and
30018b, and includes a mounting pin 30028c at one end. A second
lower toggle link 30030 defines mounting holes, 30030a, 30030b, and
30030c, for receiving the mounting pins, 30028c, 30018c, and
30018d, respectively and includes an engagement arm 30030d. A
second trigger 30032 defines a mounting hole 30032a for receiving
the mounting pin 30018e and includes an engagement arm 30032b at
one end, an engagement member 30032c, and an engagement arm 30032d
at another end.
[0248] An end of a tubular spring housing 30034 that defines a
longitudinal passage 30034a, mounting holes, 30034b and 30034c, and
mounting holes, 30034ba and 30034ca, and includes an internal
flange 30034d and an internal annular recess 30034e at one end, and
an internal flange 30034f, an internal annular recess 30034g, an
internal annular recess 30034h, and an external threaded connection
30034i at another end receives and mates with the end of the
tubular toggle bushing 30008. Mounting screws, 30035a and 30035b,
are mounted within and coupled to the mounting holes, 30008xb and
30008xa, respectively, of the tubular toggle bushing 30008 and are
received within the mounting holes, 30034ba and 30034ca,
respectively, of the tubular spring housing 30034.
[0249] A tubular retracting spring ring 30036 that defines mounting
holes, 30036a and 30036b, receives and mates with a portion of the
tubular lower mandrel 30006 and is received within and mates with a
portion of the tubular spring housing 30034. Mounting screws,
30038a and 30038b, are mounted within and coupled to the mounting
holes, 30036a and 30036b, respectively, of the tubular retracting
spring ring 30036 and extend into the mounting holes, 30034b and
30034c, respectively, of the tubular spring housing 30034.
[0250] Casing diameter sensor springs, 30040a and 30040b, are
positioned within the longitudinal slots, 30008c and 3008d,
respectively, of the tubular toggle bushing 30008 that engage the
engagement members, 30026c and 30032c, and engagement arms, 30026d
and 30032d, of the first and second triggers, 30026 and 30032,
respectively. An inner flange 30042a of an end of a tubular spring
washer 30042 mates with and receives a portion of the tubular lower
mandrel 30006 and an end face of the inner flange of the tubular
spring washer is positioned proximate and end face of the external
flange 30006d of the tubular lower mandrel. The tubular spring
washer 30042 is further received within the longitudinal passage
30034a of the tubular spring housing 30034.
[0251] An end of a retracting spring 30044 that receives the
tubular lower mandrel 30006 is positioned within the tubular spring
washer 30042 in contact with the internal flange 30042a of the
tubular spring washer and the other end of the retracting spring is
positioned in contact with an end face of the tubular retracting
spring ring 30036.
[0252] A sealing element 30046 is received within the external
annular recess 30006j of the tubular lower mandrel 30006 for
sealing the interface between the tubular lower mandrel and the
tubular spring housing 30034. A sealing element 30048 is received
within the internal annular recess 30034h of the tubular spring
housing 30034 for sealing the interface between the tubular spring
housing and the tubular lower mandrel 30006.
[0253] An internal threaded connection 30050a of an end of a
tubular upper hinge sleeve 30050 that includes an internal flange
30050b and an internal pivot 30050c receives and is coupled to the
external threaded connection 30034i of the end of the tubular
spring housing 30034.
[0254] An external flange 30052a of a base member 30052b of an
upper cam assembly 30052, that is mounted upon and receives the
lower tubular mandrel 30006, that includes an internal flange
30052c that is received within the external annular recess 30006e
of the lower tubular mandrel 30006 and a plurality of
circumferentially spaced apart tapered cam arms 30052d extending
from the base member mates with and is received within the tubular
upper hinge sleeve 30050. The base member 30052b of the upper cam
assembly 30052 further includes a plurality of circumferentially
spaced apart teeth 30052f that mate with and are received within a
plurality of circumferentially spaced apart teeth 30034j provided
on the end face of the tubular spring housing 30034 and an end face
of the external flange 30052a of the base member of the upper cam
assembly is positioned in opposing relation to an end face of the
internal flange 30050b of the tubular upper hinge sleeve 30050.
Each of the cam arms 30052d of the upper cam assembly 30052 include
external cam surfaces 30052e. In an exemplary embodiment, the teeth
30052f of the base member 30052b of the upper cam assembly 30052
and the teeth 30034j provided on the end face of the tubular spring
housing 30034 permit torsional loads to be transmitted between the
tubular spring housing and the upper cam assembly.
[0255] A plurality of circumferentially spaced apart upper
expansion segments 30054 are mounted upon and receive the lower
tubular mandrel 30006 and each include an external pivot recess
30054a at one end for mating with and receiving the internal pivot
30050c of the tubular upper hinge sleeve 30050 and an external
tapered expansion surface 30054b at another end and are pivotally
mounted within the tubular upper hinge sleeve and are interleaved
with the circumferentially spaced apart cam arms 30052d of the
upper cam assembly 30052. The upper expansion segments 30054 are
interleaved among the cam arms 30052d of the upper cam assembly
30052.
[0256] A plurality of circumferentially spaced apart lower
expansion segments 30058 are mounted upon and receive the lower
tubular mandrel 30006, are interleaved among the upper expansion
segments 30054, are oriented in the opposite direction to the upper
expansion segments 30054, each include an external pivot recess
30058a at one end and an external tapered expansion surface 30054b
at another end and are positioned in opposing relation to
corresponding circumferentially spaced apart cam arms 30052d of the
upper cam assembly 30052.
[0257] A lower cam assembly 30060 is mounted upon and receives the
lower tubular mandrel 30006 that includes a base member 30060a
having an external flange 30060b, a plurality of circumferentially
spaced apart cam arms 30060d that extend from the base member that
each include external cam surfaces 30060e and define mounting holes
30060f and 30060g. The base member 30060a of the lower cam assembly
30060 further includes a plurality of circumferentially spaced
apart teeth 30060h. The circumferentially spaced apart cam arms
30060d of the lower cam assembly 30060 are interleaved among the
lower expansion segments 30058 and the circumferentially spaced
apart cam arms 30052d of the upper cam assembly 30052 and
positioned in opposing relation to corresponding upper expansion
segments 30054.
[0258] Mounting screws, 30062a, 30062b, 30062c, and 30062e, are
mounted within the corresponding mounting holes, 30060f and 30060g,
of the lower cam assembly 30060 and are received within the
external annular recess 30006g of the lower cam assembly 30060.
[0259] A tubular lower hinge sleeve 30064 that receives the lower
expansion segments 30058 and the lower cam assembly 30060 includes
an internal flange 30064a for engaging the external flange 30060b
of the base member of the lower cam assembly 30060, an internal
pivot 30064b for engaging and receiving the external pivot recess
30058a of the lower expansion segments 30058 thereby pivotally
mounting the lower expansion segments within the tubular lower
hinge sleeve, and an internal threaded connection 30064c.
[0260] An external threaded connection 30066a of an end of a
tubular sleeve 30066 that defines mounting holes, 30066b and
30066c, and includes an internal annular recess 30066d having a
shoulder 30066e, an internal flange 30066f, and an internal
threaded connection 30066g at another end is received within and
coupled to the internal threaded connection 30064c of the tubular
lower hinge sleeve 30064. An external threaded connection 30068a of
an end of a tubular member 30068 that defines a longitudinal
passage 30068b and mounting holes, 30068c and 30068d, and includes
an external annular recess 30068e, and an external threaded
connection 30068f at another end is received within and is coupled
to the internal threaded connection 30066g of the tubular sleeve
30066.
[0261] Mounting screws, 30070a and 30070b, are mounted in and
coupled to the mounting holes, 30068c and 30068d, respectively, of
the tubular member 30068 that also extend into the mounting holes,
30066b and 30066c, respectively, of the tubular sleeve 30066. A
sealing element 30072 is received within the external annular
recess 30068e of the tubular member 30068 for sealing the interface
between the tubular member and the tubular sleeve 30066.
[0262] An internal threaded connection 30074a of a tubular
retracting piston 30074 that defines a longitudinal passage 30074b
and includes an internal annular recess 30074c and an external
annular recess 30074d receives and is coupled to the external
threaded connection 30006i of the tubular lower mandrel 30006. A
sealing element 30076 is received within the external annular
recess 30074d of the tubular retracting piston 30074 for sealing
the interface between the tubular retracting piston and the tubular
sleeve 30066. A sealing element 30078 is received within the
internal annular recess 30074c of the tubular retracting piston
30074 for sealing the interface between the tubular retracting
piston and the tubular lower mandrel 30006.
[0263] Locking dogs 30080 mate with and receive the external teeth
30006h of the tubular lower mandrel 30006. A spacer ring 30082 is
positioned between an end face of the locking dogs 30080 and an end
face of the lower cam assembly 30060. A release piston 30084
mounted upon the tubular lower mandrel 30006 defines a radial
passage 30084a for mounting a burst disk 30086 includes sealing
elements, 30084b, 30084c, and 30084d. The sealing elements, 30084b
and 30084d, sealing the interface between the release piston 30084
and the tubular lower mandrel 30006. An end face of the release
piston 30084 is positioned in opposing relation to an end face of
the locking dogs 30080.
[0264] A release sleeve 30088 that receives and is mounted upon the
locking dogs 30080 and the release piston 30084 includes an
internal flange 30088a at one end that sealingly engages the
tubular lower mandrel 30006. A bypass sleeve 30090 that receives
and is mounted upon the release sleeve 30088 includes an internal
flange 30090a at one end.
[0265] In an exemplary embodiment, during operation of the
adjustable casing expansion cone assembly 30, the retracting spring
30044 is compressed and thereby applies a biasing spring force in a
direction 30092 from the lower tubular mandrel 30006 to the tubular
spring housing 30034 that, in the absence of other forces, moves
and/or maintains the upper cam assembly 30052 and the upper
expansion segments 30054 out of engagement with the lower expansion
segments 30058 and the lower cam assembly 30060. In an exemplary
embodiment, during operation of the adjustable bell section
expansion cone assembly 28, an external threaded connection 20a of
an end of the sealing cup assembly 20 is coupled to the internal
threaded connection 30002d of the upper tubular tool joint 30002
and an internal threaded connection 30a of an end of the adjustable
casing expansion cone assembly 30 is coupled to the external
threaded connection 30068f of the tubular member 30068.
[0266] The upper cam assembly 30052 and the upper expansion
segments 30054 may be brought into engagement with the lower
expansion segments 30058 and the lower cam assembly 30060 by
pressurizing an annulus 30094 defined between the lower tubular
mandrel 30006 and the tubular spring housing 30034. In particular,
injection of fluidic materials into the adjustable casing expansion
cone assembly 30 through the longitudinal passage 30006b of the
lower tubular mandrel 30006 and into the radial passage 30006ba may
pressurize the annulus 30094 thereby creating sufficient operating
pressure to generate a force in a direction 30096 sufficient to
overcome the biasing force of the retracting spring 30044. As a
result, the spring housing 30034 may be displaced in the direction
30096 relative to the lower tubular mandrel 30006 thereby
displacing the tubular upper hinge sleeve 30050, upper cam assembly
30052, and upper expansion segments 30054 in the direction
30096.
[0267] In an exemplary embodiment, as illustrated in FIGS. 16P,
16Q, and 16R, the displacement of the upper cam assembly 30052 and
upper expansion segments 30054 in the direction 30096 will cause
the lower expansion segments 30058 to ride up the cam surfaces
30052e of the cam arms 30052d of the upper cam assembly 30052 while
also pivoting about the lower tubular hinge segment 30064, and will
also cause the upper expansion segments 30054 to ride up the cam
surfaces 30060e of the cam arms 30060d of the lower cam assembly
30060 while also pivoting about the upper tubular hinge segment
30050. In an exemplary embodiment, when the upper and lower
expansion segments, 30054 and 30058, are brought into axial
alignment, they define an outer expansion surface that is
approximately contiguous in a circumferential direction and which
provides an outer expansion surface that at least approximates a
conical surface.
[0268] In an exemplary embodiment, during the operation of the
adjustable casing expansion cone assembly 30, when the upper and
lower expansion segments, 30054 and 30058, brought into axial
alignment into a radially expanded position, the upper and lower
expansion segments, 30054 and 30058, are displaced relative to the
expandable wellbore casing 100 to thereby radially expand and
plastically deform at least a portion of the expandable wellbore
casing. In an exemplary embodiment, during the radial expansion and
plastic deformation of the expandable wellbore casing 100, the
adjustable casing expansion cone assembly 30 may then be rotated
relative to the expandable wellbore casing to enhance and/or modify
the rate at which the expandable wellbore casing is radially
expanded and plastically deformed.
[0269] In an exemplary embodiment, the upper cam assembly 30052 and
the upper expansion segments 30054 may be moved out of engagement
with the lower expansion segments 30058 and the lower cam assembly
30060 by reducing the operating pressure within the annulus
30094.
[0270] In an alternative embodiment, as illustrated in FIGS. 16S,
16T, 16U and 16V, during operation of the adjustable casing
expansion cone assembly 30, the upper cam assembly 30052 and the
upper expansion segments 30054 may also be moved out of engagement
with the lower expansion segments 30058 and the lower cam assembly
30060 by sensing the operating pressure within the longitudinal
passage 30006b of the lower tubular mandrel 30006. In particular,
as illustrated in FIG. 16T, if the operating pressure within the
longitudinal passage 30006b and radial passage 30006bb of the lower
tubular mandrel 30006 exceeds a predetermined value, the burst disc
30086 will open the passage 30084a thereby pressurizing the
interior of the tubular release sleeve 30088 thereby displacing the
tubular release sleeve 30088 downwardly in a direction 30092 away
from engagement with the locking dogs 30080.
[0271] As a result, as illustrated in FIG. 16U, the locking dogs
30080 are displaced outwardly in the radial directed and thereby
released from engagement with the lower tubular mandrel 30006
thereby permitting the lower expansion segments 30058 and the lower
cam assembly 30060 to be displaced downwardly relative to the lower
tubular mandrel.
[0272] As a result, as illustrated in FIG. 16V, the operating
pressure within the lower tubular mandrel 30066 may then cause the
lower tubular mandrel to be displaced downwardly in the direction
30094 relative to the tubular lower mandrel 30006 and the
retracting piston 30074. As a result, the lower tubular mandrel
30066, the lower expansion segments 30058, the lower cam assembly
30060, and tubular lower hinge sleeve 30064 are displaced
downwardly in the direction 30094 relative to the tubular spring
housing 30034 thereby moving the lower expansion segments 30058 and
the lower cam assembly 30060 out of engagement with the upper cam
assembly 30052 and the upper expansion segments 30054.
[0273] In an exemplary embodiment, as illustrated in FIGS. 16W,
16X, and 16Y, during operation of the adjustable casing expansion
cone assembly 30, the adjustable casing expansion cone assembly
senses the diameter of the expandable wellbore casing 100 using the
upper toggle links, 30022 and 30028, lower toggle links, 30024 and
30030, and triggers, 30026 and 30032, and then prevents the
engagement of the upper cam assembly 30052 and the upper expansion
segments 30054 with the lower expansion segments 30058 and the
lower cam assembly 30060.
[0274] In particular, as illustrated in FIG. 16W, anytime the upper
toggle links, 30022 and 30028, and lower toggle links, 30024 and
30030, are positioned within a portion of the expandable wellbore
casing 100 that has been radially expanded and plastically deformed
by the system 10, the triggers, 30026 and 30032, will be pivoted by
the engagement arms, 30024d and 30030d, of the lower toggle links,
30024 and 30030, to a position in which the triggers will no longer
engage the internal flange 30034d of the end of the tubular spring
housing 30034 thereby permitting the displacement of the tubular
spring housing in the direction 30096. As a result, the upper cam
assembly 30052 and the upper expansion segments 30054 can be
brought into engagement with the lower expansion segments 30058 and
the lower cam assembly 30060. In an exemplary embodiment, the upper
toggle links, 30022 and 30028, and the lower toggle links, 30024
and 30030, are spring biased towards the position illustrated in
FIG. 16W.
[0275] Conversely, as illustrated in FIG. 16X, anytime the upper
toggle links, 30022 and 30028, and lower toggle links, 30024 and
30030, are positioned within a portion of the expandable wellbore
casing 100 that has not been radially expanded and plastically
deformed by the system 10, the triggers, 30026 and 30032, will be
maintained in a position in which the triggers will engage the
internal flange 30034d of the end of the tubular spring housing
30034 thereby preventing the displacement of the tubular spring
housing in the direction 30096. As a result, the upper cam assembly
30052 and the upper expansion segments 30054 cannot be brought into
engagement with the lower expansion segments 30058 and the lower
cam assembly 30060. In an exemplary embodiment, the triggers, 30026
and 30032, are spring biased towards the position illustrated in
FIG. 16X.
[0276] In an exemplary embodiment, as illustrated in FIG. 16Y, the
tubular spring housing 30034 may be displaced upwardly in the
direction 30098 even if the upper toggle links, 30022 and 30028,
and lower toggle links, 30024 and 30030, are positioned within a
portion of the expandable wellbore casing 100 that has not been
radially expanded and plastically deformed by the system 10.
[0277] In an exemplary embodiment, as illustrated in FIGS. 16Z1 to
16Z4, 16AA1 to 16AA4, 16AB1 to 16AB4, 16AC1 to 16AC4, 16AD, and
16AE, the tubular spring housing 30034 of the adjustable casing
expansion cone assembly 30 defines internal annular recesses 30034k
and 300341, spaced apart by an internal flange 30034m, the tubular
toggle bushing 30008 defines an external annular recess 30008ac,
and the adjustable casing expansion cone assembly further includes
pins, 30100a and 30100b and 30102a and 30102b, mounted in holes
30008j and 30008o and 30008k and 30008n, respectively, of the
tubular toggle bushing, and a one-shot deactivation device 30104
mounted on the tubular toggle bushing between the pins, 30100a and
30100b and 30102a and 30102b.
[0278] The one-shot deactivation device 30104 includes a tubular
body 30104a that defines radial holes, 30104b and 30014c, and
includes an external annular recess 30104d at one end, a centrally
positioned external flange 30104e, a centrally positioned internal
annular recess 30104f, and an external annular recess 30104g at
another end. An engagement member 30106 that includes a base member
30106a having a tapered end 30106b and a key member 30106c having a
tapered end 30106d is received within a portion of the internal
annular recess 30104f of the tubular body 30104a and an engagement
member 30108 that includes a base member 30108a having a tapered
end 30108b and a key member 30108c having a tapered end 30108d is
received within an opposite portion of the internal annular recess
30104f of the tubular body 30104a. Spring members, 30110 and 30112,
are received within the annular recess 30104f of the tubular body
30104a for biasing the base members, base member 30106a and 30108a,
of the engagement members, 30106 and 30108, respectively, radially
inwardly relative to the tubular body 30104a.
[0279] In an exemplary embodiment, during operation of the
adjustable bell section expansion cone assembly 28, as illustrated
in FIG. 16Z, the one-shot deactivation device 30104 are positioned
proximate and in intimate contact with the pins, 30102a and 30102b,
with the tapered ends, 30106b and 30108b, of the base members,
30106a and 30108a, of the engagement members, 30106 and 30108,
received within the external annular recess 30008ac of the tubular
toggle bushing 30008. When the one-shot deactivation device 30104
is positioned as illustrated in FIG. 16Z, the external annular
recess 30104d of the tubular body 30104a of the one-shot
deactivation device is moved out of engagement with the engagement
arms, 30026d and 30032d, of the triggers, 30026 and 30032,
respectively. As a result, the triggers, 30026 and 30032, may
operate normally as described above with reference to FIGS. 16W,
16X, and 16Y.
[0280] Conversely, in an exemplary embodiment, during operation of
the adjustable casing expansion cone assembly 30, as illustrated in
FIGS. 16AA1 to 16AA4, the one-shot deactivation device 30104 are
positioned proximate and in intimate contact with the pins, 30100a
and 30100b, with the tapered ends, 30106b and 30108b, of the base
members, 30106a and 30108a, of the engagement members, 30106 and
30108, not received within the external annular recess 30008ac of
the tubular toggle bushing 30008. When the one-shot deactivation
device 30104 is positioned as illustrated in FIGS. 16AA1 to 16AA4,
the external annular recess 30104d of the tubular body 30104a of
the one-shot deactivation device is moved into engagement with the
engagement arms, 30026d and 30032d, of the triggers, 30026 and
30032, respectively. As a result, the triggers, 30026 and 30032,
are deactivated and may not operate normally as described above
with reference to FIGS. 16W, 16X, and 16Y.
[0281] In an alternative embodiment, the elements of the adjustable
casing expansion cone assembly 30 that sense the diameter of the
expandable wellbore casing 100 may be disabled or omitted or
adjusted to sense any pre-selected internal diameter of the
expandable wellbore casing.
[0282] In an exemplary embodiment, as illustrated in 17A to 17C,
the packer setting tool assembly 32 includes a tubular adaptor 3202
that defines a longitudinal passage 3202a, radial external mounting
holes, 3202b and 3202c, radial passages, 3202d and 3202e, and
includes an external threaded connection 3202f at one end and an
internal annular recess 3202g having an internal threaded
connection at another end. An external threaded connection 3204a of
an end of a tubular upper mandrel 3204 that defines a longitudinal
passage 3204b, internally threaded external mounting holes, 3204c
and 3204d, and includes an external annular recess 3204e, external
annular recess 3204f, external annular recess 3204g, external
flange 3204h, external splines 3204i, and an internal threaded
connection 3204j at another end is received within and is coupled
to the internally threaded connection of the internal annular
recess 3202g of the other end of the tubular adaptor 3202. Mounting
screws, 3205a and 3205b, are received within and coupled to the
mounting holes, 3204c and 3204d, of the tubular upper mandrel 3204
that also extend into the radial passages, 3202d and 3202e, of the
tubular adaptor 3202.
[0283] An external threaded connection 3206a of an end of a mandrel
3206 that defines a longitudinal passage 3206b and includes an
external annular recess 3206c and an external annular recess 3206d
having an external threaded connection is received within and is
coupled to the internal threaded connection 3204j of the tubular
upper mandrel 3204. An internal threaded connection 3208a of a
tubular stinger 3208 that defines a longitudinal passage 3208b and
includes an external annular recess 3208c, and an external tapered
annular recess 3208d and an engagement shoulder 3208e at another
end receives and is coupled to the external threaded connection of
the external annular recess 3206d of the mandrel 3206. A sealing
member 3210 is mounted upon and coupled to the external annular
recess 3206d of the mandrel 3206.
[0284] An internal flange 3212a of a tubular key 3212 that includes
an external annular recess 3212b at one end and an internal annular
recess 3212c at another end is movably received within and engages
the external annular recess 3204f of the tubular upper mandrel
3204. A garter spring 3214 is received within and engages the
external annular recess 3212b of the tubular key 3212.
[0285] An end of a tubular bushing 3216 that defines a longitudinal
passage 3216a for receiving and mating with the upper mandrel 3204,
and radial passages, 3216b and 3216c, and includes an external
threaded connection 3216d at an intermediate portion, and an
external flange 3216e, an internal annular recess 3216f,
circumferentially spaced apart teeth 3216g, and external flanges,
3216h and 3216i, at another end is received within and mates with
the internal annular recess 3212c of the tubular key 3212. An
internal threaded connection 3218a of a tubular drag block body
3218 that defines a longitudinal passage 3218b for receiving the
tubular bushing 3216, mounting holes, 3218c and 3218d, mounting
holes, 3218e and 3218f, and includes an internal threaded
connection 3218g at one end, a centrally positioned external
annular recess 3218h, and an external threaded connection 3218i at
another end is received within and coupled to the external threaded
connection 3216d of the tubular bushing 3216.
[0286] A first tubular keeper 3220 that defines mounting holes,
3220a and 3220b, is coupled to an end of the tubular drag block
body 3218 by mounting screws, 3222a and 3222b, that are received
within and are coupled to the mounting holes, 3218c and 3218d, of
the tubular drag block body. A second tubular keeper 3224 that
defines mounting holes, 3224a and 3224b, is coupled to an end of
the tubular drag block body 3218 by mounting screws, 3226a and
3226b, that are received within and are coupled to the mounting
holes, 3218e and 3218f, of the tubular drag block body.
[0287] Drag blocks, 3228 and 3230, that are received within the
external annular recess 3218h of the tubular drag block body 3218,
include ends that mate with and are received within the end of the
first tubular keeper 3220, and other ends that mate with and are
received within the end of the second tubular keeper 3224. The drag
blocks, 3228 and 3230, further include internal annular recesses,
3228a and 3230a, respectively, that receive and mate with ends of
springs, 3232 and 3234, respectively. The springs, 3232 and 3234,
also receive and mate with the external annular recess 3218h of the
tubular drag block body 3218.
[0288] An external threaded connection 3236a of an end of a tubular
releasing cap extension 3236 that defines a longitudinal passage
3236b and includes an internal annular recess 3236c and an internal
threaded connection 3236d at another end is received within and is
coupled to the internal threaded connection 3218g of the tubular
drag block body 3218. An external threaded connection 3238a of an
end of a tubular releasing cap 3238 that defines a longitudinal
passage 3238b and includes an internal annular recess 3238c is
received within and coupled to the internal threaded connection
3236d of the tubular releasing cap extension 3236. A sealing
element 3240 is received within the internal annular recess 3238c
of the tubular releasing cap 3238 for fluidicly sealing the
interface between the tubular releasing cap and the upper mandrel
3204.
[0289] An internal threaded connection 3242a of an end of a tubular
setting sleeve 3242 that defines a longitudinal passage 3242b,
radial passage 3242c, radial passages, 3242d and 3242e, radial
passage 3242f, and includes an internal flange 3242g at another end
receives the external threaded connection 3218i of the tubular drag
block body 3218. An internal flange 3244a of a tubular coupling
ring 3244 that defines a longitudinal passage 3244b and radial
passages, 3244c and 3244d, receives and mates with the external
flange 3216h of the tubular bushing 3216 and an end face of the
internal flange of the tubular coupling ring is positioned
proximate and in opposing relation to an end face of the external
flange 3216i of the tubular bushing.
[0290] An internal flange 3246a of a tubular retaining collet 3246
that includes a plurality of axially extending collet fingers
3246b, each having internal flanges 3246c at an end of each collet
finger, for engaging and receiving the tubular coupling ring 3244
receives and mates with external flange 3216e of the tubular
bushing 3216 and an end face of the internal flange of the tubular
retaining collet is positioned proximate and in opposing relation
to an end face of the external flange 3216h of the tubular
bushing.
[0291] In an exemplary embodiment, the packer assembly 36 operates
and is provided substantially, at least in part, as disclosed in
one or more of the following: (1) PCT patent application serial
number PCT/US03/14153, attorney docket number 25791.104.02, filed
on Nov. 13, 2003, (2) PCT patent application serial number
PCT/US03/29460, attorney docket number 25791.114.02, filed on Sep.
23, 2003, and/or (3) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.253.02, filed on Mar.
11, 2004, and/or (4) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.260, filed on Mar.
26, 2004, the disclosures of which are incorporated herein by
reference.
[0292] In an exemplary embodiment, as illustrated in FIGS. 18-1 to
18-5, the packer assembly 36 includes a tubular upper adaptor 3602
that defines a longitudinal passage 3602a having a tapered opening
3602b and mounting holes, 3602c and 3602d, that includes a
plurality of circumferentially spaced apart teeth 3602e at one end,
an external flange 3602f, and an internal threaded connection 3602g
at another end. In an exemplary embodiment, the tubular upper
adaptor 3602 is fabricated from aluminum. An external threaded
connection 3604a of an end of a tubular upper mandrel 3604 that
defines a longitudinal passage 3604b, mounting holes, 3604c and
3604d, mounting holes, 3604e and 3604f, and mounting holes, 3604g
and 3604h, and includes an external flange 3604i, an internal
annular recess 3604j, and an internal threaded connection 3604k at
another end is received within and coupled to the internal threaded
connection 3602g of the tubular upper adaptor 3602. In an exemplary
embodiment, the tubular upper mandrel 3604 is fabricated from
aluminum.
[0293] An upper tubular spacer ring 3606 that defines mounting
holes, 3606a and 3606b, receives and mates with the end of the
tubular upper mandrel 3604 and includes an angled end face 3606c
and another end face that is positioned proximate to an end face of
the tubular upper adaptor 3602 is coupled to the tubular upper
mandrel by shear pins, 3608a and 3608b, that are mounted within and
coupled to the mounting holes, 3604c and 3606a, and, 3604d and
3606b, respectively, of the tubular upper mandrel and upper tubular
spacer ring, respectively. A lower tubular spacer ring 3610 that
includes an angled end face 3610a receives, mates, and is coupled
to the other end of the tubular upper mandrel 3604 and includes
another end face that is positioned proximate to an end face of the
external flange 3604i of the tubular upper mandrel 3604. In an
exemplary embodiment, the upper and tubular spacer rings, 3606 and
3610, are fabricated from a composite material.
[0294] An upper tubular slip 3612 that receives and is movably
mounted upon the tubular upper mandrel 3604 defines a longitudinal
passage 3612a having a tapered opening 3612b and includes external
annular recesses, 3612c, 3612d, 3612e, 3612f, and 3612g, and an
angled end face 3612h that mates with and is positioned proximate
the angled end face 3606c of the upper tubular spacer ring 3606.
Slip retaining bands, 3614a, 3614b, 3614c, 3614d, and 3614e, are
received within and coupled to the external annular recesses,
3612c, 3612d, 3612e, 3612f, and 3612g, of the upper tubular slip
3612. A lower tubular slip 3616 that receives and is movably
mounted upon the tubular upper mandrel 3604 defines a longitudinal
passage 3616a having a tapered opening 3616b and includes external
annular recesses, 3616c, 3616d, 3616e, 3616f, and 3616g, and an
angled end face 3616h that mates with and is positioned proximate
the angled end face 3610a of the lower tubular spacer ring 3610.
Slip retaining bands, 3618a, 3618b, 3618c, 3618d, and 3618e, are
received within and coupled to the external annular recesses,
3616c, 3616d, 3616e, 3616f, and 3616g, of the lower tubular slip
3616. In an exemplary embodiment, the upper and lower tubular
slips, 3612 and 3616, are fabricated from composite materials, and
at least some of the slip retaining bands, 3614a, 3614b, 3614c,
3614d, 3614e, 3618a, 3618b, 3618c, 3618d, and 3618e are fabricated
from carbide insert materials.
[0295] An upper tubular wedge 3620 that defines an longitudinal
passage 3620a for receiving the tubular upper mandrel 3604 and
mounting holes, 3620b and 3620c, and includes an angled end face
3620d at one end that is received within and mates with the tapered
opening 3612b of the upper tubular slip 3612, and an angled end
face 3620e at another end is coupled to the tubular upper mandrel
by shear pins, 3622a and 3622b, mounted within and coupled to the
mounting holes, 3604e and 3620b, and, 3604f and 3620c,
respectively, of the tubular upper mandrel and upper tubular wedge,
respectively. A lower tubular wedge 3624 that defines an
longitudinal passage 3624a for receiving the tubular upper mandrel
3604 and mounting holes, 3624b and 3624c, and includes an angled
end face 3624d at one end that is received within and mates with
the tapered opening 3616b of the lower tubular slip 3616, and an
angled end face 3624e at another end is coupled to the tubular
upper mandrel by shear pins, 3626a and 3626b, mounted within and
coupled to the mounting holes, 3604g and 3624b, and, 3604h and
3624c, respectively, of the tubular upper mandrel and lower tubular
wedge, respectively. In an exemplary embodiment, the upper and
lower tubular wedges, 3620 and 3624, are fabricated from composite
materials.
[0296] An upper tubular extrusion limiter 3628 that defines a
longitudinal passage 3628a for receiving the tubular upper mandrel
3604 includes an angled end face 3628b at one end that mates with
the angled end face 3620e of the upper tubular wedge 3620, an
angled end face 3628c at another end having recesses 3628d, and
external annular recesses, 3628e, 3628f and 3628g. Retaining bands,
3630a, 3630b, and 3630c, are mounted within and coupled to the
external annular recesses, 3628e, 3628f and 3628g, respectively, of
the upper tubular extrusion limiter 3628. Circular disc-shaped
extrusion preventers 3632 are coupled and mounted within the
recesses 3628d. A lower tubular extrusion limiter 3634 that defines
a longitudinal passage 3634a for receiving the tubular upper
mandrel 3604 includes an angled end face 3634b at one end that
mates with the angled end face 3624e of the lower tubular wedge
3624, an angled end face 3634c at another end having recesses
3634d, and external annular recesses, 3634e, 3634f and 3634g.
Retaining bands, 3636a, 3636b, and 3636c, are mounted within and
coupled to the external annular recesses, 3634e, 3634f and 3634g,
respectively, of the lower tubular extrusion limiter 3634. Circular
disc-shaped extrusion preventers 3638 are coupled and mounted
within the recesses 3634d. In an exemplary embodiment, the upper
and lower extrusion limiters, 3628 and 3634, are fabricated from
composite materials.
[0297] An upper tubular elastomeric packer element 3640 that
defines a longitudinal passage 3640a for receiving the tubular
upper mandrel 3604 includes an angled end face 3640b at one end
that mates with and is positioned proximate the angled end face
3628c of the upper tubular extrusion limiter 3628 and an curved end
face 3640c at another end. A lower tubular elastomeric packer
element 3642 that defines a longitudinal passage 3642a for
receiving the tubular upper mandrel 3604 includes an angled end
face 3642b at one end that mates with and is positioned proximate
the angled end face 3634c of the lower tubular extrusion limiter
3634 and an curved end face 3642c at another end.
[0298] A central tubular elastomeric packer element 3644 that
defines a longitudinal passage 3644a for receiving the tubular
upper mandrel 3604 includes a curved outer surface 3644b for mating
with and engaging the curved end faces, 3640c and 3642c, of the
upper and lower tubular elastomeric packer elements, 3640 and 3642,
respectively.
[0299] An external threaded connection 3646a of a tubular lower
mandrel 3646 that defines a longitudinal passage 3646b having
throat passages, 3646c and 3646d, and flow ports, 3646e and 3646f,
and a mounting hole 3646g, and includes an internal annular recess
3646h at one end, and an external flange 3646i, internal annular
recess 3646j, and internal threaded connection 3646k at another
end. In an exemplary embodiment, the tubular lower mandrel 3646 is
fabricated from aluminum. A sealing element 3648 is received within
the inner annular recess 3604j of the other end of the tubular
upper mandrel 3604 for sealing an interface between the tubular
upper mandrel and the tubular lower mandrel 3646.
[0300] A tubular sliding sleeve valve 3650 that defines a
longitudinal passage 3650a and radial flow ports, 3650b and 3650c,
and includes collet fingers 3650d at one end for engaging the
internal annular recess 3646h of the lower tubular mandrel 3646, an
external annular recess 3650e, an external annular recess 3650f, an
external annular recess 3650g, and circumferentially spaced apart
teeth 3650h at another end is received within and is slidably
coupled to the longitudinal passage 3646b of the tubular lower
mandrel 3646. In an exemplary embodiment, the tubular sliding
sleeve valve 3650 is fabricated from aluminum. A set screw 3652 is
mounted within and coupled to the mounting hole 3646g of the
tubular lower mandrel 3646 that is received within the external
annular recess 3650e of the tubular sliding sleeve 3650. Sealing
elements, 3654 and 3656, are mounted within the external annular
recesses, 3650f and 3650g, respectively, of the tubular sliding
sleeve valve 3650 for sealing an interface between the tubular
sliding sleeve valve and the tubular lower mandrel 3646.
[0301] An end of a tubular outer sleeve 3658 that defines a
longitudinal passage 3658a, radial passages, 3658b and 3658c, upper
flow ports, 3658d and 3658e, lower flow ports, 3658f and 3658g, and
radial passages, 3658h and 3658i, receives, mates with, and is
coupled to the other end of the tubular upper mandrel 3604 and an
end face of the end of the tubular outer sleeve is positioned
proximate and end face of the lower tubular spacer ring 3610. The
other end of the tubular outer sleeve 3658 receives, mates with,
and is coupled to the other end of the tubular lower mandrel
3646.
[0302] An external threaded connection 3660a of an end of a tubular
bypass mandrel 3660 that defines a longitudinal passage 3660b,
upper flow ports, 3660c and 3660d, lower flow ports, 3660e and
3660f, and a mounting hole 3660g and includes an internal annular
recess 3660h and an external threaded connection 3660i at another
end is received within and coupled to the internal threaded
connection 3646k of the tubular lower mandrel 3646. A sealing
element 3662 is received within the internal annular recess 3646j
of the tubular lower mandrel 3646 for sealing an interface between
the tubular lower mandrel and the tubular bypass mandrel 3660.
[0303] A tubular plug seat 3664 that defines a longitudinal passage
3664a having a tapered opening 3664b at one end, and flow ports,
3664c and 3664d, and includes an external annular recess 3664e, an
external annular recess 3664f, an external annular recess 3664g, an
external annular recess 3664h, and an external annular recess 3664i
having an external threaded connection at another end is received
within and is movably coupled to the longitudinal passage 3660b of
the tubular bypass mandrel 3660. A tubular nose 3666 is threadably
coupled to and mounted upon the external annular recess 3664i of
the tubular plug seat 3664. In an exemplary embodiment, the tubular
plug seat 3664 is fabricated from aluminum. Sealing elements, 3668,
3670, and 3672, are received within the external annular recesses,
3664e, 3664g, and 3664h, respectively, of the tubular plug seat
3664 for sealing an interface between the tubular plug seat and the
tubular bypass mandrel 3660. A set screw 3674 is mounted within and
coupled to the mounting hole 3660g of the tubular bypass mandrel
3660 that is received within the external annular recess 3664f of
the tubular plug seat 3664.
[0304] An end of a tubular bypass sleeve 3676 that defines a
longitudinal passage 3676a and includes an internal annular recess
3676b at one end and an internal threaded connection 3676c at
another end is coupled to the other end of the tubular outer sleeve
3658 and mates with and receives the tubular bypass mandrel 3660.
In an exemplary embodiment, the tubular bypass sleeve 3676 is
fabricated from aluminum.
[0305] An external threaded connection 3678a of a tubular valve
seat 3678 that defines a longitudinal passage 3678b including a
valve seat 3678c and up-jet flow ports, 3678d and 3678e, and
includes a spring retainer 3678f and an external annular recess
3678g is received within and is coupled to the internal threaded
connection 3676c of the tubular bypass sleeve 3676. In an exemplary
embodiment, the tubular valve seat 3678 is fabricated from
aluminum. A sealing element 3680 is received within the external
annular recess 3678g of the tubular valve seat 3678 for fluidicly
sealing an interface between the tubular valve seat and the tubular
bypass sleeve 3676.
[0306] A poppet valve 3682 mates with and is positioned within the
valve seat 3678c of the tubular valve seat 3678. An end of the
poppet valve 3682 is coupled to an end of a stem bolt 3684 that is
slidingly supported for longitudinal displacement by the spring
retainer 3678f A valve spring 3686 that surrounds a portion of the
stem bolt 3684 is positioned in opposing relation to the head of
the stem bolt and a support 3678fa of the spring retainer 3678f for
biasing the poppet valve 3682 into engagement with the valve seat
3678c of the tubular valve seat 3678.
[0307] An end of a composite nose 3688 that defines a longitudinal
passage 3688a and mounting holes, 3688b and 3688c, and includes an
internal threaded connection 3688d at another end receives, mates
with, and is coupled to the other end of the tubular valve seat
3678. A tubular nose sleeve 3690 that defines mounting holes, 3690a
and 3690b, is coupled to the composite nose 3688 by shear pins,
3692a and 3692b, that are mounted in and coupled to the mounting
holes, 3688b and 3690a, and, 3688c and 3690b, respectively, of the
composite nose and tubular nose sleeve, respectively.
[0308] An external threaded connection 3694a of a baffle nose 3694
that defines longitudinal passages, 3694b and 3694c, is received
within and is coupled to the internal threaded connection internal
threaded connection 3688d of the composite nose 3688.
[0309] In an exemplary embodiment, as illustrated in FIGS. 19A1 to
19A5, during the operation of the packer setting tool assembly 32
and packer assembly 36, the packer setting tool and packer assembly
are coupled to one another by inserting the end of the tubular
upper adaptor 3602 into the other end of the tubular coupling ring
3244, bringing the circumferentially spaced teeth 3216g of the
other end of the tubular bushing 3216 into engagement with the
circumferentially spaced teeth 3602e of the end of the tubular
upper adaptor, and mounting shear pins, 36100a and 36100b, within
the mounting holes, 3244c and 3602c, and, 3244d and 3602d,
respectively, of the tubular coupling ring and tubular upper
adaptor, respectively. As a result, the tubular mandrel 3206 and
tubular stinger 3208 of the packer setting tool assembly 32 are
thereby positioned within the longitudinal passage 3604a of the
tubular upper mandrel 3604 with the 3208e of the tubular stinger
positioned within the longitudinal passage 3646b of the tubular
lower mandrel 3646 proximate the collet fingers 3650d of the
tubular sliding sleeve valve 3650.
[0310] Furthermore, in an exemplary embodiment, during the
operation of the packer setting tool 32 and packer assembly 36, as
illustrated in FIGS. 19A1 to 19A5, the packer setting tool and
packer assembly are positioned within the expandable wellbore
casing 100 and an internal threaded connection 30a of an end of the
adjustable casing expansion cone assembly 30 receives and is
coupled to the external threaded connection 3202f of the end of the
tubular adaptor 3202 of the packer setting tool assembly.
Furthermore, shear pins, 36102a and 36102b, mounted within the
mounting holes, 3658b and 3658c, of the tubular outer sleeve 3658
couple the tubular outer sleeve to the expandable wellbore casing.
As a result, torsion loads may transferred between the tubular
outer sleeve 3658 and the expandable wellbore casing 100.
[0311] In an exemplary embodiment, as illustrated in FIGS. 19B1 to
19B5, a conventional plug 36104 is then injected into the setting
tool assembly 32 and packer assembly 36 by injecting a fluidic
material 36106 into the setting tool assembly and packer assembly
through the longitudinal passages, 3202a, 3204b, 3206b, 3208b,
3650a, 3646a, 3660b, and 3664a of the tubular adaptor 3202, tubular
upper mandrel 3204, tubular mandrel 3206, tubular stinger 3208,
tubular sliding sleeve valve 3650, tubular lower mandrel 3646,
tubular bypass mandrel 3660, and tubular plug seat 3664,
respectively. The plug 36104 is thereby positioned within the
longitudinal passage 3664a of the tubular plug seat 3664. Continued
injection of the fluidic material 36106 following the seating of
the plug 1606 within the longitudinal passage 3664a of the tubular
plug seat 3664 causes the plug and the tubular plug seat to be
displaced downwardly in a direction 36108 until further movement of
the tubular plug seat is prevented by interaction of the set screw
3674 with the external annular recess 3664f of the tubular plug
seat. As a result, the flow ports, 3664c and 3664d, of the tubular
plug seat 3664 are moved out of alignment with the upper flow
ports, 3660c and 3660d, of the tubular bypass mandrel 3660.
[0312] In an exemplary embodiment, as illustrated in FIGS. 19C1 to
19C5, after the expandable wellbore casing 100 has been radially
expanded and plastically deformed to form at least the bell section
112 of the expandable wellbore casing 100 thereby shearing the
shear pins, 36102a and 36102b, the setting tool assembly 32 and
packer assembly 36 are then moved upwardly to a position within the
expandable wellbore casing 100 above the bell section. The tubular
adaptor 3202 is then rotated, by rotating the tool string of the
system 10 above the setting tool assembly 32, to displace and
position the drag blocks, 3228 and 3230, into engagement with the
interior surface of the expandable wellbore casing 100.
[0313] As a result of the engagement of the drag blocks, 3228 and
3230, with the interior surface of the expandable wellbore casing
100, further rotation of the drag blocks relative to the wellbore
casing is prevented. Consequently, due to the operation and
interaction of the threaded connections, 3216d and 3218a, of the
tubular bushing 3216 and tubular drag block body 3218,
respectively, further rotation of the tubular adaptor 3202 causes
the tubular drag block body and setting sleeve 3242 to be displaced
downwardly in a direction 36112 relative to the remaining elements
of the setting tool assembly 32 and packer assembly 36. As a
result, the setting sleeve 3242 engages and displaces the upper
tubular spacer ring 3606 thereby shearing the shear pins, 3622a and
3622b, and driving the upper tubular slip 3612 onto and up the
angled end face 3620d of the upper tubular wedge 3620 and into
engagement with the interior surface of the expandable wellbore
casing 100. As a result, longitudinal displacement of the upper
tubular slip 3612 relative to the expandable wellbore casing 100 is
prevented. Furthermore, as a result, the 3246b collet fingers of
the tubular retaining collet 3246 are disengaged from the tubular
upper adaptor 3602.
[0314] In an alternative embodiment, after the drag blocks, 3228
and 3230, engage the interior surface of the expandable wellbore
casing 100, an upward tensile force is applied to the tubular
support member 12, and the ball gripper assembly 16 is then operate
to engage the interior surface of the expandable wellbore casing.
The tension actuator assembly 18 is then operated to apply an
upward tensile force to the tubular adaptor 3202 thereby pulling
the upper tubular spacer ring 3606, lower tubular spacer ring 3610,
upper tubular slip 3612, lower tubular slip 3616, upper tubular
wedge 3620, lower tubular wedge 3624, upper tubular extrusion
limiter 3628, lower tubular extrusion limiter 3634, and central
tubular elastomeric element 3644 upwardly into contact with the
3242 thereby compressing the upper tubular spacer ring, lower
tubular spacer ring, upper tubular slip, lower tubular slip, upper
tubular wedge, lower tubular wedge, upper tubular extrusion
limiter, lower tubular extrusion limiter, and central tubular
elastomeric element. As a result, the upper tubular slip 3612,
lower tubular slip 3616, and central tubular elastomeric element
3644 engage the interior surface of the expandable wellbore casing
100.
[0315] In an exemplary embodiment, as illustrated in FIGS. 19D1 to
19D5, an upward tensile force is then applied to the tubular
adaptor 3202 thereby compressing the lower tubular slip 3616, lower
tubular wedge 3624, central elastomeric packer element 3644, upper
tubular extrusion limiter 3628, and upper tubular wedge 3620
between the lower tubular spacer ring 3610 and the stationary upper
tubular slip 3612. As a result, the lower tubular slip 3616 is
driven onto and up the angled end face 3624d of the lower tubular
wedge 3624 and into engagement with the interior surface of the
expandable wellbore casing 100, and the central elastomeric packer
element 3644 is compressed radially outwardly into engagement with
the interior surface of the expandable tubular member. As a result,
further longitudinal displacement of the upper tubular slip 3612,
lower tubular slip 3616, and central elastomeric packer element
3644 relative to the expandable wellbore casing 100 is
prevented.
[0316] In an exemplary embodiment, as illustrated in FIGS. 19E1 to
19E6, continued application of the upward tensile force to tubular
adaptor 3202 will then shear the shear pins, 1602a and 1602b,
thereby disengaging the setting tool assembly 32 from the packer
assembly 36.
[0317] In an exemplary embodiment, as illustrated in FIGS. 19F1 to
19F6, with the drag blocks, 3228 and 3230, in engagement with the
interior surface of the expandable wellbore casing 100, the tubular
adaptor 102 is further rotated thereby causing the tubular drag
block body 3218 and setting sleeve 3242 to be displaced further
downwardly in the direction 1612 until the tubular drag block body
and setting sleeve are disengaged from the tubular stinger 3208. As
a result, the tubular stinger 3208 of the setting tool assembly 32
may then be displaced downwardly into complete engagement with the
tubular sliding sleeve valve 3650.
[0318] In an exemplary embodiment, as illustrated in FIGS. 19G1 to
19G6, a fluidic material 36114 is then injected into the setting
tool assembly 32 and the packer assembly 36 through the
longitudinal passages 3202a, 3204b, 3206b, 3208b, 3604b, 3650a, and
3646b of the tubular adaptor 3202, tubular upper mandrel 3204,
tubular mandrel 3206, tubular stinger 3208, tubular upper mandrel
3604, tubular sliding sleeve valve 3650, and tubular lower mandrel
3646, respectively. Because, the plug 36104 is seated within and
blocks the longitudinal passage 3664a of the tubular plug seat
3664, the longitudinal passages 3604b, 3650a, and 3646b of the
tubular upper mandrel 3604, tubular sliding sleeve valve 3650, and
tubular lower mandrel 3646 are pressurized thereby displacing the
tubular upper adaptor 3602 and tubular upper mandrel 3604
downwardly until the end face of the tubular upper mandrel impacts
the end face of the upper tubular spacer ring 3606.
[0319] In an exemplary embodiment, as illustrated in FIGS. 19H1 to
19H5, the setting tool assembly 32 is brought back into engagement
with the packer assembly 36 until the engagement shoulder 3208e of
the other end of the tubular stinger 3208 engages the collet
fingers 3650d of the end of the tubular sliding sleeve valve 3650.
As a result, further downward displacement of the tubular stinger
3208 displaces the tubular sliding sleeve valve 3650 downwardly
until the radial flow ports, 3650b and 3650c, of the tubular
sliding sleeve valve are aligned with the flow ports, 3646e and
3646f, of the tubular lower mandrel 3646. A hardenable fluidic
sealing material 36116 may then be injected into the setting tool
assembly 32 and the packer assembly 36 through the longitudinal
passages 3202a, 3204b, 3206b, 3208b, and 3650a of the tubular
adaptor 3202, tubular upper mandrel 3204, tubular mandrel 3206,
tubular stinger 3208, and tubular sliding sleeve valve 3650,
respectively. The hardenable fluidic sealing material may then flow
out of the packer assembly 36 through the upper flow ports, 3658d
and 3658e, into the annulus between the expandable wellbore casing
100 and the wellbore 102.
[0320] The tubular sliding sleeve valve 3650 may then be returned
to its original position, with the radial flow ports, 3650b and
3650c, of the tubular sliding sleeve valve out of alignment with
the flow ports, 3646e and 3646f, of the tubular lower mandrel 3646.
The hardenable fluidic sealing material 36116 may then be allowed
to cure before, during, or after the continued operation of the
system 10 to further radially expand and plastically deform the
expandable wellbore casing.
[0321] In an alternative embodiment, as illustrated in FIGS. 20 and
20A to 20AX, the packer assembly 36 includes an upper tubular
spacer ring 36200 receives and mates with the end of the tubular
upper mandrel 3604 and includes an angled end face 36200a that
includes a plurality of spaced apart radial grooves 36200b and
another end face that is positioned proximate to an end face of the
tubular upper adaptor 3602 is coupled to the tubular upper mandrel
by shear pins, 36202a, 36202b, 36202c, and 36202d. A lower tubular
spacer ring 36204 that includes an angled end face 36204a that
includes a plurality of spaced apart radial grooves 36204b
receives, mates, and is coupled to the other end of the tubular
upper mandrel 3604 and includes another end face that is positioned
proximate to an end face of the external flange 3604i of the
tubular upper mandrel 3604. In an exemplary embodiment, the upper
and tubular spacer rings, 3606 and 3610, are fabricated from a
composite material.
[0322] An upper tubular slip assembly 36206 that receives and is
movably mounted upon the tubular upper mandrel 3604 includes a
plurality of substantially identical slip elements 36206a that each
include an exterior arcuate cylindrical surface 36206aa including
mounting holes, 36206ab, 36206ac, 36206ad, 36206ae, 36206af,
36206ag, 36206ah, 36206ai, and 36206aj, and grooves, 36206aj and
36206ak, a front end face 36206al, a rear end face 36206am
including a mounting hole 36206an, side faces, 36206ao and 36206ap,
an interior arcuate cylindrical surface 36206aq that mates with the
exterior surface of the tubular upper mandrel 3604, and an interior
tapered surface 36206ar including a mounting hole 36206as. Mounting
pins 36206 at are received within and coupled to the mounting holes
36206an and are received within corresponding radial grooves 36200b
of the angled end face 36200a of the upper tubular spacer ring
36200. Retaining pins 36206au are mounted within and coupled to the
mounting holes 36206 as that include heads 36206av. Slip retaining
bands, 36206aw and 36206ax, are received within and coupled to
grooves, 36206aj and 36206ak, respectively, of the slip elements
36206a. Slip gripping elements, 36206ay, 36206az, 36206aaa,
36206aab, 36206aac, 36206aad, 36206aae, 36206aaf, and 36206aag, are
mounted within, coupled to, and extend out of the mounting holes,
36206ab, 36206ac, 36206ad, 36206ae, 36206af, 36206ag, 36206ah,
36206ai, and 36206aj, respectively. In an exemplary embodiment, the
adjacent exterior arcuate cylindrical surfaces 36206aa of the
identical slip elements 36206a of the upper tubular slip assembly
36206 together define a substantially contiguous cylindrical
surface.
[0323] A lower tubular slip assembly 36208 that receives and is
movably mounted upon the tubular upper mandrel 3604 includes a
plurality of substantially identical slip elements 36208a that each
include an exterior arcuate cylindrical surface 36208aa including
mounting holes, 36208ab, 36208ac, 36208ad, 36208ae, 36208af,
36208ag, 36208ah, 36208ai, and 36208aj, and grooves, 36208aj and
36208ak, a front end face 36208al, a rear end face 36208am
including a mounting hole 36208an, side faces, 36208ao and 36208ap,
an interior arcuate cylindrical surface 36208aq that mates with the
exterior surface of the tubular upper mandrel 3604, and an interior
tapered surface 36208ar including a mounting hole 36208as. Mounting
pins 36208 at are received within and coupled to the mounting holes
36208an and are received within corresponding radial grooves 36204b
of the angled end face 36204a of the lower tubular spacer ring
36204. Retaining pins 36208au are mounted within and coupled to the
mounting holes 36208 as that include heads 36208av. Slip retaining
bands, 36208aw and 36208ax, are received within and coupled to
grooves, 36208aj and 36208ak, respectively, of the slip elements
36208a. Slip gripping elements, 36208ay, 36208az, 36208aaa,
36208aab, 36208aac, 36208aad, 36208aae, 36208aaf, and 36208aag, are
mounted within, coupled to, and extend out of the mounting holes,
36208ab, 36208ac, 36208ad, 36208ae, 36208af, 36208ag, 36208ah,
36208ai, and 36208aj, respectively. In an exemplary embodiment, the
adjacent exterior arcuate cylindrical surfaces 36208aa of the
identical slip elements 36208a of the upper tubular slip assembly
36208 together define a substantially contiguous cylindrical
surface.
[0324] An upper tubular wedge 36210 that receives the tubular upper
mandrel 3604 includes an angled front end face 36210a including
spaced apart radial grooves 36210b, a rear end face 36210c, an
exterior cylindrical surface 36210d, a plurality of spaced apart
faceted tapered exterior surface segments 36210e that mate with
corresponding tapered internal surfaces 36206ar of corresponding
slip elements 36206a of the upper tubular slip assembly 36206, and
T-shaped exterior grooves 36210f aligned with the midline of
corresponding faceted tapered exterior surface segments that extend
from the angled end face to the rear end face that receive and mate
with corresponding retaining pins 36206au of corresponding slip
elements of the upper tubular slip assembly. The upper tubular
wedge 36210 is releasably coupled to the tubular upper mandrel 3604
by shear pins 36211.
[0325] A lower tubular wedge 36212 that receives the tubular upper
mandrel 3604 includes an angled front end face 36212a including
spaced apart radial grooves 36212b, a rear end face 36212c, an
exterior cylindrical surface 36212d, a plurality of spaced apart
faceted tapered exterior surface segments 36212e that mate with
corresponding tapered internal surfaces 36208ar of corresponding
slip elements 36208a of the upper tubular slip assembly 36208, and
T-shaped exterior grooves 36212f aligned with the midline of
corresponding faceted tapered exterior surface segments that extend
from the angled end face to the rear end face that receive and mate
with corresponding retaining pins 36208au of corresponding slip
elements of the lower tubular slip assembly. The lower tubular
wedge 36212 is releasably coupled to the tubular upper mandrel 3604
by shear pins 36213.
[0326] An upper tubular extrusion limiter assembly 36214 that
receives and is movably mounted upon the tubular upper mandrel 3604
includes a plurality of substantially identical extrusion limiter
elements 36214a that each include an angled front end face 36214aa
having a recessed portion 36214ab, an angled rear end face 36214ac
that defines a mounting hole 36214ad, an interior arcuate
cylindrical surface 36214ae that mates with the tubular upper
mandrel, and an exterior arcuate cylindrical surface 36214af
including grooves, 36214ag, 36214ah, and 36214ai. Disk extrusion
preventers 36214aj are mounted within and coupled to the recessed
portions 36214ab of adjacent extrusion limiter elements 36214a, and
mounting pins 36214ak are mounted within and coupled to mounting
holes 36214ad of corresponding extrusion limiter elements 36214a
that are received within corresponding radial grooves 36210b of the
front end face 36210a of the upper tubular wedge 36210. Retaining
bands, 36214al, 36214am, and 36214an, are positioned within and
coupled to the grooves, 36214ai, 36214ah, and 36214ag,
respectively, of the extrusion limiter elements 36214a.
[0327] A lower tubular extrusion limiter assembly 36216 that
receives and is movably mounted upon the tubular upper mandrel 3604
includes a plurality of substantially identical extrusion limiter
elements 36216a that each include an angled front end face 36216aa
having a recessed portion 36216ab, an angled rear end face 36216ac
that defines a mounting hole 36216ad, an interior arcuate
cylindrical surface 36216ae that mates with the tubular upper
mandrel, and an exterior arcuate cylindrical surface 36216af
including grooves, 36216ag, 36216ah, and 36216ai. Disk extrusion
preventers 36216aj are mounted within and coupled to the recessed
portions 36216ab of adjacent extrusion limiter elements 36216a, and
mounting pins 36216ak are mounted within and coupled to mounting
holes 36216ad of corresponding extrusion limiter elements 36216a
that are received within corresponding radial grooves 36212b of the
front end face 36212a of the lower tubular wedge 36212. Retaining
bands, 36216al, 36216am, and 36216an, are positioned within and
coupled to the grooves, 36216ag, 36216ah, and 36216ai, of the
extrusion limiter elements 36216a.
[0328] The angled end face 3640b of the upper tubular elastomeric
packer element 3640 mates with and is positioned proximate the
angled end faces 36214aa and disk extrusion preventers 36214aj of
the extrusion limiter elements 36214a of the upper tubular
extrusion limiter assembly 36214, and the angled end face 3642b of
the lower tubular elastomeric packer element 3642 mates with and is
positioned proximate the angled end faces 36216aa and disk
extrusion preventers 36216aj of the extrusion limiter elements
36216a of the lower tubular extrusion limiter assembly 36216.
[0329] During operation of the alternative embodiment of the packer
assembly 36 described above with reference to FIGS. 20 and 20A to
20AX, the first step in setting the packer assembly 36 includes
pushing the slip elements, 36206a and 36208a, of the upper and
lower slip assemblies, 36206 and 36208, respectively, up the upper
and lower tubular wedges, 36210 and 36212, respectively, which
breaks the retaining rings, 36206aw and 36206ax, and 36208aw and
36208ax, respectively, and moves the slip elements outwardly
against the interior surface of the expandable wellbore casing 100.
In an exemplary embodiment, during the radial displacement of the
slip elements, 36206a and 36208a, the retaining pins, 36206au and
36208au, respectively, and the mounting pins, 36206 at and 36208
at, respectively, maintain the slip elements in an evenly spaced
apart configuration. In an exemplary embodiment, during the
operation of the packer assembly 36, the mounting pins, 36214ak and
36216ak, maintain the extrusion limiter elements, 36214a and
36216a, of the upper and lower tubular extrusion limiter
assemblies, 36214 and 36216, respectively, in an evenly spaced
apart configuration.
[0330] An apparatus for radially expanding and plastically
deforming an expandable tubular member has been described that
includes a support member, a cutting device for cutting the tubular
member coupled to the support member, and an expansion device for
radially expanding and plastically deforming the tubular member
coupled to the support member. In an exemplary embodiment, the
apparatus further includes a gripping device for gripping the
tubular member coupled to the support member. In an exemplary
embodiment, the gripping device comprises a plurality of movable
gripping elements. In an exemplary embodiment, the gripping
elements are moveable in a radial direction relative to the support
member. In an exemplary embodiment, the gripping elements are
moveable in an axial direction relative to the support member. In
an exemplary embodiment, the gripping elements are moveable in a
radial and an axial direction relative to the support member. In an
exemplary embodiment, the gripping elements are moveable from a
first position to a second position; wherein in the first position,
the gripping elements do not engage the tubular member, wherein in
the second position, the gripping elements do engage the tubular
member; and wherein, during the movement from the first position to
the second position, the gripping elements move in a radial and an
axial direction relative to the support member. In an exemplary
embodiment, the gripping elements are moveable from a first
position to a second position; wherein in the first position, the
gripping elements do not engage the tubular member; wherein in the
second position, the gripping elements do engage the tubular
member; and wherein, during the movement from the first position to
the second position, the gripping elements move in a radial
direction relative to the support member. In an exemplary
embodiment, the gripping elements are moveable from a first
position to a second position; wherein in the first position, the
gripping elements do not engage the tubular member; wherein in the
second position, the gripping elements do engage the tubular
member; and wherein, during the movement from the first position to
the second position, the gripping elements move in an axial
direction relative to the support member. In an exemplary
embodiment, if the tubular member is displaced in a first axial
direction, the gripping device grips the tubular member; and, if
the tubular member is displaced in a second axial direction, the
gripping device does not grip the tubular member. In an exemplary
embodiment, the gripping elements are moveable from a first
position to a second position; wherein in the first position, the
gripping elements do not engage the tubular member; wherein in the
second position, the gripping elements do engage the tubular
member; and wherein, the gripping elements are biased to remain in
the first position. In an exemplary embodiment, the gripping device
further includes an actuator for moving the gripping elements from
a first position to a second position; wherein in the first
position, the gripping elements do not engage the tubular member;
wherein in the second position, the gripping elements do engage the
tubular member; and
[0331] wherein the actuator is a fluid powered actuator. In an
exemplary embodiment, the apparatus further includes a sealing
device for sealing an interface with the tubular member coupled to
the support member. In an exemplary embodiment, the sealing device
seals an annulus defines between the support member and the tubular
member. In an exemplary embodiment, the apparatus further includes
a locking device for locking the position of the tubular member
relative to the support member. In an exemplary embodiment, the
apparatus further includes a packer assembly coupled to the support
member. In an exemplary embodiment, the packer assembly includes a
packer; and a packer control device for controlling the operation
of the packer coupled to the support member. In an exemplary
embodiment, the packer includes: a support member defining a
passage; a shoe comprising a float valve coupled to an end of the
support member; one or more compressible packer elements movably
coupled to the support member; and a sliding sleeve valve movably
positioned within the passage of the support member. In an
exemplary embodiment, the packer control device includes a support
member; one or more drag blocks releasably coupled to the support
member; and a stinger coupled to the support member for engaging
the packer. In an exemplary embodiment, the packer includes a
support member defining a passage; a shoe comprising a float valve
coupled to an end of the support member; one or more compressible
packer elements movably coupled to the support member; and a
sliding sleeve valve positioned within the passage of the support
member; and wherein the packer control device includes: a support
member; one or more drag blocks releasably coupled to the support
member; and a stinger coupled to the support member for engaging
the sliding sleeve valve. In an exemplary embodiment, the apparatus
further includes an actuator for displacing the expansion device
relative to the support member. In an exemplary embodiment, the
actuator includes a first actuator for pulling the expansion
device; and a second actuator for pushing the expansion device. In
an exemplary embodiment, the actuator includes means for
transferring torsional loads between the support member and the
expansion device. In an exemplary embodiment, the first and second
actuators include means for transferring torsional loads between
the support member and the expansion device. In an exemplary
embodiment, the actuator includes a plurality of pistons positioned
within corresponding piston chambers. In an exemplary embodiment,
the cutting device includes a support member; and a plurality of
movable cutting elements coupled to the support member. In an
exemplary embodiment, the apparatus further includes an actuator
coupled to the support member for moving the cutting elements
between a first position and a second position; wherein in the
first position, the cutting elements do not engage the tubular
member; and wherein in the second position, the cutting elements
engage the tubular member. In an exemplary embodiment, the
apparatus further includes a sensor coupled to the support member
for sensing the internal diameter of the tubular member. In an
exemplary embodiment, the sensor prevents the cutting elements from
being moved to the second position if the internal diameter of the
tubular member is less than a predetermined value. In an exemplary
embodiment, the cutting elements includes a first set of cutting
elements; and a second set of cutting elements; wherein the first
set of cutting elements are interleaved with the second set of
cutting elements. In an exemplary embodiment, in the first
position, the first set of cutting elements are not axially aligned
with the second set of cutting elements. In an exemplary
embodiment, in the second position, the first set of cutting
elements are axially aligned with the second set of cutting
elements. In an exemplary embodiment, the expansion device includes
a support member; and a plurality of movable expansion elements
coupled to the support member. In an exemplary embodiment,
apparatus further includes an actuator coupled to the support
member for moving the expansion elements between a first position
and a second position; wherein in the first position, the expansion
elements do not engage the tubular member; and wherein in the
second position, the expansion elements engage the tubular member.
In an exemplary embodiment, the apparatus further includes a sensor
coupled to the support member for sensing the internal diameter of
the tubular member. In an exemplary embodiment, the sensor prevents
the expansion elements from being moved to the second position if
the internal diameter of the tubular member is less than a
predetermined value. In an exemplary embodiment, the expansion
elements include a first set of expansion elements; and a second
set of expansion elements; wherein the first set of expansion
elements are interleaved with the second set of expansion elements.
In an exemplary embodiment, in the first position, the first set of
expansion elements are not axially aligned with the second set of
expansion elements. In an exemplary embodiment, in the second
position, the first set of expansion elements are axially aligned
with the second set of expansion elements. In an exemplary
embodiment, the expansion device includes an adjustable expansion
device. In an exemplary embodiment, the expansion device includes a
plurality of expansion devices. In an exemplary embodiment, at
least one of the expansion devices includes an adjustable expansion
device. In an exemplary embodiment, the adjustable expansion device
includes a support member; and a plurality of movable expansion
elements coupled to the support member. In an exemplary embodiment,
the apparatus further includes an actuator coupled to the support
member for moving the expansion elements between a first position
and a second position; wherein in the first position, the expansion
elements do not engage the tubular member; and wherein in the
second position, the expansion elements engage the tubular member.
In an exemplary embodiment, the apparatus further includes a sensor
coupled to the support member for sensing the internal diameter of
the tubular member. In an exemplary embodiment, the sensor prevents
the expansion elements from being moved to the second position if
the internal diameter of the tubular member is less than a
predetermined value. In an exemplary embodiment, the expansion
elements include a first set of expansion elements; and a second
set of expansion elements; wherein the first set of expansion
elements are interleaved with the second set of expansion elements.
In an exemplary embodiment, in the first position, the first set of
expansion elements are not axially aligned with the second set of
expansion elements. In an exemplary embodiment, in the second
position, the first set of expansion elements are axially aligned
with the second set of expansion elements.
[0332] An apparatus for radially expanding and plastically
deforming an expandable tubular member has been described that
includes a support member, an expansion device for radially
expanding and plastically deforming the tubular member coupled to
the support member, and an actuator coupled to the support member
for displacing the expansion device relative to the support member.
In an exemplary embodiment, the apparatus further includes a
cutting device coupled to the support member for cutting the
tubular member. In an exemplary embodiment, the cutting device
includes a support member; and a plurality of movable cutting
elements coupled to the support member. In an exemplary embodiment,
the apparatus further includes an actuator coupled to the support
member for moving the cutting elements between a first position and
a second position; wherein in the first position, the cutting
elements do not engage the tubular member; and wherein in the
second position, the cutting elements engage the tubular member. In
an exemplary embodiment, the apparatus further includes a sensor
coupled to the support member for sensing the internal diameter of
the tubular member. In an exemplary embodiment, the sensor prevents
the cutting elements from being moved to the second position if the
internal diameter of the tubular member is less than a
predetermined value. In an exemplary embodiment, the cutting
elements include a first set of cutting elements; and a second set
of cutting elements; wherein the first set of cutting elements are
interleaved with the second set of cutting elements. In an
exemplary embodiment, in the first position, the first set of
cuffing elements are not axially aligned with the second set of
cutting elements. In an exemplary embodiment, in the second
position, the first set of cutting elements are axially aligned
with the second set of cutting elements. In an exemplary
embodiment, the apparatus further includes a gripping device for
gripping the tubular member coupled to the support member. In an
exemplary embodiment, the gripping device includes a plurality of
movable gripping elements. In an exemplary embodiment, the gripping
elements are moveable in a radial direction relative to the support
member. In an exemplary embodiment, the gripping elements are
moveable in an axial direction relative to the support member. In
an exemplary embodiment, the gripping elements are moveable in a
radial and an axial direction relative to the support member. In an
exemplary embodiment, the gripping elements are moveable from a
first position to a second position; wherein in the first position,
the gripping elements do not engage the tubular member; wherein in
the second position, the gripping elements do engage the tubular
member; and wherein, during the movement from the first position to
the second position, the gripping elements move in a radial and an
axial direction relative to the support member. In an exemplary
embodiment, the gripping elements are moveable from a first
position to a second position; wherein in the first position, the
gripping elements do not engage the tubular member; wherein in the
second position, the gripping elements do engage the tubular
member; and wherein, during the movement from the first position to
the second position, the gripping elements move in a radial
direction relative to the support member. In an exemplary
embodiment, the gripping elements are moveable from a first
position to a second position; wherein in the first position, the
gripping elements do not engage the tubular member; wherein in the
second position, the gripping elements do engage the tubular
member; and wherein, during the movement from the first position to
the second position, the gripping elements move in an axial
direction relative to the support member. In an exemplary
embodiment, if the tubular member is displaced in a first axial
direction, the gripping device grips the tubular member; and
wherein, if the tubular member is displaced in a second axial
direction, the gripping device does not grip the tubular member. In
an exemplary embodiment, the gripping elements are moveable from a
first position to a second position; wherein in the first position,
the gripping elements do not engage the tubular member; wherein in
the second position, the gripping elements do engage the tubular
member; and wherein, the gripping elements are biased to remain in
the first position. In an exemplary embodiment, the gripping device
further includes an actuator for moving the gripping elements from
a first position to a second position; wherein in the first
position, the gripping elements do not engage the tubular member;
wherein in the second position, the gripping elements do engage the
tubular member; and wherein the actuator is a fluid powered
actuator. In an exemplary embodiment, the apparatus further
includes a sealing device for sealing an interface with the tubular
member coupled to the support member. In an exemplary embodiment,
the sealing device seals an annulus defines between the support
member and the tubular member. In an exemplary embodiment, the
apparatus further includes a locking device for locking the
position of the tubular member relative to the support member. In
an exemplary embodiment, the apparatus further includes a packer
assembly coupled to the support member. In an exemplary embodiment,
the packer assembly includes a packer; and a packer control device
for controlling the operation of the packer coupled to the support
member. In an exemplary embodiment, the packer includes a support
member defining a passage; a shoe comprising a float valve coupled
to an end of the support member; one or more compressible packer
elements movably coupled to the support member; and a sliding
sleeve valve movably positioned within the passage of the support
member. In an exemplary embodiment, the packer control device
includes a support member; one or more drag blocks releasably
coupled to the support member; and a stinger coupled to the support
member for engaging the packer. In an exemplary embodiment, the
packer includes a support member defining a passage; a shoe
comprising a float valve coupled to an end of the support member;
one or more compressible packer elements movably coupled to the
support member; and a sliding sleeve valve positioned within the
passage of the support member; and wherein the packer control
device comprises: a support member; one or more drag blocks
releasably coupled to the support member; and a stinger coupled to
the support member for engaging the sliding sleeve valve. In an
exemplary embodiment, the expansion device includes a support
member; and a plurality of movable expansion elements coupled to
the support member. In an exemplary embodiment, the apparatus
further includes an actuator coupled to the support member for
moving the expansion elements between a first position and a second
position; wherein in the first position, the expansion elements do
not engage the tubular member; and wherein in the second position,
the expansion elements engage the tubular member. In an exemplary
embodiment, the apparatus further includes a sensor coupled to the
support member for sensing the internal diameter of the tubular
member. In an exemplary embodiment, the sensor prevents the
expansion elements from being moved to the second position if the
internal diameter of the tubular member is less than a
predetermined value. In an exemplary embodiment, the expansion
elements include a first set of expansion elements; and a second
set of expansion elements; wherein the first set of expansion
elements are interleaved with the second set of expansion elements.
In an exemplary embodiment, the in the first position, the first
set of expansion elements are not axially aligned with the second
set of expansion elements. In an exemplary embodiment, in the
second position, the first set of expansion elements are axially
aligned with the second set of expansion elements. In an exemplary
embodiment, the expansion device includes an adjustable expansion
device. In an exemplary embodiment, the expansion device includes a
plurality of expansion devices. In an exemplary embodiment, at
least one of the expansion devices includes an adjustable expansion
device. In an exemplary embodiment, the adjustable expansion device
includes a support member; and a plurality of movable expansion
elements coupled to the support member. In an exemplary embodiment,
the apparatus further includes an actuator coupled to the support
member for moving the expansion elements between a first position
and a second position; wherein in the first position, the expansion
elements do not engage the tubular member; and wherein in the
second position, the expansion elements engage the tubular member.
In an exemplary embodiment, the apparatus further includes a sensor
coupled to the support member for sensing the internal diameter of
the tubular member. In an exemplary embodiment, the sensor prevents
the expansion elements from being moved to the second position if
the internal diameter of the tubular member is less than a
predetermined value. In an exemplary embodiment, the expansion
elements include a first set of expansion elements; and a second
set of expansion elements; wherein the first set of expansion
elements are interleaved with the second set of expansion elements.
In an exemplary embodiment, in the first position, the first set of
expansion elements are not axially aligned with the second set of
expansion elements. In an exemplary embodiment, in the second
position, the first set of expansion elements are axially aligned
with the second set of expansion elements.
[0333] An apparatus for radially expanding and plastically
deforming an expandable tubular member has been described that
includes a support member; an expansion device for radially
expanding and plastically deforming the tubular member coupled to
the support member; and a sealing assembly for sealing an annulus
defined between the support member and the tubular member. In an
exemplary embodiment, the apparatus further includes a gripping
device for gripping the tubular member coupled to the support
member. In an exemplary embodiment, the gripping device includes a
plurality of movable gripping elements. In an exemplary embodiment,
the gripping elements are moveable in a radial direction relative
to the support member. In an exemplary embodiment, the gripping
elements are moveable in an axial direction relative to the support
member. In an exemplary embodiment, the gripping elements are
moveable in a radial and an axial direction relative to the support
member. In an exemplary embodiment, the gripping elements are
moveable from a first position to a second position; wherein in the
first position, the gripping elements do not engage the tubular
member; wherein in the second position, the gripping elements do
engage the tubular member; and wherein, during the movement from
the first position to the second position, the gripping elements
move in a radial and an axial direction relative to the support
member. In an exemplary embodiment, the gripping elements are
moveable from a first position to a second position; wherein in the
first position, the gripping elements do not engage the tubular
member; wherein in the second position, the gripping elements do
engage the tubular member; and wherein, during the movement from
the first position to the second position, the gripping elements
move in a radial direction relative to the support member. In an
exemplary embodiment, the gripping elements are moveable from a
first position to a second position; wherein in the first position,
the gripping elements do not engage the tubular member; wherein in
the second position, the gripping elements do engage the tubular
member; and wherein, during the movement from the first position to
the second position, the gripping elements move in an axial
direction relative to the support member. In an exemplary
embodiment, the if the tubular member is displaced in a first axial
direction, the gripping device grips the tubular member; and
wherein, if the tubular member is displaced in a second axial
direction, the gripping device does not grip the tubular member. In
an exemplary embodiment, the gripping elements are moveable from a
first position to a second position; wherein in the first position,
the gripping elements do not engage the tubular member; wherein in
the second position, the gripping elements do engage the tubular
member; and wherein, the gripping elements are biased to remain in
the first position. In an exemplary embodiment, the gripping device
further includes an actuator for moving the gripping elements from
a first position to a second position; wherein in the first
position, the gripping elements do not engage the tubular member;
wherein in the second position, the gripping elements do engage the
tubular member; and wherein the actuator is a fluid powered
actuator. In an exemplary embodiment, the apparatus further
includes a locking device for locking the position of the tubular
member relative to the support member. In an exemplary embodiment,
the apparatus further includes a packer assembly coupled to the
support member. In an exemplary embodiment, the packer assembly
includes a packer; and a packer control device for controlling the
operation of the packer coupled to the support member. In an
exemplary embodiment, the packer includes a support member defining
a passage; a shoe comprising a float valve coupled to an end of the
support member; one or more compressible packer elements movably
coupled to the support member; and a sliding sleeve valve movably
positioned within the passage of the support member. In an
exemplary embodiment, the packer control device includes a support
member; one or more drag blocks releasably coupled to the support
member; and a stinger coupled to the support member for engaging
the packer. In an exemplary embodiment, the packer includes a
support member defining a passage; a shoe comprising a float valve
coupled to an end of the support member; one or more compressible
packer elements movably coupled to the support member; and a
sliding sleeve valve positioned within the passage of the support
member; and wherein the packer control device includes a support
member; one or more drag blocks releasably coupled to the support
member; and a stinger coupled to the support member for engaging
the sliding sleeve valve. In an exemplary embodiment, the apparatus
further includes an actuator for displacing the expansion device
relative to the support member. In an exemplary embodiment, the
actuator includes a first actuator for pulling the expansion
device; and a second actuator for pushing the expansion device. In
an exemplary embodiment, the actuator includes means for
transferring torsional loads between the support member and the
expansion device. In an exemplary embodiment, the first and second
actuators comprise means for transferring torsional loads between
the support member and the expansion device. In an exemplary
embodiment, the actuator includes a plurality of pistons positioned
within corresponding piston chambers. In an exemplary embodiment,
the cutting device includes a support member; and a plurality of
movable cutting elements coupled to the support member. In an
exemplary embodiment, the apparatus further includes an actuator
coupled to the support member for moving the cutting elements
between a first position and a second position; wherein in the
first position, the cutting elements do not engage the tubular
member; and wherein in the second position, the cutting elements
engage the tubular member. In an exemplary embodiment, the
apparatus further includes a sensor coupled to the support member
for sensing the internal diameter of the tubular member. In an
exemplary embodiment, the sensor prevents the cutting elements from
being moved to the second position if the internal diameter of the
tubular member is less than a predetermined value. In an exemplary
embodiment, the cutting elements include a first set of cutting
elements; and a second set of cutting elements; wherein the first
set of cutting elements are interleaved with the second set of
cutting elements. In an exemplary embodiment, in the first
position, the first set of cutting elements are not axially aligned
with the second set of cutting elements. In an exemplary
embodiment, in the second position, the first set of cutting
elements are axially aligned with the second set of cutting
elements. In an exemplary embodiment, the expansion device includes
a support member; and a plurality of movable expansion elements
coupled to the support member. In an exemplary embodiment, the
apparatus further includes an actuator coupled to the support
member for moving the expansion elements between a first position
and a second position; wherein in the first position, the expansion
elements do not engage the tubular member; and wherein in the
second position, the expansion elements engage the tubular member.
In an exemplary embodiment, the apparatus further includes a sensor
coupled to the support member for sensing the internal diameter of
the tubular member. In an exemplary embodiment, the sensor prevents
the expansion elements from being moved to the second position if
the internal diameter of the tubular member is less than a
predetermined value. In an exemplary embodiment, the expansion
elements includes a first set of expansion elements; and a second
set of expansion elements; wherein the first set of expansion
elements are interleaved with the second set of expansion elements.
In an exemplary embodiment, in the first position, the first set of
expansion elements are not axially aligned with the second set of
expansion elements. In an exemplary embodiment, in the second
position, the first set of expansion elements are axially aligned
with the second set of expansion elements. In an exemplary
embodiment, the expansion device includes an adjustable expansion
device. In an exemplary embodiment, the expansion device includes a
plurality of expansion devices. In an exemplary embodiment, at
least one of the expansion devices includes an adjustable expansion
device. In an exemplary embodiment, the adjustable expansion device
includes a support member; and a plurality of movable expansion
elements coupled to the support member. In an exemplary embodiment,
the apparatus further includes an actuator coupled to the support
member for moving the expansion elements between a first position
and a second position; wherein in the first position, the expansion
elements do not engage the tubular member; and wherein in the
second position, the expansion elements engage the tubular member.
In an exemplary embodiment, the apparatus further includes a sensor
coupled to the support member for sensing the internal diameter of
the tubular member. In an exemplary embodiment, the sensor prevents
the expansion elements from being moved to the second position if
the internal diameter of the tubular member is less than a
predetermined value. In an exemplary embodiment, the expansion
elements include a first set of expansion elements; and a second
set of expansion elements; wherein the first set of expansion
elements are interleaved with the second set of expansion elements.
In an exemplary embodiment, in the first position, the first set of
expansion elements are not axially aligned with the second set of
expansion elements. In an exemplary embodiment, in the second
position, the first set of expansion elements are axially aligned
with the second set of expansion elements.
[0334] An apparatus for radially expanding and plastically
deforming an expandable tubular member has been described that
includes a support member; a first expansion device for radially
expanding and plastically deforming the tubular member coupled to
the support member; and a second expansion device for radially
expanding and plastically deforming the tubular member coupled to
the support member. In an exemplary embodiment, the apparatus
further includes a gripping device for gripping the tubular member
coupled to the support member. In an exemplary embodiment, the
gripping device includes a plurality of movable gripping elements.
In an exemplary embodiment, the gripping elements are moveable in a
radial direction relative to the support member. In an exemplary
embodiment, the gripping elements are moveable in an axial
direction relative to the support member. In an exemplary
embodiment, the gripping elements are moveable in a radial and an
axial direction relative to the support member. In an exemplary
embodiment, the gripping elements are moveable from a first
position to a second position; wherein in the first position, the
gripping elements do not engage the tubular member; wherein in the
second position, the gripping elements do engage the tubular
member; and wherein, during the movement from the first position to
the second position, the gripping elements move in a radial and an
axial direction relative to the support member. In an exemplary
embodiment, the gripping elements are moveable from a first
position to a second position; wherein in the first position, the
gripping elements do not engage the tubular member; wherein in the
second position, the gripping elements do engage the tubular
member; and wherein, during the movement from the first position to
the second position, the gripping elements move in a radial
direction relative to the support member. In an exemplary
embodiment, the gripping elements are moveable from a first
position to a second position; wherein in the first position, the
gripping elements do not engage the tubular member; wherein in the
second position, the gripping elements do engage the tubular
member; and wherein, during the movement from the first position to
the second position, the gripping elements move in an axial
direction relative to the support member. In an exemplary
embodiment, if the tubular member is displaced in a first axial
direction, the gripping device grips the tubular member; and
wherein, if the tubular member is displaced in a second axial
direction, the gripping device does not grip the tubular member. In
an exemplary embodiment, the gripping elements are moveable from a
first position to a second position; wherein in the first position,
the gripping elements do not engage the tubular member; wherein in
the second position, the gripping elements do engage the tubular
member; and wherein, the gripping elements are biased to remain in
the first position. In an exemplary embodiment, the gripping device
further includes an actuator for moving the gripping elements from
a first position to a second position; wherein in the first
position, the gripping elements do not engage the tubular member;
wherein in the second position, the gripping elements do engage the
tubular member; and wherein the actuator is a fluid powered
actuator. In an exemplary embodiment, the apparatus further
includes a sealing device for sealing an interface with the tubular
member coupled to the support member. In an exemplary embodiment,
the sealing device seals an annulus defines between the support
member and the tubular member. In an exemplary embodiment, the
apparatus further includes a locking device for locking the
position of the tubular member relative to the support member. In
an exemplary embodiment, the apparatus further includes a packer
assembly coupled to the support member. In an exemplary embodiment,
the packer assembly includes a packer; and a packer control device
for controlling the operation of the packer coupled to the support
member. In an exemplary embodiment, the packer includes a support
member defining a passage; a shoe comprising a float valve coupled
to an end of the support member; one or more compressible packer
elements movably coupled to the support member; and a sliding
sleeve valve movably positioned within the passage of the support
member. In an exemplary embodiment, the packer control device
includes a support member; one or more drag blocks releasably
coupled to the support member; and a stinger coupled to the support
member for engaging the packer. In an exemplary embodiment, the
packer includes a support member defining a passage; a shoe
comprising a float valve coupled to an end of the support member;
one or more compressible packer elements movably coupled to the
support member; and a sliding sleeve valve positioned within the
passage of the support member; and wherein the packer control
device comprises: a support member; one or more drag blocks
releasably coupled to the support member; and a stinger coupled to
the support member for engaging the sliding sleeve valve. In an
exemplary embodiment, the apparatus further includes an actuator
for displacing the expansion device relative to the support member.
In an exemplary embodiment, the actuator includes a first actuator
for pulling the expansion device; and a second actuator for pushing
the expansion device. In an exemplary embodiment, the actuator
includes means for transferring torsional loads between the support
member and the expansion device. In an exemplary embodiment, the
first and second actuators include means for transferring torsional
loads between the support member and the expansion device. In an
exemplary embodiment, the actuator includes a plurality of pistons
positioned within corresponding piston chambers. In an exemplary
embodiment, the apparatus further includes a cutting device for
cutting the tubular member coupled to the support member. In an
exemplary embodiment, the cutting device includes a support member;
and a plurality of movable cutting elements coupled to the support
member. In an exemplary embodiment, the apparatus further includes
an actuator coupled to the support member for moving the cutting
elements between a first position and a second position; wherein in
the first position, the cutting elements do not engage the tubular
member; and wherein in the second position, the cutting elements
engage the tubular member. In an exemplary embodiment, the
apparatus further includes a sensor coupled to the support member
for sensing the internal diameter of the tubular member. In an
exemplary embodiment, the sensor prevents the cutting elements from
being moved to the second position if the internal diameter of the
tubular member is less than a predetermined value. In an exemplary
embodiment, the cutting elements include a first set of cutting
elements; and a second set of cutting elements; wherein the first
set of cutting elements are interleaved with the second set of
cutting elements. In an exemplary embodiment, in the first
position, the first set of cutting elements are not axially aligned
with the second set of cutting elements. In an exemplary
embodiment, in the second position, the first set of cutting
elements are axially aligned with the second set of cutting
elements. In an exemplary embodiment, at least one of the first
second expansion devices include a support member; and a plurality
of movable expansion elements coupled to the support member. In an
exemplary embodiment, the apparatus further includes an actuator
coupled to the support member for moving the expansion elements
between a first position and a second position; wherein in the
first position, the expansion elements do not engage the tubular
member; and wherein in the second position, the expansion elements
engage the tubular member. In an exemplary embodiment, the
apparatus further includes a sensor coupled to the support member
for sensing the internal diameter of the tubular member. In an
exemplary embodiment, the sensor prevents the expansion elements
from being moved to the second position if the internal diameter of
the tubular member is less than a predetermined value. In an
exemplary embodiment, the expansion elements include a first set of
expansion elements; and a second set of expansion elements; wherein
the first set of expansion elements are interleaved with the second
set of expansion elements. In an exemplary embodiment, in the first
position, the first set of expansion elements are not axially
aligned with the second set of expansion elements. In an exemplary
embodiment, in the second position, the first set of expansion
elements are axially aligned with the second set of expansion
elements. In an exemplary embodiment, at least one of the first and
second expansion devices comprise a plurality of expansion devices.
In an exemplary embodiment, at least one of the first and second
expansion device comprise an adjustable expansion device. In an
exemplary embodiment, the adjustable expansion device includes a
support member; and a plurality of movable expansion elements
coupled to the support member. In an exemplary embodiment, the
apparatus further includes an actuator coupled to the support
member for moving the expansion elements between a first position
and a second position; wherein in the first position, the expansion
elements do not engage the tubular member; and wherein in the
second position, the expansion elements engage the tubular member.
In an exemplary embodiment, the apparatus further includes a sensor
coupled to the support member for sensing the internal diameter of
the tubular member. In an exemplary embodiment, the sensor prevents
the expansion elements from being moved to the second position if
the internal diameter of the tubular member is less than a
predetermined value. In an exemplary embodiment, the expansion
elements include a first set of expansion elements; and a second
set of expansion elements; wherein the first set of expansion
elements are interleaved with the second set of expansion elements.
In an exemplary embodiment, in the first position, the first set of
expansion elements are not axially aligned with the second set of
expansion elements. In an exemplary embodiment, in the second
position, the first set of expansion elements are axially aligned
with the second set of expansion elements.
[0335] An apparatus for radially expanding and plastically
deforming an expandable tubular member has been described that
includes a support member; an expansion device for radially
expanding and plastically deforming the tubular member coupled to
the support member; and a packer coupled to the support member. In
an exemplary embodiment, the apparatus further includes a gripping
device for gripping the tubular member coupled to the support
member. In an exemplary embodiment, the gripping device comprises a
plurality of movable gripping elements. In an exemplary embodiment,
the gripping elements are moveable in a radial direction relative
to the support member. In an exemplary embodiment, the gripping
elements are moveable in an axial direction relative to the support
member. In an exemplary embodiment, the gripping elements are
moveable in a radial and an axial direction relative to the support
member. In an exemplary embodiment, the gripping elements are
moveable from a first position to a second position; wherein in the
first position, the gripping elements do not engage the tubular
member; wherein in the second position, the gripping elements do
engage the tubular member; and wherein, during the movement from
the first position to the second position, the gripping elements
move in a radial and an axial direction relative to the support
member. In an exemplary embodiment, the gripping elements are
moveable from a first position to a second position; wherein in the
first position, the gripping elements do not engage the tubular
member; wherein in the second position, the gripping elements do
engage the tubular member; and wherein, during the movement from
the first position to the second position, the gripping elements
move in a radial direction relative to the support member. In an
exemplary embodiment, the gripping elements are moveable from a
first position to a second position; wherein in the first position,
the gripping elements do not engage the tubular member; wherein in
the second position, the gripping elements do engage the tubular
member; and wherein, during the movement from the first position to
the second position, the gripping elements move in an axial
direction relative to the support member. In an exemplary
embodiment, if the tubular member is displaced in a first axial
direction, the gripping device grips the tubular member; and
wherein, if the tubular member is displaced in a second axial
direction, the gripping device does not grip the tubular member. In
an exemplary embodiment, the gripping elements are moveable from a
first position to a second position; wherein in the first position,
the gripping elements do not engage the tubular member; wherein in
the second position, the gripping elements do engage the tubular
member; and wherein, the gripping elements are biased to remain in
the first position. In an exemplary embodiment, the gripping device
further includes an actuator for moving the gripping elements from
a first position to a second position; wherein in the first
position, the gripping elements do not engage the tubular member;
wherein in the second position, the gripping elements do engage the
tubular member; and wherein the actuator is a fluid powered
actuator. In an exemplary embodiment, the apparatus further
includes a sealing device for sealing an interface with the tubular
member coupled to the support member. In an exemplary embodiment,
the sealing device seals an annulus defines between the support
member and the tubular member. In an exemplary embodiment, the
apparatus further includes a locking device for locking the
position of the tubular member relative to the support member. In
an exemplary embodiment, the packer assembly includes a packer, and
a packer control device for controlling the operation of the packer
coupled to the support member. In an exemplary embodiment, the
packer includes a support member defining a passage; a shoe
comprising a float valve coupled to an end of the support member;
one or more compressible packer elements movably coupled to the
support member; and a sliding sleeve valve movably positioned
within the passage of the support member. In an exemplary
embodiment, the packer control device includes a support member;
one or more drag blocks releasably coupled to the support member;
and a stinger coupled to the support member for engaging the
packer. In an exemplary embodiment, the packer includes a support
member defining a passage; a shoe comprising a float valve coupled
to an end of the support member; one or more compressible packer
elements movably coupled to the support member; and a sliding
sleeve valve positioned within the passage of the support member;
and wherein the packer control device includes a support member;
one or more drag blocks releasably coupled to the support member;
and a stinger coupled to the support member for engaging the
sliding sleeve valve. In an exemplary embodiment, the apparatus
further includes an actuator for displacing the expansion device
relative to the support member. In an exemplary embodiment, the
actuator includes a first actuator for pulling the expansion
device; and a second actuator for pushing the expansion device. In
an exemplary embodiment, the actuator includes means for
transferring torsional loads between the support member and the
expansion device. In an exemplary embodiment, the first and second
actuators include means for transferring torsional loads between
the support member and the expansion device. In an exemplary
embodiment, the actuator includes a plurality of pistons positioned
within corresponding piston chambers. In an exemplary embodiment,
the apparatus further includes a cutting device coupled to the
support member for cutting the tubular member. In an exemplary
embodiment, the cutting device includes a support member; and a
plurality of movable cutting elements coupled to the support
member. In an exemplary embodiment, the apparatus further includes
an actuator coupled to the support member for moving the cutting
elements between a first position and a second position; wherein in
the first position, the cutting elements do not engage the tubular
member; and wherein in the second position, the cutting elements
engage the tubular member. In an exemplary embodiment, the
apparatus further includes a sensor coupled to the support member
for sensing the internal diameter of the tubular member. In an
exemplary embodiment, the sensor prevents the cutting elements from
being moved to the second position if the internal diameter of the
tubular member is less than a predetermined value. In an exemplary
embodiment, the cutting elements include a first set of cutting
elements; and a second set of cutting elements; wherein the first
set of cutting elements are interleaved with the second set of
cutting elements. In an exemplary embodiment, in the first
position, the first set of cutting elements are not axially aligned
with the second set of cutting elements. In an exemplary
embodiment, in the second position, the first set of cutting
elements are axially aligned with the second set of cutting
elements. In an exemplary embodiment, the expansion device includes
a support member; and a plurality of movable expansion elements
coupled to the support member. In an exemplary embodiment, the
apparatus further includes an actuator coupled to the support
member for moving the expansion elements between a first position
and a second position; wherein in the first position, the expansion
elements do not engage the tubular member; and wherein in the
second position, the expansion elements engage the tubular member.
In an exemplary embodiment, the apparatus further includes a sensor
coupled to the support member for sensing the internal diameter of
the tubular member. In an exemplary embodiment, the sensor prevents
the expansion elements from being moved to the second position if
the internal diameter of the tubular member is less than a
predetermined value. In an exemplary embodiment, the expansion
elements include a first set of expansion elements; and a second
set of expansion elements; wherein the first set of expansion
elements are interleaved with the second set of expansion elements.
In an exemplary embodiment, in the first position, the first set of
expansion elements are not axially aligned with the second set of
expansion elements. In an exemplary embodiment, in the second
position, the first set of expansion elements are axially aligned
with the second set of expansion elements. In an exemplary
embodiment, the expansion device includes an adjustable expansion
device. In an exemplary embodiment, the expansion device includes a
plurality of expansion devices. In an exemplary embodiment, at
least one of the expansion devices comprises an adjustable
expansion device. In an exemplary embodiment, the adjustable
expansion device includes a support member; and a plurality of
movable expansion elements coupled to the support member. In an
exemplary embodiment, the apparatus further includes an actuator
coupled to the support member for moving the expansion elements
between a first position and a second position; wherein in the
first position, the expansion elements do not engage the tubular
member; and wherein in the second position, the expansion elements
engage the tubular member. In an exemplary embodiment, the
apparatus further includes a sensor coupled to the support member
for sensing the internal diameter of the tubular member. In an
exemplary embodiment, the sensor prevents the expansion elements
from being moved to the second position if the internal diameter of
the tubular member is less than a predetermined value. In an
exemplary embodiment, the expansion elements include a first set of
expansion elements; and a second set of expansion elements; wherein
the first set of expansion elements are interleaved with the second
set of expansion elements. In an exemplary embodiment, in the first
position, the first set of expansion elements are not axially
aligned with the second set of expansion elements. In an exemplary
embodiment, in the second position, the first set of expansion
elements are axially aligned with the second set of expansion
elements.
[0336] An apparatus for radially expanding and plastically
deforming an expandable tubular member has been described that
includes a support member; a cutting device for cutting the tubular
member coupled to the support member; a gripping device for
gripping the tubular member coupled to the support member; a
sealing device for sealing an interface with the tubular member
coupled to the support member, a locking device for locking the
position of the tubular member relative to the support member; a
first adjustable expansion device for radially expanding and
plastically deforming the tubular member coupled to the support
member; a second adjustable expansion device for radially expanding
and plastically deforming the tubular member coupled to the support
member; a packer coupled to the support member; and an actuator for
displacing one or more of the sealing assembly, first and second
adjustable expansion devices, and packer relative to the support
member. In an exemplary embodiment, the gripping device includes a
plurality of movable gripping elements. In an exemplary embodiment,
the gripping elements are moveable in a radial direction relative
to the support member. In an exemplary embodiment, the gripping
elements are moveable in an axial direction relative to the support
member. In an exemplary embodiment, the gripping elements are
moveable in a radial and an axial direction relative to the support
member. In an exemplary embodiment, the gripping elements are
moveable from a first position to a second position; wherein in the
first position, the gripping elements do not engage the tubular
member; wherein in the second position, the gripping elements do
engage the tubular member; and wherein, during the movement from
the first position to the second position, the gripping elements
move in a radial and an axial direction relative to the support
member. In an exemplary embodiment, the gripping elements are
moveable from a first position to a second position; wherein in the
first position, the gripping elements do not engage the tubular
member; wherein in the second position, the gripping elements do
engage the tubular member; and wherein, during the movement from
the first position to the second position, the gripping elements
move in a radial direction relative to the support member. In an
exemplary embodiment, the gripping elements are moveable from a
first position to a second position; wherein in the first position,
the gripping elements do not engage the tubular member; wherein in
the second position, the gripping elements do engage the tubular
member, and wherein, during the movement from the first position to
the second position, the gripping elements move in an axial
direction relative to the support member. In an exemplary
embodiment, if the tubular member is displaced in a first axial
direction, the gripping device grips the tubular member; and
wherein, if the tubular member is displaced in a second axial
direction, the gripping device does not grip the tubular member. In
an exemplary embodiment, the gripping elements are moveable from a
first position to a second position; wherein in the first position,
the gripping elements do not engage the tubular member; wherein in
the second position, the gripping elements do engage the tubular
member; and wherein, the gripping elements are biased to remain in
the first position. In an exemplary embodiment, the gripping device
further includes an actuator for moving the gripping elements from
a first position to a second position; wherein in the first
position, the gripping elements do not engage the tubular member;
wherein in the second position, the gripping elements do engage the
tubular member; and wherein the actuator is a fluid powered
actuator. In an exemplary embodiment, the sealing device seals an
annulus defines between the support member and the tubular member.
In an exemplary embodiment, the packer assembly includes a packer;
and a packer control device for controlling the operation of the
packer coupled to the support member. In an exemplary embodiment,
the packer includes a support member defining a passage; a shoe
comprising a float valve coupled to an end of the support member;
one or more compressible packer elements movably coupled to the
support member; and a sliding sleeve valve movably positioned
within the passage of the support member. In an exemplary
embodiment, the packer control device includes a support member;
one or more drag blocks releasably coupled to the support member;
and a stinger coupled to the support member for engaging the
packer. In an exemplary embodiment, the packer includes a support
member defining a passage; a shoe comprising a float valve coupled
to an end of the support member; one or more compressible packer
elements movably coupled to the support member; and a sliding
sleeve valve positioned within the passage of the support member;
and wherein the packer control device includes a support member;
one or more drag blocks releasably coupled to the support member;
and a stinger coupled to the support member for engaging the
sliding sleeve valve. In an exemplary embodiment, the actuator
includes a first actuator for pulling the expansion device; and a
second actuator for pushing the expansion device. In an exemplary
embodiment, the actuator includes means for transferring torsional
loads between the support member and the expansion device. In an
exemplary embodiment, the first and second actuators include means
for transferring torsional loads between the support member and the
expansion device. In an exemplary embodiment, the actuator includes
a plurality of pistons positioned within corresponding piston
chambers. In an exemplary embodiment, the cutting device includes a
support member; and a plurality of movable cutting elements coupled
to the support member. In an exemplary embodiment, the apparatus
further includes an actuator coupled to the support member for
moving the cutting elements between a first position and a second
position; wherein in the first position, the cutting elements do
not engage the tubular member; and wherein in the second position,
the cutting elements engage the tubular member. In an exemplary
embodiment, the apparatus further includes a sensor coupled to the
support member for sensing the internal diameter of the tubular
member. In an exemplary embodiment, the sensor prevents the cutting
elements from being moved to the second position if the internal
diameter of the tubular member is less than a predetermined value.
In an exemplary embodiment, the cutting elements include a first
set of cutting elements; and a second set of cutting elements;
wherein the first set of cutting elements are interleaved with the
second set of cutting elements. In an exemplary embodiment, in the
first position, the first set of cutting elements are not axially
aligned with the second set of cutting elements. In an exemplary
embodiment, in the second position, the first set of cutting
elements are axially aligned with the second set of cutting
elements. In an exemplary embodiment, at least one of the
adjustable expansion devices include a support member; and a
plurality of movable expansion elements coupled to the support
member. In an exemplary embodiment, the apparatus further includes
an actuator coupled to the support member for moving the expansion
elements between a first position and a second position; wherein in
the first position, the expansion elements do not engage the
tubular member; and wherein in the second position, the expansion
elements engage the tubular member. In an exemplary embodiment, the
apparatus further includes a sensor coupled to the support member
for sensing the internal diameter of the tubular member. In an
exemplary embodiment, the sensor prevents the expansion elements
from being moved to the second position if the internal diameter of
the tubular member is less than a predetermined value. In an
exemplary embodiment, the expansion elements include a first set of
expansion elements; and a second set of expansion elements; wherein
the first set of expansion elements are interleaved with the second
set of expansion elements. In an exemplary embodiment, in the first
position, the first set of expansion elements are not axially
aligned with the second set of expansion elements. In an exemplary
embodiment, in the second position, the first set of expansion
elements are axially aligned with the second set of expansion
elements. In an exemplary embodiment, at least one of the
adjustable expansion devices comprise a plurality of expansion
devices. In an exemplary embodiment, at least one of the adjustable
expansion devices include a support member; and a plurality of
movable expansion elements coupled to the support member. In an
exemplary embodiment, the apparatus further includes an actuator
coupled to the support member for moving the expansion elements
between a first position and a second position; wherein in the
first position, the expansion elements do not engage the tubular
member; and wherein in the second position, the expansion elements
engage the tubular member. In an exemplary embodiment, the
apparatus further includes a sensor coupled to the support member
for sensing the internal diameter of the tubular member. In an
exemplary embodiment, the sensor prevents the expansion elements
from being moved to the second position if the internal diameter of
the tubular member is less than a predetermined value. In an
exemplary embodiment, the expansion elements include a first set of
expansion elements; and a second set of expansion elements; wherein
the first set of expansion elements are interleaved with the second
set of expansion elements. In an exemplary embodiment, in the first
position, the first set of expansion elements are not axially
aligned with the second set of expansion elements. In an exemplary
embodiment, in the second position, the first set of expansion
elements are axially aligned with the second set of expansion
elements.
[0337] An apparatus for cutting a tubular member has been described
that includes a support member; and a plurality of movable cutting
elements coupled to the support member. In an exemplary embodiment,
the apparatus further includes an actuator coupled to the support
member for moving the cutting elements between a first position and
a second position; wherein in the first position, the cutting
elements do not engage the tubular member; and wherein in the
second position, the cutting elements engage the tubular member. In
an exemplary embodiment, the apparatus further includes a sensor
coupled to the support member for sensing the internal diameter of
the tubular member. In an exemplary embodiment, the sensor prevents
the cutting elements from being moved to the second position if the
internal diameter of the tubular member is less than a
predetermined value. In an exemplary embodiment, the cutting
elements include a first set of cutting elements; and a second set
of cutting elements; wherein the first set of cutting elements are
interleaved with the second set of cutting elements. In an
exemplary embodiment, in the first position, the first set of
cutting elements are not axially aligned with the second set of
cutting elements. In an exemplary embodiment, in the second
position, the first set of cutting elements are axially aligned
with the second set of cutting elements.
[0338] An apparatus for engaging a tubular member has been
described that includes a support member; and a plurality of
movable elements coupled to the support member. In an exemplary
embodiment, the apparatus further includes an actuator coupled to
the support member for moving the elements between a first position
and a second position; wherein in the first position, the elements
do not engage the tubular member; and wherein in the second
position, the elements engage the tubular member. In an exemplary
embodiment, the apparatus further includes a sensor coupled to the
support member for sensing the internal diameter of the tubular
member. In an exemplary embodiment, the sensor prevents the
elements from being moved to the second position if the internal
diameter of the tubular member is less than a predetermined value.
In an exemplary embodiment, the elements include a first set of
elements; and a second set of elements; wherein the first set of
elements are interleaved with the second set of elements. In an
exemplary embodiment, in the first position, the first set of
elements are not axially aligned with the second set of elements.
In an exemplary embodiment, in the second position, the first set
of elements are axially aligned with the second set of
elements.
[0339] An apparatus for gripping a tubular member has been
described that includes a plurality of movable gripping elements.
In an exemplary embodiment, the gripping elements are moveable in a
radial direction. In an exemplary embodiment, the gripping elements
are moveable in an axial direction. In an exemplary embodiment, the
gripping elements are moveable from a first position to a second
position; wherein in the first position, the gripping elements do
not engage the tubular member; wherein in the second position, the
gripping elements do engage the tubular member; and wherein, during
the movement from the first position to the second position, the
gripping elements move in a radial and an axial direction. In an
exemplary embodiment, the gripping elements are moveable from a
first position to a second position; wherein in the first position,
the gripping elements do not engage the tubular member; wherein in
the second position, the gripping elements do engage the tubular
member; and wherein, during the movement from the first position to
the second position, the gripping elements move in a radial
direction. In an exemplary embodiment, the gripping elements are
moveable from a first position to a second position; wherein in the
first position, the gripping elements do not engage the tubular
member; wherein in the second position, the gripping elements do
engage the tubular member; and wherein, during the movement from
the first position to the second position, the gripping elements
move in an axial direction. In an exemplary embodiment, in a first
axial direction, the gripping device grips the tubular member; and
wherein, in a second axial direction, the gripping device does not
grip the tubular member. In an exemplary embodiment, the apparatus
further includes an actuator for moving the gripping elements. In
an exemplary embodiment, the gripping elements include a plurality
of separate and distinct gripping elements.
[0340] An actuator has been described that includes a tubular
housing; a tubular piston rod movably coupled to and at least
partially positioned within the housing; a plurality of annular
piston chambers defined by the tubular housing and the tubular
piston rod; and a plurality of tubular pistons coupled to the
tubular piston rod, each tubular piston movably positioned within a
corresponding annular piston chamber. In an exemplary embodiment,
the actuator further includes means for transmitting torsional
loads between the tubular housing and the tubular piston rod.
[0341] An apparatus for controlling a packer has been described
that includes a tubular support member; one or more drag blocks
releasably coupled to the tubular support member; and a tubular
stinger coupled to the tubular support member for engaging the
packer. In an exemplary embodiment, the apparatus further includes
a tubular sleeve coupled to the drag blocks. In an exemplary
embodiment, the tubular support member includes one or more axially
aligned teeth for engaging the packer.
[0342] A packer has been described that includes a support member
defining a passage; a shoe comprising a float valve coupled to an
end of the support member; one or more compressible packer elements
movably coupled to the support member; and a sliding sleeve valve
movably positioned within the passage of the support member.
[0343] A method of radially expanding and plastically deforming an
expandable tubular member within a borehole having a preexisting
wellbore casing has been described that includes positioning the
tubular member within the borehole in overlapping relation to the
wellbore casing; radially expanding and plastically deforming a
portion of the tubular member to form a bell section; and radially
expanding and plastically deforming a portion of the tubular member
above the bell section comprising a portion of the tubular member
that overlaps with the wellbore casing; wherein the inside diameter
of the bell section is greater than the inside diameter of the
radially expanded and plastically deformed portion of the tubular
member above the bell section. In an exemplary embodiment, radially
expanding and plastically deforming a portion of the tubular member
to form a bell section includes positioning an adjustable expansion
device within the expandable tubular member; supporting the
expandable tubular member and the adjustable expansion device
within the borehole; lowering the adjustable expansion device out
of the expandable tubular member; increasing the outside dimension
of the adjustable expansion device; and displacing the adjustable
expansion device upwardly relative to the expandable tubular member
n times to radially expand and plastically deform n portions of the
expandable tubular member, wherein n is greater than or equal to
1.
[0344] A method for forming a mono diameter wellbore casing has
been described that includes positioning an adjustable expansion
device within a first expandable tubular member; supporting the
first expandable tubular member and the adjustable expansion device
within a borehole; lowering the adjustable expansion device out of
the first expandable tubular member; increasing the outside
dimension of the adjustable expansion device; displacing the
adjustable expansion device upwardly relative to the first
expandable tubular member m times to radially expand and
plastically deform m portions of the first expandable tubular
member within the borehole; positioning the adjustable expansion
device within a second expandable tubular member; supporting the
second expandable tubular member and the adjustable expansion
device within the borehole in overlapping relation to the first
expandable tubular member; lowering the adjustable expansion device
out of the second expandable tubular member; increasing the outside
dimension of the adjustable expansion device; and displacing the
adjustable expansion device upwardly relative to the second
expandable tubular member n times to radially expand and
plastically deform n portions of the second expandable tubular
member within the borehole.
[0345] A method for radially expanding and plastically deforming an
expandable tubular member within a borehole has been described that
includes positioning an adjustable expansion device within the
expandable tubular member; supporting the expandable tubular member
and the adjustable expansion device within the borehole; lowering
the adjustable expansion device out of the expandable tubular
member; increasing the outside dimension of the adjustable
expansion device; displacing the adjustable expansion mandrel
upwardly relative to the expandable tubular member n times to
radially expand and plastically deform n portions of the expandable
tubular member within the borehole; and pressurizing an interior
region of the expandable tubular member above the adjustable
expansion device during the radial expansion and plastic
deformation of the expandable tubular member within the
borehole.
[0346] A method for forming a mono diameter wellbore casing has
been described that includes positioning an adjustable expansion
device within a first expandable tubular member; supporting the
first expandable tubular member and the adjustable expansion device
within a borehole; lowering the adjustable expansion device out of
the first expandable tubular member; increasing the outside
dimension of the adjustable expansion device; displacing the
adjustable expansion device upwardly relative to the first
expandable tubular member m times to radially expand and
plastically deform m portions of the first expandable tubular
member within the borehole; pressurizing an interior region of the
first expandable tubular member above the adjustable expansion
device during the radial expansion and plastic deformation of the
first expandable tubular member within the borehole; positioning
the adjustable expansion mandrel within a second expandable tubular
member; supporting the second expandable tubular member and the
adjustable expansion mandrel within the borehole in overlapping
relation to the first expandable tubular member; lowering the
adjustable expansion mandrel out of the second expandable tubular
member; increasing the outside dimension of the adjustable
expansion mandrel; displacing the adjustable expansion mandrel
upwardly relative to the second expandable tubular member n times
to radially expand and plastically deform n portions of the second
expandable tubular member within the borehole; and pressurizing an
interior region of the second expandable tubular member above the
adjustable expansion mandrel during the radial expansion and
plastic deformation of the second expandable tubular member within
the borehole.
[0347] A method for radially expanding and plastically deforming an
expandable tubular member within a borehole has been described that
includes positioning first and second adjustable expansion devices
within the expandable tubular member; supporting the expandable
tubular member and the first and second adjustable expansion
devices within the borehole; lowering the first adjustable
expansion device out of the expandable tubular member; increasing
the outside dimension of the first adjustable expansion device;
displacing the first adjustable expansion device upwardly relative
to the expandable tubular member to radially expand and plastically
deform a lower portion of the expandable tubular member; displacing
the first adjustable expansion device and the second adjustable
expansion device downwardly relative to the expandable tubular
member; decreasing the outside dimension of the first adjustable
expansion device and increasing the outside dimension of the second
adjustable expansion device; displacing the second adjustable
expansion device upwardly relative to the expandable tubular member
to radially expand and plastically deform portions of the
expandable tubular member above the lower portion of the expandable
tubular member; wherein the outside dimension of the first
adjustable expansion device is greater than the outside dimension
of the second adjustable expansion device.
[0348] A method for forming a mono diameter wellbore casing has
been described that includes positioning first and second
adjustable expansion devices within a first expandable tubular
member; supporting the first expandable tubular member and the
first and second adjustable expansion devices within a borehole;
lowering the first adjustable expansion device out of the first
expandable tubular member; increasing the outside dimension of the
first adjustable expansion device; displacing the first adjustable
expansion device upwardly relative to the first expandable tubular
member to radially expand and plastically deform a lower portion of
the first expandable tubular member; displacing the first
adjustable expansion device and the second adjustable expansion
device downwardly relative to the first expandable tubular member;
decreasing the outside dimension of the first adjustable expansion
device and increasing the outside dimension of the second
adjustable expansion device; displacing the second adjustable
expansion device upwardly relative to the first expandable tubular
member to radially expand and plastically deform portions of the
first expandable tubular member above the lower portion of the
expandable tubular member; positioning first and second adjustable
expansion devices within a second expandable tubular member;
supporting the first expandable tubular member and the first and
second adjustable expansion devices within the borehole in
overlapping relation to the first expandable tubular member;
lowering the first adjustable expansion device out of the second
expandable tubular member; increasing the outside dimension of the
first adjustable expansion device; displacing the first adjustable
expansion device upwardly relative to the second expandable tubular
member to radially expand and plastically deform a lower portion of
the second expandable tubular member; displacing the first
adjustable expansion device and the second adjustable expansion
device downwardly relative to the second expandable tubular member;
decreasing the outside dimension of the first adjustable expansion
device and increasing the outside dimension of the second
adjustable expansion device; and displacing the second adjustable
expansion device upwardly relative to the second expandable tubular
member to radially expand and plastically deform portions of the
second expandable tubular member above the lower portion of the
second expandable tubular member; wherein the outside dimension of
the first adjustable expansion device is greater than the outside
dimension of the second adjustable expansion device.
[0349] A method for radially expanding and plastically deforming an
expandable tubular member within a borehole has been described that
includes positioning first and second adjustable expansion devices
within the expandable tubular member; supporting the expandable
tubular member and the first and second adjustable expansion
devices within the borehole; lowering the first adjustable
expansion device out of the expandable tubular member; increasing
the outside dimension of the first adjustable expansion device;
displacing the first adjustable expansion device upwardly relative
to the expandable tubular member to radially expand and plastically
deform a lower portion of the expandable tubular member;
pressurizing an interior region of the expandable tubular member
above the first adjustable expansion device during the radial
expansion of the lower portion of the expandable tubular member by
the first adjustable expansion device; displacing the first
adjustable expansion device and the second adjustable expansion
device downwardly relative to the expandable tubular member;
decreasing the outside dimension of the first adjustable expansion
device and increasing the outside dimension of the second
adjustable expansion device; displacing the second adjustable
expansion device upwardly relative to the expandable tubular member
to radially expand and plastically deform portions of the
expandable tubular member above the lower portion of the expandable
tubular member; and pressurizing an interior region of the
expandable tubular member above the second adjustable expansion
device during the radial expansion of the portions of the
expandable tubular member above the lower portion of the expandable
tubular member by the second adjustable expansion device; wherein
the outside dimension of the first adjustable expansion device is
greater than the outside dimension of the second adjustable
expansion device.
[0350] A method for forming a mono diameter wellbore casing has
been described that includes positioning first and second
adjustable expansion devices within a first expandable tubular
member; supporting the first expandable tubular member and the
first and second adjustable expansion devices within a borehole;
lowering the first adjustable expansion device out of the first
expandable tubular member; increasing the outside dimension of the
first adjustable expansion device; displacing the first adjustable
expansion device upwardly relative to the first expandable tubular
member to radially expand and plastically deform a lower portion of
the first expandable tubular member; pressurizing an interior
region of the first expandable tubular member above the first
adjustable expansion device during the radial expansion of the
lower portion of the first expandable tubular member by the first
adjustable expansion device; displacing the first adjustable
expansion device and the second adjustable expansion device
downwardly relative to the first expandable tubular member;
decreasing the outside dimension of the first adjustable expansion
device and increasing the outside dimension of the second
adjustable expansion device; displacing the second adjustable
expansion device upwardly relative to the first expandable tubular
member to radially expand and plastically deform portions of the
first expandable tubular member above the lower portion of the
expandable tubular member; pressurizing an interior region of the
first expandable tubular member above the second adjustable
expansion device during the radial expansion of the portions of the
first expandable tubular member above the lower portion of the
first expandable tubular member by the second adjustable expansion
device; positioning first and second adjustable expansion devices
within a second expandable tubular member; supporting the first
expandable tubular member and the first and second adjustable
expansion devices within the borehole in overlapping relation to
the first expandable tubular member; lowering the first adjustable
expansion device out of the second expandable tubular member;
increasing the outside dimension of the first adjustable expansion
device; displacing the first adjustable expansion device upwardly
relative to the second expandable tubular member to radially expand
and plastically deform a lower portion of the second expandable
tubular member; pressurizing an interior region of the second
expandable tubular member above the first adjustable expansion
device during the radial expansion of the lower portion of the
second expandable tubular member by the first adjustable expansion
device; displacing the first adjustable expansion device and the
second adjustable expansion device downwardly relative to the
second expandable tubular member; decreasing the outside dimension
of the first adjustable expansion device and increasing the outside
dimension of the second adjustable expansion device; displacing the
second adjustable expansion device upwardly relative to the second
expandable tubular member to radially expand and plastically deform
portions of the second expandable tubular member above the lower
portion of the second expandable tubular member; and pressurizing
an interior region of the second expandable tubular member above
the second adjustable expansion device during the radial expansion
of the portions of the second expandable tubular member above the
lower portion of the second expandable tubular member by the second
adjustable expansion device; wherein the outside dimension of the
first adjustable expansion device is greater than the outside
dimension of the second adjustable expansion device.
[0351] A method for radially expanding and plastically deforming an
expandable tubular member within a borehole has been described that
includes supporting the expandable tubular member, an hydraulic
actuator, and an adjustable expansion device within the borehole;
increasing the size of the adjustable expansion device; and
displacing the adjustable expansion device upwardly relative to the
expandable tubular member using the hydraulic actuator to radially
expand and plastically deform a portion of the expandable tubular
member. In an exemplary embodiment, the method further includes
reducing the size of the adjustable expansion device after the
portion of the expandable tubular member has been radially expanded
and plastically deformed. In an exemplary embodiment, the method
further includes fluidicly sealing the radially expanded and
plastically deformed end of the expandable tubular member after
reducing the size of the adjustable expansion device. In an
exemplary embodiment, the method further includes permitting the
position of the expandable tubular member to float relative to the
position of the hydraulic actuator after fluidicly sealing the
radially expanded and plastically deformed end of the expandable
tubular member. In an exemplary embodiment, the method further
includes injecting a hardenable fluidic sealing material into an
annulus between the expandable tubular member and a preexisting
structure after permitting the position of the expandable tubular
member to float relative to the position of the hydraulic actuator.
In an exemplary embodiment, the method further includes increasing
the size of the adjustable expansion device after permitting the
position of the expandable tubular member to float relative to the
position of the hydraulic actuator. In an exemplary embodiment, the
method further includes displacing the adjustable expansion cone
upwardly relative to the expandable tubular member to radially
expand and plastically deform another portion of the expandable
tubular member. In an exemplary embodiment, the method further
includes if the end of the other portion of the expandable tubular
member overlaps with a preexisting structure, then not permitting
the position of the expandable tubular member to float relative to
the position of the hydraulic actuator; and displacing the
adjustable expansion cone upwardly relative to the expandable
tubular member using the hydraulic actuator to radially expand and
plastically deform the end of the other portion of the expandable
tubular member that overlaps with the preexisting structure.
[0352] A method for forming a mono diameter wellbore casing within
a borehole that includes a preexisting wellbore casing has been
described that includes supporting the expandable tubular member,
an hydraulic actuator, and an adjustable expansion device within
the borehole; increasing the size of the adjustable expansion
device; displacing the adjustable expansion device upwardly
relative to the expandable tubular member using the hydraulic
actuator to radially expand and plastically deform a portion of the
expandable tubular member; and displacing the adjustable expansion
device upwardly relative to the expandable tubular member to
radially expand and plastically deform the remaining portion of the
expandable tubular member and a portion of the preexisting wellbore
casing that overlaps with an end of the remaining portion of the
expandable tubular member. In an exemplary embodiment, the method
further includes reducing the size of the adjustable expansion
device after the portion of the expandable tubular member has been
radially expanded and plastically deformed. In an exemplary
embodiment, the method further includes fluidicly sealing the
radially expanded and plastically deformed end of the expandable
tubular member after reducing the size of the adjustable expansion
device. In an exemplary embodiment, the method further includes
permitting the position of the expandable tubular member to float
relative to the position of the hydraulic actuator after fluidicly
sealing the radially expanded and plastically deformed end of the
expandable tubular member. In an exemplary embodiment, the method
further includes injecting a hardenable fluidic sealing material
into an annulus between the expandable tubular member and the
borehole after permitting the position of the expandable tubular
member to float relative to the position of the hydraulic actuator.
In an exemplary embodiment, the method further includes increasing
the size of the adjustable expansion device after permitting the
position of the expandable tubular member to float relative to the
position of the hydraulic actuator. In an exemplary embodiment, the
method further includes displacing the adjustable expansion cone
upwardly relative to the expandable tubular member to radially
expand and plastically deform the remaining portion of the
expandable tubular member. In an exemplary embodiment, the method
further includes not permitting the position of the expandable
tubular member to float relative to the position of the hydraulic
actuator; and displacing the adjustable expansion cone upwardly
relative to the expandable tubular member using the hydraulic
actuator to radially expand and plastically deform the end of the
remaining portion of the expandable tubular member that overlaps
with the preexisting wellbore casing after not permitting the
position of the expandable tubular member to float relative to the
position of the hydraulic actuator.
[0353] A method of radially expanding and plastically deforming a
tubular member has been described that includes positioning the
tubular member within a preexisting structure; radially expanding
and plastically deforming a lower portion of the tubular member to
form a bell section; and radially expanding and plastically
deforming a portion of the tubular member above the bell section.
In an exemplary embodiment, positioning the tubular member within a
preexisting structure includes locking the tubular member to an
expansion device. In an exemplary embodiment, the outside diameter
of the expansion device is less than the inside diameter of the
tubular member. In an exemplary embodiment, the expansion device is
positioned within the tubular member. In an exemplary embodiment,
the expansion device includes an adjustable expansion device. In an
exemplary embodiment, the adjustable expansion device is adjustable
to a plurality of sizes. In an exemplary embodiment, the expansion
device includes a plurality of expansion devices. In an exemplary
embodiment, at least one of the expansion devices includes an
adjustable expansion device. In an exemplary embodiment, at least
one of the adjustable expansion device is adjustable to a plurality
of sizes. In an exemplary embodiment, radially expanding and
plastically deforming a lower portion of the tubular member to form
a bell section includes lowering an expansion device out of an end
of the tubular member; and pulling the expansion device through the
end of the tubular member. In an exemplary embodiment, lowering an
expansion device out of an end of the tubular member includes
lowering the expansion device out of the end of the tubular member;
and adjusting the size of the expansion device. In an exemplary
embodiment, the adjustable expansion device is adjustable to a
plurality of sizes. In an exemplary embodiment, the expansion
device includes a plurality of adjustable expansion devices. In an
exemplary embodiment, at least one of the adjustable expansion
devices is adjustable to a plurality of sizes. In an exemplary
embodiment, pulling the expansion device through the end of the
tubular member includes gripping the tubular member; and pulling an
expansion device through an end of the tubular member. In an
exemplary embodiment, gripping the tubular member includes
permitting axial displacement of the tubular member in a first
direction; and not permitting axial displacement of the tubular
member in a second direction. In an exemplary embodiment, pulling
the expansion device through the end of the tubular member includes
pulling the expansion device through the end of the tubular member
using an actuator. In an exemplary embodiment, radially expanding
and plastically deforming a portion of the tubular member above the
bell section includes lowering an expansion device out of an end of
the tubular member; and pulling the expansion device through the
end of the tubular member. In an exemplary embodiment, lowering an
expansion device out of an end of the tubular member includes
lowering the expansion device out of the end of the tubular member;
and adjusting the size of the expansion device. In an exemplary
embodiment, the adjustable expansion device is adjustable to a
plurality of sizes. In an exemplary embodiment, the expansion
device includes a plurality of adjustable expansion devices. In an
exemplary embodiment, at least one of the adjustable expansion
devices is adjustable to a plurality of sizes. In an exemplary
embodiment, pulling the expansion device through the end of the
tubular member includes gripping the tubular member; and pulling an
expansion device through an end of the tubular member. In an
exemplary embodiment, gripping the tubular member includes
permitting axial displacement of the tubular member in a first
direction; and not permitting axial displacement of the tubular
member in a second direction. In an exemplary embodiment, pulling
the expansion device through the end of the tubular member includes
pulling the expansion device through the end of the tubular member
using an actuator. In an exemplary embodiment, pulling the
expansion device through the end of the tubular member includes
pulling the expansion device through the end of the tubular member
using fluid pressure. In an exemplary embodiment, pulling the
expansion device through the end of the tubular member using fluid
pressure includes pressurizing an annulus within the tubular member
above the expansion device. In an exemplary embodiment, radially
expanding and plastically deforming a portion of the tubular member
above the bell section includes fluidicly sealing an end of the
tubular member; and pulling the expansion device through the
tubular member. In an exemplary embodiment, the expansion device is
adjustable. In an exemplary embodiment, the expansion device is
adjustable to a plurality of sizes. In an exemplary embodiment, the
expansion device comprises a plurality of adjustable expansion
devices. In an exemplary embodiment, at least one of the adjustable
expansion devices is adjustable to a plurality of sizes. In an
exemplary embodiment, pulling the expansion device through the end
of the tubular member includes gripping the tubular member; and
pulling an expansion device through an end of the tubular member.
In an exemplary embodiment, gripping the tubular member includes
permitting axial displacement of the tubular member in a first
direction; and not permitting axial displacement of the tubular
member in a second direction. In an exemplary embodiment, pulling
the expansion device through the end of the tubular member includes
pulling the expansion device through the end of the tubular member
using an actuator. In an exemplary embodiment, pulling the
expansion device through the end of the tubular member includes
pulling the expansion device through the end of the tubular member
using fluid pressure. In an exemplary embodiment, pulling the
expansion device through the end of the tubular member using fluid
pressure includes pressurizing an annulus within the tubular member
above the expansion device. In an exemplary embodiment, radially
expanding and plastically deforming a portion of the tubular member
above the bell section includes overlapping the portion of the
tubular member above the bell section with an end of a preexisting
tubular member; and pulling an expansion device through the
overlapping portions of the tubular member and the preexisting
tubular member. In an exemplary embodiment, the expansion device is
adjustable. In an exemplary embodiment, the expansion device is
adjustable to a plurality of sizes. In an exemplary embodiment, the
expansion device includes a plurality of adjustable expansion
devices. In an exemplary embodiment, at least one of the adjustable
expansion devices is adjustable to a plurality of sizes. In an
exemplary embodiment, pulling the expansion device through the
overlapping portions of the tubular member and the preexisting
tubular member includes gripping the tubular member; and pulling
the expansion device through the overlapping portions of the
tubular member and the preexisting tubular member. In an exemplary
embodiment, gripping the tubular member includes permitting axial
displacement of the tubular member in a first direction; and not
permitting axial displacement of the tubular member in a second
direction. In an exemplary embodiment, pulling the expansion device
through the overlapping portions of the tubular member and the
preexisting tubular member includes pulling the expansion device
through the overlapping portions of the tubular member and the
preexisting tubular member using an actuator. In an exemplary
embodiment, pulling the expansion device through the overlapping
portions of the tubular member and the preexisting tubular member
includes pulling the expansion device through the overlapping
portions of the tubular member and the preexisting tubular member
using fluid pressure. In an exemplary embodiment, pulling the
expansion device through the overlapping portions of the tubular
member and the preexisting tubular member using fluid pressure
includes pressurizing an annulus within the tubular member above
the expansion device. In an exemplary embodiment, the method
further includes cutting an end of the portion of the tubular
member that overlaps with the preexisting tubular member. In an
exemplary embodiment, the method further includes removing the cut
off end of the expandable tubular member from the preexisting
structure. In an exemplary embodiment, the method further includes
injecting a hardenable fluidic sealing material into an annulus
between the expandable tubular member and the preexisting
structure. In an exemplary embodiment, the method further includes
cutting off an end of the expandable tubular member. In an
exemplary embodiment, the method further includes removing the cut
off end of the expandable tubular member from the preexisting
structure.
[0354] A method of radially expanding and plastically deforming a
tubular member has been described that includes applying internal
pressure to the inside surface of the tubular member at a plurality
of discrete location separated from one another.
[0355] A system for radially expanding and plastically deforming an
expandable tubular member within a borehole having a preexisting
wellbore casing has been described that includes means for
positioning the tubular member within the borehole in overlapping
relation to the wellbore casing; means for radially expanding and
plastically deforming a portion of the tubular member to form a
bell section; and means for radially expanding and plastically
deforming a portion of the tubular member above the bell section
comprising a portion of the tubular member that overlaps with the
wellbore casing; wherein the inside diameter of the bell section is
greater than the inside diameter of the radially expanded and
plastically deformed portion of the tubular member above the bell
section. In an exemplary embodiment, means for radially expanding
and plastically deforming a portion of the tubular member to form a
bell section includes means for positioning an adjustable expansion
device within the expandable tubular member; means for supporting
the expandable tubular member and the adjustable expansion device
within the borehole; means for lowering the adjustable expansion
device out of the expandable tubular member; means for increasing
the outside dimension of the adjustable expansion device; and means
for displacing the adjustable expansion device upwardly relative to
the expandable tubular member n times to radially expand and
plastically deform n portions of the expandable tubular member,
wherein n is greater than or equal to 1.
[0356] A system for forming a mono diameter wellbore casing has
been described that includes means for positioning an adjustable
expansion device within a first expandable tubular member; means
for supporting the first expandable tubular member and the
adjustable expansion device within a borehole; means for lowering
the adjustable expansion device out of the first expandable tubular
member; means for increasing the outside dimension of the
adjustable expansion device; means for displacing the adjustable
expansion device upwardly relative to the first expandable tubular
member m times to radially expand and plastically deform m portions
of the first expandable tubular member within the borehole; means
for positioning the adjustable expansion device within a second
expandable tubular member; means for supporting the second
expandable tubular member and the adjustable expansion device
within the borehole in overlapping relation to the first expandable
tubular member; means for lowering the adjustable expansion device
out of the second expandable tubular member; means for increasing
the outside dimension of the adjustable expansion device; and means
for displacing the adjustable expansion device upwardly relative to
the second expandable tubular member n times to radially expand and
plastically deform n portions of the second expandable tubular
member within the borehole.
[0357] A system for radially expanding and plastically deforming an
expandable tubular member within a borehole has been described that
includes means for positioning an adjustable expansion device
within the expandable tubular member; means for supporting the
expandable tubular member and the adjustable expansion device
within the borehole; means for lowering the adjustable expansion
device out of the expandable tubular member; means for increasing
the outside dimension of the adjustable expansion device; means for
displacing the adjustable expansion mandrel upwardly relative to
the expandable tubular member n times to radially expand and
plastically deform n portions of the expandable tubular member
within the borehole; and means for pressurizing an interior region
of the expandable tubular member above the adjustable expansion
device during the radial expansion and plastic deformation of the
expandable tubular member within the borehole.
[0358] A system for forming a mono diameter wellbore casing has
been described that includes means for positioning an adjustable
expansion device within a first expandable tubular member; means
for supporting the first expandable tubular member and the
adjustable expansion device within a borehole; means for lowering
the adjustable expansion device out of the first expandable tubular
member; means for increasing the outside dimension of the
adjustable expansion device; means for displacing the adjustable
expansion device upwardly relative to the first expandable tubular
member m times to radially expand and plastically deform m portions
of the first expandable tubular member within the borehole; means
for pressurizing an interior region of the first expandable tubular
member above the adjustable expansion device during the radial
expansion and plastic deformation of the first expandable tubular
member within the borehole; means for positioning the adjustable
expansion mandrel within a second expandable tubular member; means
for supporting the second expandable tubular member and the
adjustable expansion mandrel within the borehole in overlapping
relation to the first expandable tubular member; means for lowering
the adjustable expansion mandrel out of the second expandable
tubular member; means for increasing the outside dimension of the
adjustable expansion mandrel; means for displacing the adjustable
expansion mandrel upwardly relative to the second expandable
tubular member n times to radially expand and plastically deform n
portions of the second expandable tubular member within the
borehole; and means for pressurizing an interior region of the
second expandable tubular member above the adjustable expansion
mandrel during the radial expansion and plastic deformation of the
second expandable tubular member within the borehole.
[0359] A system for radially expanding and plastically deforming an
expandable tubular member within a borehole has been described that
includes means for positioning first and second adjustable
expansion devices within the expandable tubular member; means for
supporting the expandable tubular member and the first and second
adjustable expansion devices within the borehole; means for
lowering the first adjustable expansion device out of the
expandable tubular member; means for increasing the outside
dimension of the first adjustable expansion device; means for
displacing the first adjustable expansion device upwardly relative
to the expandable tubular member to radially expand and plastically
deform a lower portion of the expandable tubular member; means for
displacing the first adjustable expansion device and the second
adjustable expansion device downwardly relative to the expandable
tubular member; means for decreasing the outside dimension of the
first adjustable expansion device and increasing the outside
dimension of the second adjustable expansion device; means for
displacing the second adjustable expansion device upwardly relative
to the expandable tubular member to radially expand and plastically
deform portions of the expandable tubular member above the lower
portion of the expandable tubular member; wherein the outside
dimension of the first adjustable expansion device is greater than
the outside dimension of the second adjustable expansion
device.
[0360] A system for forming a mono diameter wellbore casing has
been described that includes means for positioning first and second
adjustable expansion devices within a first expandable tubular
member; means for supporting the first expandable tubular member
and the first and second adjustable expansion devices within a
borehole; means for lowering the first adjustable expansion device
out of the first expandable tubular member; means for increasing
the outside dimension of the first adjustable expansion device;
displacing the first adjustable expansion device upwardly relative
to the first expandable tubular member to radially expand and
plastically deform a lower portion of the first expandable tubular
member; means for displacing the first adjustable expansion device
and the second adjustable expansion device downwardly relative to
the first expandable tubular member; means for decreasing the
outside dimension of the first adjustable expansion device and
increasing the outside dimension of the second adjustable expansion
device; means for displacing the second adjustable expansion device
upwardly relative to the first expandable tubular member to
radially expand and plastically deform portions of the first
expandable tubular member above the lower portion of the expandable
tubular member; means for positioning first and second adjustable
expansion devices within a second expandable tubular member; means
for supporting the first expandable tubular member and the first
and second adjustable expansion devices within the borehole in
overlapping relation to the first expandable tubular member; means
for lowering the first adjustable expansion device out of the
second expandable tubular member; means for increasing the outside
dimension of the first adjustable expansion device; means for
displacing the adjustable expansion device upwardly relative to the
second expandable tubular member to radially expand and plastically
deform a lower portion of the second expandable tubular member;
means for displacing the first adjustable expansion device and the
second adjustable expansion device downwardly relative to the
second expandable tubular member; means for decreasing the outside
dimension of the first adjustable expansion device and increasing
the outside dimension of the second adjustable expansion device;
and means for displacing the second adjustable expansion device
upwardly relative to the second expandable tubular member to
radially expand and plastically deform portions of the second
expandable tubular member above the lower portion of the second
expandable tubular member; wherein the outside dimension of the
first adjustable expansion device is greater than the outside
dimension of the second adjustable expansion device.
[0361] A system for radially expanding and plastically deforming an
expandable tubular member within a borehole has been described that
includes means for positioning first and second adjustable
expansion devices within the expandable tubular member; means for
supporting the expandable tubular member and the first and second
adjustable expansion devices within the borehole; means for
lowering the first adjustable expansion device out of the
expandable tubular member; means for increasing the outside
dimension of the first adjustable expansion device; means for
displacing the first adjustable expansion device upwardly relative
to the expandable tubular member to radially expand and plastically
deform a lower portion of the expandable tubular member; means for
pressurizing an interior region of the expandable tubular member
above the first adjustable expansion device during the radial
expansion of the lower portion of the expandable tubular member by
the first adjustable expansion device; means for displacing the
first adjustable expansion device and the second adjustable
expansion device downwardly relative to the expandable tubular
member; means for decreasing the outside dimension of the first
adjustable expansion device and increasing the outside dimension of
the second adjustable expansion device; means for displacing the
second adjustable expansion device upwardly relative to the
expandable tubular member to radially expand and plastically deform
portions of the expandable tubular member above the lower portion
of the expandable tubular member; and means for pressurizing an
interior region of the expandable tubular member above the second
adjustable expansion device during the radial expansion of the
portions of the expandable tubular member above the lower portion
of the expandable tubular member by the second adjustable expansion
device; wherein the outside dimension of the first adjustable
expansion device is greater than the outside dimension of the
second adjustable expansion device.
[0362] A system for forming a mono diameter wellbore casing has
been described that includes means for positioning first and second
adjustable expansion devices within a first expandable tubular
member; means for supporting the first expandable tubular member
and the first and second adjustable expansion devices within a
borehole; means for lowering the first adjustable expansion device
out of the first expandable tubular member; means for increasing
the outside dimension of the first adjustable expansion device;
means for displacing the first adjustable expansion device upwardly
relative to the first expandable tubular member to radially expand
and plastically deform a lower portion of the first expandable
tubular member; means for pressurizing an interior region of the
first expandable tubular member above the first adjustable
expansion device during the radial expansion of the lower portion
of the first expandable tubular member by the first adjustable
expansion device; means for displacing the first adjustable
expansion device and the second adjustable expansion device
downwardly relative to the first expandable tubular member; means
for decreasing the outside dimension of the first adjustable
expansion device and increasing the outside dimension of the second
adjustable expansion device; means for displacing the second
adjustable expansion device upwardly relative to the first
expandable tubular member to radially expand and plastically deform
portions of the first expandable tubular member above the lower
portion of the expandable tubular member; means for pressurizing an
interior region of the first expandable tubular member above the
second adjustable expansion device during the radial expansion of
the portions of the first expandable tubular member above the lower
portion of the first expandable tubular member by the second
adjustable expansion device; means for positioning first and second
adjustable expansion devices within a second expandable tubular
member; means for supporting the first expandable tubular member
and the first and second adjustable expansion devices within the
borehole in overlapping relation to the first expandable tubular
member; means for lowering the first adjustable expansion device
out of the second expandable tubular member; means for increasing
the outside dimension of the first adjustable expansion device;
means for displacing the first adjustable expansion device upwardly
relative to the second expandable tubular member to radially expand
and plastically deform a lower portion of the second expandable
tubular member; means for pressurizing an interior region of the
second expandable tubular member above the first adjustable
expansion device during the radial expansion of the lower portion
of the second expandable tubular member by the first adjustable
expansion device; means for displacing the first adjustable
expansion device and the second adjustable expansion device
downwardly relative to the second expandable tubular member; means
for decreasing the outside dimension of the first adjustable
expansion device and increasing the outside dimension of the second
adjustable expansion device; means for displacing the second
adjustable expansion device upwardly relative to the second
expandable tubular member to radially expand and plastically deform
portions of the second expandable tubular member above the lower
portion of the second expandable tubular member; and means for
pressurizing an interior region of the second expandable tubular
member above the second adjustable expansion device during the
radial expansion of the portions of the second expandable tubular
member above the lower portion of the second expandable tubular
member by the second adjustable expansion device; wherein the
outside dimension of the first adjustable expansion device is
greater than the outside dimension of the second adjustable
expansion device.
[0363] A system for radially expanding and plastically deforming an
expandable tubular member within a borehole has been described that
includes means for supporting the expandable tubular member, an
hydraulic actuator, and an adjustable expansion device within the
borehole; means for increasing the size of the adjustable expansion
device; and means for displacing the adjustable expansion device
upwardly relative to the expandable tubular member using the
hydraulic actuator to radially expand and plastically deform a
portion of the expandable tubular member. In an exemplary
embodiment, the system further includes means for reducing the size
of the adjustable expansion device after the portion of the
expandable tubular member has been radially expanded and
plastically deformed. In an exemplary embodiment, the system
further includes means for fluidicly sealing the radially expanded
and plastically deformed end of the expandable tubular member after
reducing the size of the adjustable expansion device. In an
exemplary embodiment, the system further includes means for
permitting the position of the expandable tubular member to float
relative to the position of the hydraulic actuator after fluidicly
sealing the radially expanded and plastically deformed end of the
expandable tubular member. In an exemplary embodiment, the system
further includes means for injecting a hardenable fluidic sealing
material into an annulus between the expandable tubular member and
a preexisting structure after permitting the position of the
expandable tubular member to float relative to the position of the
hydraulic actuator. In an exemplary embodiment, the system further
includes means for increasing the size of the adjustable expansion
device after permitting the position of the expandable tubular
member to float relative to the position of the hydraulic actuator.
In an exemplary embodiment, system further includes means for
displacing the adjustable expansion cone upwardly relative to the
expandable tubular member to radially expand and plastically deform
another portion of the expandable tubular member. In an exemplary
embodiment, the system further includes if the end of the other
portion of the expandable tubular member overlaps with a
preexisting structure, then means for not permitting the position
of the expandable tubular member to float relative to the position
of the hydraulic actuator; and means for displacing the adjustable
expansion cone upwardly relative to the expandable tubular member
using the hydraulic actuator to radially expand and plastically
deform the end of the other portion of the expandable tubular
member that overlaps with the preexisting structure.
[0364] A system for forming a mono diameter wellbore casing within
a borehole that includes a preexisting wellbore casing has been
described that includes means for supporting the expandable tubular
member, an hydraulic actuator, and an adjustable expansion device
within the borehole; means for increasing the size of the
adjustable expansion device; means for displacing the adjustable
expansion device upwardly relative to the expandable tubular member
using the hydraulic actuator to radially expand and plastically
deform a portion of the expandable tubular member; and means for
displacing the adjustable expansion device upwardly relative to the
expandable tubular member to radially expand and plastically deform
the remaining portion of the expandable tubular member and a
portion of the preexisting wellbore casing that overlaps with an
end of the remaining portion of the expandable tubular member. In
an exemplary embodiment, the system further includes means for
reducing the size of the adjustable expansion device after the
portion of the expandable tubular member has been radially expanded
and plastically deformed. In an exemplary embodiment, the system
further includes means for fluidicly sealing the radially expanded
and plastically deformed end of the expandable tubular member after
reducing the size of the adjustable expansion device. In an
exemplary embodiment, the system further includes means for
permitting the position of the expandable tubular member to float
relative to the position of the hydraulic actuator after fluidicly
sealing the radially expanded and plastically deformed end of the
expandable tubular member. In an exemplary embodiment, the system
further includes means for injecting a hardenable fluidic sealing
material into an annulus between the expandable tubular member and
the borehole after permitting the position of the expandable
tubular member to float relative to the position of the hydraulic
actuator. In an exemplary embodiment, the system further includes
means for increasing the size of the adjustable expansion device
after permitting the position of the expandable tubular member to
float relative to the position of the hydraulic actuator. In an
exemplary embodiment, the system further includes means for
displacing the adjustable expansion cone upwardly relative to the
expandable tubular member to radially expand and plastically deform
the remaining portion of the expandable tubular member. In an
exemplary embodiment, the system further includes means for not
permitting the position of the expandable tubular member to float
relative to the position of the hydraulic actuator; and means for
displacing the adjustable expansion cone upwardly relative to the
expandable tubular member using the hydraulic actuator to radially
expand and plastically deform the end of the remaining portion of
the expandable tubular member that overlaps with the preexisting
wellbore casing after not permitting the position of the expandable
tubular member to float relative to the position of the hydraulic
actuator.
[0365] A system for radially expanding and plastically deforming a
tubular member has been described that includes means for
positioning the tubular member within a preexisting structure;
means for radially expanding and plastically deforming a lower
portion of the tubular member to form a bell section; and means for
radially expanding and plastically deforming a portion of the
tubular member above the bell section. In an exemplary embodiment,
positioning the tubular member within a preexisting structure
includes means for locking the tubular member to an expansion
device. In an exemplary embodiment, the outside diameter of the
expansion device is less than the inside diameter of the tubular
member. In an exemplary embodiment, the expansion device is
positioned within the tubular member. In an exemplary embodiment,
the expansion device includes an adjustable expansion device. In an
exemplary embodiment, the adjustable expansion device is adjustable
to a plurality of sizes. In an exemplary embodiment, the expansion
device includes a plurality of expansion devices. In an exemplary
embodiment, at least one of the expansion devices includes an
adjustable expansion device. In an exemplary embodiment, at least
one of the adjustable expansion device is adjustable to a plurality
of sizes. In an exemplary embodiment, means for radially expanding
and plastically deforming a lower portion of the tubular member to
form a bell section includes means for lowering an expansion device
out of an end of the tubular member; and means for pulling the
expansion device through the end of the tubular member. In an
exemplary embodiment, means for lowering an expansion device out of
an end of the tubular member includes means for lowering the
expansion device out of the end of the tubular member; and means
for adjusting the size of the expansion device. In an exemplary
embodiment, the adjustable expansion device is adjustable to a
plurality of sizes. In an exemplary embodiment, the expansion
device includes a plurality of adjustable expansion devices. In an
exemplary embodiment, at least one of the adjustable expansion
devices is adjustable to a plurality of sizes. In an exemplary
embodiment, means for pulling the expansion device through the end
of the tubular member includes means for gripping the tubular
member; and means for pulling an expansion device through an end of
the tubular member. In an exemplary embodiment, means for gripping
the tubular member includes means for permitting axial displacement
of the tubular member in a first direction; and means for not
permitting axial displacement of the tubular member in a second
direction. In an exemplary embodiment, means for pulling the
expansion device through the end of the tubular member includes
means for pulling the expansion device through the end of the
tubular member using an actuator. In an exemplary embodiment, means
for radially expanding and plastically deforming a portion of the
tubular member above the bell section includes means for lowering
an expansion device out of an end of the tubular member; and means
for pulling the expansion device through the end of the tubular
member. In an exemplary embodiment, means for lowering an expansion
device out of an end of the tubular member includes means for
lowering the expansion device out of the end of the tubular member;
and means for adjusting the size of the expansion device. In an
exemplary embodiment, the adjustable expansion device is adjustable
to a plurality of sizes. In an exemplary embodiment, the expansion
device comprises a plurality of adjustable expansion devices. In an
exemplary embodiment, at least one of the adjustable expansion
devices is adjustable to a plurality of sizes. In an exemplary
embodiment, means for pulling the expansion device through the end
of the tubular member includes means for gripping the tubular
member; and means for pulling an expansion device through an end of
the tubular member. In an exemplary embodiment, means for gripping
the tubular member includes means for permitting axial displacement
of the tubular member in a first direction; and means for not
permitting axial displacement of the tubular member in a second
direction. In an exemplary embodiment, means for pulling the
expansion device through the end of the tubular member includes
means for pulling the expansion device through the end of the
tubular member using an actuator. In an exemplary embodiment, means
for pulling the expansion device through the end of the tubular
member includes means for pulling the expansion device through the
end of the tubular member using fluid pressure. In an exemplary
embodiment, means for pulling the expansion device through the end
of the tubular member using fluid pressure includes means for
pressurizing an annulus within the tubular member above the
expansion device. In an exemplary embodiment, means for radially
expanding and plastically deforming a portion of the tubular member
above the bell section includes means for fluidicly sealing an end
of the tubular member; and means for pulling the expansion device
through the tubular member. In an exemplary embodiment, the
expansion device is adjustable. In an exemplary embodiment, the
expansion device is adjustable to a plurality of sizes. In an
exemplary embodiment, the expansion device includes a plurality of
adjustable expansion devices. In an exemplary embodiment, at least
one of the adjustable expansion devices is adjustable to a
plurality of sizes. In an exemplary embodiment, means for pulling
the expansion device through the end of the tubular member includes
means for gripping the tubular member; and means for pulling an
expansion device through an end of the tubular member. In an
exemplary embodiment, means for gripping the tubular member
includes means for permitting axial displacement of the tubular
member in a first direction; and means for not permitting axial
displacement of the tubular member in a second direction. In an
exemplary embodiment, means for pulling the expansion device
through the end of the tubular member includes means for pulling
the expansion device through the end of the tubular member using an
actuator. In an exemplary embodiment, means for pulling the
expansion device through the end of the tubular member includes
means for pulling the expansion device through the end of the
tubular member using fluid pressure. In an exemplary embodiment,
means for pulling the expansion device through the end of the
tubular member using fluid pressure includes means for pressurizing
an annulus within the tubular member above the expansion device. In
an exemplary embodiment, means for radially expanding and
plastically deforming a portion of the tubular member above the
bell section includes means for overlapping the portion of the
tubular member above the bell section with an end of a preexisting
tubular member; and means for pulling an expansion device through
the overlapping portions of the tubular member and the preexisting
tubular member. In an exemplary embodiment, the expansion device is
adjustable. In an exemplary embodiment, the expansion device is
adjustable to a plurality of sizes. In an exemplary embodiment, the
expansion device includes a plurality of adjustable expansion
devices. In an exemplary embodiment, at least one of the adjustable
expansion devices is adjustable to a plurality of sizes. In an
exemplary embodiment, means for pulling the expansion device
through the overlapping portions of the tubular member and the
preexisting tubular member includes means for gripping the tubular
member; and means for pulling the expansion device through the
overlapping portions of the tubular member and the preexisting
tubular member. In an exemplary embodiment, means for gripping the
tubular member includes means for permitting axial displacement of
the tubular member in a first direction; and means for not
permitting axial displacement of the tubular member in a second
direction. In an exemplary embodiment, means for pulling the
expansion device through the overlapping portions of the tubular
member and the preexisting tubular member includes means for
pulling the expansion device through the overlapping portions of
the tubular member and the preexisting tubular member using an
actuator. In an exemplary embodiment, means for pulling the
expansion device through the overlapping portions of the tubular
member and the preexisting tubular member includes means for
pulling the expansion device through the overlapping portions of
the tubular member and the preexisting tubular member using fluid
pressure. In an exemplary embodiment, means for pulling the
expansion device through the overlapping portions of the tubular
member and the preexisting tubular member using fluid pressure
includes means for pressurizing an annulus within the tubular
member above the expansion device. In an exemplary embodiment, the
system further includes means for cutting an end of the portion of
the tubular member that overlaps with the preexisting tubular
member. In an exemplary embodiment, the system further includes
means for removing the cut off end of the expandable tubular member
from the preexisting structure. In an exemplary embodiment, the
system further includes means for injecting a hardenable fluidic
sealing material into an annulus between the expandable tubular
member and the preexisting structure. In an exemplary embodiment,
the system further includes means for cutting off an end of the
expandable tubular member. In an exemplary embodiment, the system
further includes means for removing the cut off end of the
expandable tubular member from the preexisting structure.
[0366] A system of radially expanding and plastically deforming a
tubular member has been described that includes a support member;
and means for applying internal pressure to the inside surface of
the tubular member at a plurality of discrete location separated
from one another coupled to the support member.
[0367] A method of cutting a tubular member has been described that
includes positioning a plurality of cutting elements within the
tubular member; and bringing the cutting elements into engagement
with the tubular member. In an exemplary embodiment, the cutting
elements include a first group of cutting elements; and a second
group of cutting elements; wherein the first group of cutting
elements are interleaved with the second group of cutting elements.
In an exemplary embodiment, bringing the cutting elements into
engagement with the tubular member includes bringing the cutting
elements into axial alignment. In an exemplary embodiment, bringing
the cutting elements into engagement with the tubular member
further includes pivoting the cutting elements. In an exemplary
embodiment, bringing the cutting elements into engagement with the
tubular member further includes translating the cutting elements.
In an exemplary embodiment, bringing the culling elements into
engagement with the tubular member further includes pivoting the
cuffing elements; and translating the cutting elements. In an
exemplary embodiment, bringing the cutting elements into engagement
with the tubular member includes rotating the cutting elements
about a common axis. In an exemplary embodiment, bringing the
cutting elements into engagement with the tubular member includes
pivoting the cutting elements about corresponding axes; translating
the cutting elements; and rotating the cutting elements about a
common axis. In an exemplary embodiment, the method further
includes preventing the cutting elements from coming into
engagement with the tubular member if the inside diameter of the
tubular member is less than a predetermined value. In an exemplary
embodiment, preventing the cutting elements from coming into
engagement with the tubular member if the inside diameter of the
tubular member is less than a predetermined value includes sensing
the inside diameter of the tubular member.
[0368] A method of gripping a tubular member has been described
that includes positioning a plurality of gripping elements within
the tubular member; bringing the gripping elements into engagement
with the tubular member. In an exemplary embodiment, bringing the
gripping elements into engagement with the tubular member includes
displacing the gripping elements in an axial direction; and
displacing the gripping elements in a radial direction. In an
exemplary embodiment, the method further includes biasing the
gripping elements against engagement with the tubular member.
[0369] A method of operating an actuator has been described that
includes pressurizing a plurality of pressure chamber. In an
exemplary embodiment, the method further includes transmitting
torsional loads.
[0370] A method of injecting a hardenable fluidic sealing material
into an annulus between a tubular member and a preexisting
structure has been described that includes positioning the tubular
member into the preexisting structure; sealing off an end of the
tubular member; operating a valve within the end of the tubular
member; and injecting a hardenable fluidic sealing material through
the valve into the annulus between the tubular member and the
preexisting structure.
[0371] A system for cutting a tubular member has been described
that includes means for positioning a plurality of cutting elements
within the tubular member; and means for bringing the cutting
elements into engagement with the tubular member. In an exemplary
embodiment, the cutting elements include a first group of cutting
elements; and a second group of cutting elements; wherein the first
group of cutting elements are interleaved with the second group of
cutting elements. In an exemplary embodiment, means for bringing
the cutting elements into engagement with the tubular member
includes means for bringing the cutting elements into axial
alignment. In an exemplary embodiment, means for bringing the
cutting elements into engagement with the tubular member further
includes means for pivoting the cutting elements. In an exemplary
embodiment, means for bringing the cutting elements into engagement
with the tubular member further includes means for translating the
cutting elements. In an exemplary embodiment, means for bringing
the cutting elements into engagement with the tubular member
further includes means for pivoting the cutting elements; and means
for translating the cutting elements. In an exemplary embodiment,
means for bringing the cutting elements into engagement with the
tubular member includes means for rotating the cutting elements
about a common axis. In an exemplary embodiment, means for bringing
the cutting elements into engagement with the tubular member
includes means for pivoting the cutting elements about
corresponding axes; means for translating the cutting elements; and
means for rotating the cutting elements about a common axis. In an
exemplary embodiment, the system further includes means for
preventing the cutting elements from coming into engagement with
the tubular member if the inside diameter of the tubular member is
less than a predetermined value. In an exemplary embodiment, means
for preventing the cutting elements from coming into engagement
with the tubular member if the inside diameter of the tubular
member is less than a predetermined value includes means for
sensing the inside diameter of the tubular member.
[0372] A system for gripping a tubular member has been described
that includes means for positioning a plurality of gripping
elements within the tubular member; and means for bringing the
gripping elements into engagement with the tubular member. In an
exemplary embodiment, means for bringing the gripping elements into
engagement with the tubular member includes means for displacing
the gripping elements in an axial direction; and means for
displacing the gripping elements in a radial direction. In an
exemplary embodiment, the system further includes means for biasing
the gripping elements against engagement with the tubular
member.
[0373] An actuator system has been described that includes a
support member; and means for pressurizing a plurality of pressure
chambers coupled to the support member. In an exemplary embodiment,
the system further includes means for transmitting torsional
loads.
[0374] A system for injecting a hardenable fluidic sealing material
into an annulus between a tubular member and a preexisting
structure has been described that includes means for positioning
the tubular member into the preexisting structure; means for
sealing off an end of the tubular member; means for operating a
valve within the end of the tubular member; and means for injecting
a hardenable fluidic sealing material through the valve into the
annulus between the tubular member and the preexisting
structure.
[0375] A method of engaging a tubular member has been described
that includes positioning a plurality of elements within the
tubular member; and bringing the elements into engagement with the
tubular member. In an exemplary embodiment, the elements include a
first group of elements; and a second group of elements; wherein
the first group of elements are interleaved with the second group
of elements. In an exemplary embodiment, bringing the elements into
engagement with the tubular member includes bringing the elements
into axial alignment. In an exemplary embodiment, bringing the
elements into engagement with the tubular member further includes
pivoting the elements. In an exemplary embodiment, bringing the
elements into engagement with the tubular member further includes
translating the elements. In an exemplary embodiment, bringing the
elements into engagement with the tubular member further includes
pivoting the elements; and translating the elements. In an
exemplary embodiment, bringing the elements into engagement with
the tubular member includes rotating the elements about a common
axis. In an exemplary embodiment, bringing the elements into
engagement with the tubular member includes pivoting the elements
about corresponding axes; translating the elements; and rotating
the elements about a common axis. In an exemplary embodiment, the
method further includes preventing the elements from coming into
engagement with the tubular member if the inside diameter of the
tubular member is less than a predetermined value. In an exemplary
embodiment, preventing the elements from coming into engagement
with the tubular member if the inside diameter of the tubular
member is less than a predetermined value includes sensing the
inside diameter of the tubular member.
[0376] A system for engaging a tubular member has been described
that includes means for positioning a plurality of elements within
the tubular member; and means for bringing the elements into
engagement with the tubular member. In an exemplary embodiment, the
elements include a first group of elements; and a second group of
elements; wherein the first group of elements are interleaved with
the second group of elements. In an exemplary embodiment, means for
bringing the elements into engagement with the tubular member
includes means for bringing the elements into axial alignment. In
an exemplary embodiment, means for bringing the elements into
engagement with the tubular member further includes means for
pivoting the elements. In an exemplary embodiment, means for
bringing the elements into engagement with the tubular member
further includes means for translating the elements. In an
exemplary embodiment, means for bringing the elements into
engagement with the tubular member further includes means for
pivoting the elements; and means for translating the elements. In
an exemplary embodiment, means for bringing the elements into
engagement with the tubular member includes means for rotating the
elements about a common axis. In an exemplary embodiment, means for
bringing the elements into engagement with the tubular member
includes means for pivoting the elements about corresponding axes;
means for translating the elements; and means for rotating the
elements about a common axis. In an exemplary embodiment, the
system further includes means for preventing the elements from
coming into engagement with the tubular member if the inside
diameter of the tubular member is less than a predetermined value.
In an exemplary embodiment, means for preventing the elements from
coming into engagement with the tubular member if the inside
diameter of the tubular member is less than a predetermined value
includes means for sensing the inside diameter of the tubular
member.
[0377] It is understood that variations may be made in the
foregoing without departing from the scope of the invention. For
example, the teachings of the present illustrative embodiments may
be used to provide a wellbore casing, a pipeline, or a structural
support. Furthermore, the elements and teachings of the various
illustrative embodiments may be combined in whole or in part in
some or all of the illustrative embodiments.
[0378] 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.
* * * * *