U.S. patent application number 11/963526 was filed with the patent office on 2008-04-24 for system for lining a wellbore casing.
This patent application is currently assigned to Enventure Global Technology. Invention is credited to David Paul Brisco, Lev Ring, Kevin Waddell.
Application Number | 20080093089 11/963526 |
Document ID | / |
Family ID | 39316819 |
Filed Date | 2008-04-24 |
United States Patent
Application |
20080093089 |
Kind Code |
A1 |
Waddell; Kevin ; et
al. |
April 24, 2008 |
System for Lining a Wellbore Casing
Abstract
A system for lining a wellbore casing.
Inventors: |
Waddell; Kevin; (Houston,
TX) ; Ring; Lev; (Houston, TX) ; Brisco; David
Paul; (Duncan, OK) |
Correspondence
Address: |
KING & SPALDING, LLP
1100 LOUISIANA ST., STE. 4000
ATTN.: IP Docketing
HOUSTON
TX
77002-5213
US
|
Assignee: |
Enventure Global Technology
Houston
TX
|
Family ID: |
39316819 |
Appl. No.: |
11/963526 |
Filed: |
December 21, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10488664 |
Mar 4, 2004 |
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PCT/US02/25727 |
Aug 14, 2002 |
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11963526 |
Dec 21, 2007 |
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60317985 |
Sep 6, 2001 |
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60318386 |
Sep 10, 2001 |
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Current U.S.
Class: |
166/380 ;
166/207 |
Current CPC
Class: |
E21B 43/108 20130101;
E21B 29/10 20130101 |
Class at
Publication: |
166/380 ;
166/207 |
International
Class: |
E21B 17/00 20060101
E21B017/00 |
Claims
1-48. (canceled)
49. A method of lining a wellbore casing, comprising: positioning a
tubular liner within the wellbore casing; and radially expanding
one or more discrete portions of the tubular liner into engagement
with the wellbore casing, wherein the tubular liner comprises one
or more expandable tubular members that each comprise: a first
tubular portion, a second tubular portion, and an intermediate
tubular portion coupled between the first and second tubular
portions; and a sealing member coupled to the exterior surface of
the intermediate tubular portion, and wherein the inside diameters
of the first and second tubular portions are greater than the
inside diameter of the intermediate tubular portion.
50. The method of claim 49, wherein a plurality of discrete
portions of the tubular liner are radially expanded into engagement
with the wellbore casing.
51. The method of claim 49, wherein the remaining portions of the
tubular liner are not radially expanded.
52. The method of claim 49, wherein the discrete portions of the
tubular liner are radially expanded by injecting a fluidic material
into the tubular liner.
53. The method of claim 49, wherein the tubular liner comprises a
plurality of expandable tubular members, wherein one or more of the
expandable tubular members are radially expanded into engagement
with the wellbore casing, and wherein a plurality of the expandable
tubular members are not radially expanded into engagement with the
wellbore casing.
54. A system for lining a wellbore casing, comprising: means for
positioning a tubular liner within the wellbore casing; and means
for radially expanding one or more discrete portions of the tubular
liner into engagement with the wellbore casing, wherein the tubular
liner comprises one or more expandable tubular members that each
comprise: a first tubular portion, a second tubular portion, and an
intermediate tubular portion coupled between the first and second
tubular portions; and a sealing member coupled to the exterior
surface of the intermediate tubular portion, and wherein the inside
diameters of the first and second tubular portions are greater than
the inside diameter of the intermediate tubular portion.
55. The system of claim 54, wherein a plurality of discrete
portions of the tubular liner are radially expanded into engagement
with the wellbore casing.
56. The system of claim 54, wherein the remaining portions of the
tubular liner are not radially expanded.
57. The system of claim 54, wherein the discrete portions of the
tubular liner are radially expanded by injecting a fluidic material
into the tubular liner.
58. The system of claim 54, wherein the tubular liner comprises a
plurality of tubular members, wherein one or more of the tubular
members are radially expanded into engagement with the wellbore
casing, and wherein a plurality of the tubular members are not
radially expanded into engagement with the wellbore casing.
59. An apparatus, comprising: a subterranean formation defining a
borehole; a casing positioned in and coupled to the borehole; and a
tubular liner positioned in and coupled to the casing at one or
more discrete locations, wherein the tubular liner comprises one or
more radially expanded and plastically deformed tubular members
that each comprise: a first tubular portion, a second tubular
portion, and an intermediate tubular portion coupled between the
first and second tubular portions; and a sealing member coupled to
the exterior surface of the intermediate tubular portion that
engages the interior surface of the casing, wherein the
intermediate tubular portion is radially expanded and plastically
deformed, and wherein the first and second tubular portions are not
radially expanded and plastically deformed.
60. The apparatus of claim 59, wherein the tubular liner comprises
a plurality of the radially expanded and plastically deformed
tubular members.
61. The apparatus of claim 60, wherein the tubular liner further
comprises one or more other tubular members, and wherein the other
tubular members are interleaved among the radially expanded and
plastically deformed tubular members.
62. A method of lining a wellbore casing, comprising: positioning a
tubular liner within the wellbore casing; and radially expanding a
plurality of discrete portions of the tubular liner into engagement
with the wellbore casing, wherein the tubular liner comprises one
or more expandable tubular members that each comprise: a first
tubular portion, a second tubular portion, and an intermediate
tubular portion coupled between the first and second tubular
portions; and a sealing member coupled to the exterior surface of
the intermediate tubular portion, and wherein the inside diameters
of the first and second tubular portions are greater than the
inside diameter of the intermediate tubular portion.
63. The method of claim 62, wherein remaining portions of the
tubular liner, other than the discrete portions, are not radially
expanded.
64. The method of claim 62, wherein the discrete portions of the
tubular liner are radially expanded by injecting a fluidic material
into the tubular liner.
65. The method of claim 62, wherein one or more of the expandable
tubular members are radially expanded into engagement with the
wellbore casing, and wherein a plurality of the expandable tubular
members are not radially expanded into engagement with the wellbore
casing.
66. The method of claim 62, wherein one or more of the expandable
tubular members are radially expanded into engagement with the
wellbore casing, and wherein the tubular liner comprises one or
more other tubular members that are interleaved among the
expandable tubular members.
67. A system for lining a wellbore casing, comprising: means for
positioning a tubular liner within the wellbore casing; and means
for radially expanding a plurality of discrete portions of the
tubular liner into engagement with the wellbore casing, wherein the
tubular liner comprises one or more expandable tubular members that
each comprise: a first tubular portion, a second tubular portion,
and an intermediate tubular portion coupled between the first and
second tubular portions; and a sealing member coupled to the
exterior surface of the intermediate tubular portion, and wherein
the inside diameters of the first and second tubular portions are
greater than the inside diameter of the intermediate tubular
portion.
68. The system of claim 67, wherein the remaining portions of the
tubular liner, other than the discrete portions, are not radially
expanded.
69. The system of claim 67, wherein the discrete portions of the
tubular liner are radially expanded by injecting a fluidic material
into the tubular liner.
70. The system of claim 67, wherein one or more of the expandable
tubular members are radially expanded into engagement with the
wellbore casing, and wherein a plurality of the expandable tubular
members are not radially expanded into engagement with the wellbore
casing.
71. The system of claim 67, wherein one or more of the expandable
tubular members are radially expanded into engagement with the
wellbore casing, wherein the tubular liner comprises one or more
other tubular members that are interleaved among the expandable
tubular members.
72. An apparatus, comprising: a subterranean formation defining a
borehole; a casing positioned in and coupled to the borehole; and a
tubular liner positioned in and coupled to the casing at a
plurality of discrete spaced apart locations, wherein the tubular
liner comprises one or more radially expanded and plastically
deformed tubular members that each comprise: a first tubular
portion, a second tubular portion, and an intermediate tubular
portion coupled between the first and second tubular portions; and
a sealing member coupled to the exterior surface of the
intermediate tubular portion that engages the interior surface of
the casing, wherein the intermediate tubular portion is radially
expanded and plastically deformed, and wherein the first and second
tubular portions are not radially expanded and plastically
deformed.
73. The apparatus of claim 72, wherein the tubular liner comprises
a plurality of the radially expanded and plastically deformed
tubular members.
74. The system of claim 72, wherein the tubular liner further
comprises one or more other tubular members, and wherein the other
tubular members are interleaved among the radially expanded and
plastically deformed tubular members.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is the National Stage filing for PCT
patent application serial number PCT/US02/25727, attorney docket
number 25791.67.03, filed on Aug. 14, 2002, which claimed the
benefit of the filing dates of 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, the
disclosures of which are incorporated herein by reference.
[0002] The present application is a continuation-in-part of U.S.
utility patent application Ser. No. 10/030,593, attorney docket
number 25791.25.08, filed on Jan. 8, 2002, which was the National
Stage filing for PCT patent application serial number
PCT/US00/18635, attorney docket no. 25791.25.02, filed on Jul. 9,
2000, which claimed the benefit of the filing dates of U.S.
provisional patent application Ser. No. 60/146,203, attorney docket
no. 25791.25, filed on Jul. 29, 1999, and U.S. provisional patent
application Ser. No. 60/143,039, attorney docket no. 25791.26,
filed on Jul. 9, 1999, the disclosures of which are incorporated
herein by reference.
The present application is related to 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. 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.
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U.S. patent application Ser. No. 10/261,926, attorney docket no.
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priority from U.S. provisional patent application Ser. No.
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(77) PCT application US 03/19993, filed on Jun. 24, 2003, attorney
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(91) U.S. provisional patent application Ser. No. 60/423,363,
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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
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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.
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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,
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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
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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
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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
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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, and
(122) U.S. utility patent application Ser. No. ______, attorney
docket no. 25791.318, filed on Feb. 23, 2004, which was a
continuation-in-part of U.S. utility patent application Ser. No.
10/089,419, attorney docket no. 25791.36.03, filed on Sep. 19,
2002, which issued as U.S. Pat. No. 6,695,012, the disclosures of
which are incorporated herein by reference.
[0003] BACKGROUND
[0004] This invention relates generally to wellbore casings, and in
particular to wellbore casings that are formed using expandable
tubing.
[0005] Conventionally, when a wellbore is created, a number of
casings are installed in the borehole to prevent collapse of the
borehole wall and to prevent undesired outflow of drilling fluid
into the formation or inflow of fluid from the formation into the
borehole. The borehole is drilled in intervals whereby a casing
which is to be installed in a lower borehole interval is lowered
through a previously installed casing of an upper borehole
interval. As a consequence of this procedure the casing of the
lower interval is of smaller diameter than the casing of the upper
interval. Thus, the casings are in a nested arrangement with casing
diameters decreasing in downward direction. Cement annuli are
provided between the outer surfaces of the casings and the borehole
wall to seal the casings from the borehole wall. As a consequence
of this nested arrangement a relatively large borehole diameter is
required at the upper part of the wellbore. Such a large borehole
diameter involves increased costs due to heavy casing handling
equipment, large drill bits and increased volumes of drilling fluid
and drill cuttings. Moreover, increased drilling rig time is
involved due to required cement pumping, cement hardening, required
equipment changes due to large variations in hole diameters drilled
in the course of the well, and the large volume of cuttings drilled
and removed.
[0006] The present invention is directed to overcoming one or more
of the limitations of the existing procedures for forming wellbore
casings.
SUMMARY
[0007] According to one aspect of the present invention, a system
for lining a wellbore casing is provided that includes a tubular
support member defining a first passage, a tubular expansion cone
defining a second passage fluidicly coupled to the first passage
coupled to an end of the tubular support member and comprising a
tapered end, a tubular liner coupled to and supported by the
tapered end of the tubular expansion cone, and a shoe defining a
valveable passage coupled to an end of the tubular liner, wherein
the tubular liner includes one or more expandable tubular members
that each include a tubular body comprising an intermediate portion
and first and second expanded end portions coupled to opposing ends
of the intermediate portion, and a sealing member coupled to the
exterior surface of the intermediate portion, and one or more other
tubular members coupled to the expandable tubular members, wherein
the inside diameters of the other tubular members are greater than
or equal to the outside diameter of the tubular expansion cone.
[0008] According to another aspect of the present invention, a
method of lining a wellbore casing is provided that includes
positioning a tubular liner within the wellbore casing, and
radially expanding one or more discrete portions of the tubular
liner into engagement with the wellbore casing.
[0009] According to another aspect of the present invention, a
system for lining a wellbore casing is provided that includes means
for positioning a tubular liner within the wellbore casing, and
means for radially expanding one or more discrete portions of the
tubular liner into engagement with the wellbore casing. In an
exemplary embodiment, a plurality of discrete portions of the
tubular liner are radially expanded into engagement with the
wellbore casing.
[0010] According to another aspect of the present invention, an
apparatus is provided that includes a subterranean formation
defining a borehole, a casing positioned in and coupled to the
borehole, and a tubular liner positioned in and coupled to the
casing at one or more discrete locations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1a is a cross sectional illustration of the placement
of an illustrative embodiment of a system for lining a wellbore
casing within a borehole having a preexisting wellbore casing.
[0012] FIG. 1b is a cross sectional illustration of the system of
FIG. 1a during the injection of a fluidic material into the tubular
support member.
[0013] FIG. 1c is a cross sectional illustration of the system of
FIG. 1b during the pressurization of the interior portion of the
shoe after sealing off the valveable fluid passage of the shoe.
[0014] FIG. 1d is a cross sectional illustration of the system of
FIG. 1c during the continued injection of the fluidic material into
the tubular support member.
[0015] FIG. 1e is a cross sectional illustration of the system of
FIG. 1d after the completion of the radial expansion and plastic
deformation of the expandable tubular members.
[0016] FIG. 1f is a cross sectional illustration of the system of
FIG. 1e after machining the bottom central portion of the shoe.
[0017] FIG. 2 is a cross sectional illustration of an illustrative
embodiment of the expandable tubular members of the system of FIG.
1a.
[0018] FIG. 3 is a flow chart illustration of an illustrative
embodiment of a method for manufacturing the expandable tubular
member of FIG. 2.
[0019] FIG. 4a is a cross sectional illustration of an illustrative
embodiment of the upsetting of the ends of a tubular member.
[0020] FIG. 4b is a cross sectional illustration of the expandable
tubular member of FIG. 4a after radially expanding and plastically
deforming the ends of the expandable tubular member.
[0021] FIG. 4c is a cross sectional illustration of the expandable
tubular member of FIG. 4b after forming threaded connections on the
ends of the expandable tubular member.
[0022] FIG. 4d is a cross sectional illustration of the expandable
tubular member of FIG. 4c after coupling sealing members to the
exterior surface of the intermediate unexpanded portion of the
expandable tubular member.
[0023] FIG. 5 is a cross-sectional illustration of an exemplary
embodiment of a tubular expansion cone.
[0024] FIG. 6 is a cross-sectional illustration of an exemplary
embodiment of a tubular expansion cone.
DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0025] Referring initially to FIG. 1a, the reference numeral 10
refers, in general, to a system for lining a wellbore casing that
includes a tubular support member 12 that defines a passage 12a. A
tubular expansion cone 14 that defines a passage 14a is coupled to
an end of the tubular support member 12. In an exemplary
embodiment, the tubular expansion cone 14 includes a tapered outer
surface 14b for reasons to be described. A pre-expanded end 16a of
a first expandable tubular member 16 that defines a passage 16b is
adapted to mate with and be supported by the tapered outer surface
14b of the tubular expansion cone 14. The first expandable tubular
member 16 further includes an unexpanded intermediate portion 16c,
another pre-expanded end 16d, and a sealing member 16e coupled to
the exterior surface of the unexpanded intermediate portion. In an
exemplary embodiment, the inside and outside diameters of the
pre-expanded ends, 16a and 16d, of the first expandable tubular
member 16 are greater than the inside and outside diameters of the
unexpanded intermediate portion 16c. An end 18a of a shoe 18 that
defines a passage 18b and a valveable passage 18c is coupled to the
pre-expanded end 16a of the first expandable tubular member 16 by a
conventional threaded connection.
[0026] An end 20a of a tubular member 20 that defines a passage 20b
is coupled to the other pre-expanded end 16d of the first
expandable tubular member 16 by a conventional threaded connection.
Another end 20c of the tubular member 20 is coupled to an end 22a
of a tubular member 22 that defines a passage 22b by a conventional
threaded connection. A pre-expanded end 24a of a second expandable
tubular member 24 that defines a passage 24b is coupled to the
other end 22c of the tubular member 22. The second expandable
tubular member 24 further includes an unexpanded intermediate
portion 24c, another pre-expanded end 24d, and a sealing member 24e
coupled to the exterior surface of the unexpanded intermediate
portion. In an exemplary embodiment, the inside and outside
diameters of the pre-expanded ends, 24a and 24d, of the second
expandable tubular member 24 are greater than the inside and
outside diameters of the unexpanded intermediate portion 24c.
[0027] An end 26a of a tubular member 26 that defines a passage 26b
is coupled to the other pre-expanded end 24d of the second
expandable tubular member 24 by a conventional threaded connection.
Another end 26c of the tubular member 26 is coupled to an end 28a
of a tubular member 28 that defines a passage 28b by a conventional
threaded connection. A pre-expanded end 30a of a third expandable
tubular member 30 that defines a passage 30b is coupled to the
other end 28c of the tubular member 28. The third expandable
tubular member 30 further includes an unexpanded intermediate
portion 30c, another pre-expanded end 30d, and a sealing member 30e
coupled to the exterior surface of the unexpanded intermediate
portion. In an exemplary embodiment, the inside and outside
diameters of the pre-expanded ends, 30a and 30d, of the third
expandable tubular member 30 are greater than the inside and
outside diameters of the unexpanded intermediate portion 30c.
[0028] In an exemplary embodiment, the inside and outside diameters
of the pre-expanded ends, 16a, 16d, 24a, 24d, 30a and 30d, of the
expandable tubular members, 16, 24, and 30, and the tubular members
20, 22, 26, and 28, are substantially equal. In several exemplary
embodiments, the sealing members, 16e, 24e, and 30e, of the
expandable tubular members, 16, 24, and 30, respectively, further
include anchoring elements for engaging the wellbore casing 104. In
several exemplary embodiments, the tubular members, 20, 22, 26, and
28, are conventional tubular members having threaded end
connections suitable for use in an oil or gas well, an underground
pipeline, or as a structural support.
[0029] In an exemplary embodiment, as illustrated in FIG. 1a, the
system 10 is initially positioned in a borehole 100 formed in a
subterranean formation 102 that includes a pre-existing wellbore
casing 104. The borehole 100 may be positioned in any orientation
from vertical to horizontal. Furthermore, the wellbore casing 104
may be, for example, a wellbore casing for an oil or gas well, an
underground pipeline, or a structural support. In an exemplary
embodiment, the upper end of the tubular support member 12 may be
supported in a conventional manner using, for example, a slip
joint, or equivalent device in order to permit upward movement of
the tubular support member and tubular expansion cone 14 relative
to one or more of the expandable tubular members, 16, 24, and 30,
and tubular members, 20, 22, 26, and 28.
[0030] In an exemplary embodiment, as illustrated in FIG. 1b, a
fluidic material 106 is then injected into the system 10, through
the passages, 12a and 14a, of the tubular support member 12 and
tubular expansion cone 14, respectively. The fluidic material 106
then passes into the passages, 18b and 18c, of the shoe 18 into the
borehole 100.
[0031] In an exemplary embodiment, as illustrated in FIG. 1c, a
ball 108, plug or other equivalent device is then introduced into
the injected fluidic material 106. The ball 108 will then pass
through the passages, 12a, 14a, and 18b, of the tubular support
member 12, the tubular expansion cone 14, and the shoe 18,
respectively, and will then be positioned within the valveable
passage 18c of the shoe. In this manner, the valveable passage 18c
of the shoe 18 is closed thereby permitting the passage 18b of the
shoe below the tubular expansion cone 14 to be pressurized by the
continued injection of the fluidic material 106.
[0032] In an exemplary embodiment, as illustrated in FIG. 1d, the
continued injection of the fluidic material 106 through the
passages, 12a and 14a, of the tubular support member 12 and the
tubular expansion cone 14, respectively, pressurizes the passage
18b of the shoe 18 below the tubular expansion cone thereby
radially expanding and plastically deforming the expandable tubular
member 16 off of the tapered external surface 14b of the tubular
expansion cone 14. In particular, the intermediate non pre-expanded
portion 16c of the expandable tubular member 16 is radially
expanded and plastically deformed off of the tapered external
surface 14b of the tubular expansion cone 14. As a result, the
sealing member 16e engages the interior surface of the wellbore
casing 104. Consequently, the radially expanded intermediate
portion 16c of the expandable tubular member 16 is thereby coupled
to the wellbore casing 104. In an exemplary embodiment, the
radially expanded intermediate portion 16c of the expandable
tubular member 16 is also thereby anchored to the wellbore casing
104.
[0033] The continued injection of the fluidic material 106 through
the passages, 12a and 14a, of the tubular support member 12 and the
tubular expansion cone 14, respectively, will then displace the
tubular expansion cone 14 upwardly into engagement with the
pre-expanded end 24a of the second expandable tubular member
24.
[0034] In an exemplary embodiment, as illustrated in FIG. 1e, the
continued injection of the fluidic material 106 through the
passages, 12a and 14a, of the tubular support member 12 and tubular
expansion cone 14, respectively, will then pressurize the passages
18b, 16b, 20b and 22b below the tubular expansion cone thereby
radially expanding and plastically deforming the second expandable
tubular member 24 off of the tapered external surface 14b of the
tubular expansion cone 14. In particular, the intermediate non
pre-expanded portion 24c of the second expandable tubular member 24
is radially expanded and plastically deformed off of the tapered
external surface 14b of the tubular expansion cone 14. As a result,
the sealing member 24e engages the interior surface of the wellbore
casing 104. Consequently, the radially expanded intermediate
portion 24c of the second expandable tubular member 24 is thereby
coupled to the wellbore casing 104. In an exemplary embodiment, the
radially expanded intermediate portion 24c of the second expandable
tubular member 24 is also thereby anchored to the wellbore casing
104.
[0035] The continued injection of the fluidic material 106 through
the passages, 12a and 14a, of the tubular support member 12 and the
tubular expansion cone 14, respectively, will then displace the
tubular expansion cone 14 upwardly into engagement with the
pre-expanded end 30a of the third expandable tubular member 30.
[0036] The continued injection of the fluidic material 106 through
the passages, 12a and 14a, of the tubular support member 12 and
tubular expansion cone 14, respectively, will then pressurize the
passages 18b, 16b, 20b, 22b, 24b, 26b, and 28b below the tubular
expansion cone thereby radially expanding and plastically deforming
the third expandable tubular member 30 off of the tapered external
surface 14b of the tubular expansion cone 14. In particular, the
intermediate non pre-expanded portion 30c of the third expandable
tubular member 30 is radially expanded and plastically deformed off
of the tapered external surface 14b of the tubular expansion cone
14. As a result, the sealing member 30e engages the interior
surface of the wellbore casing 104. Consequently, the radially
expanded intermediate portion 30c of the third expandable tubular
member 30 is thereby coupled to the wellbore casing 104. In an
exemplary embodiment, the radially expanded intermediate portion
30c of the third expandable tubular member 30 is also thereby
anchored to the wellbore casing 104.
[0037] In an exemplary embodiment, during the injection of the
fluidic material 106 through the passages, 12a and 14a, of the
tubular support member 12 and the tubular expansion cone 14,
respectively, the tubular support member 12 and tubular expansion
cone 14 are displaced upwardly relative to the expandable tubular
members, 16, 24, and 30, and the tubular members, 20, 22, 26, and
28, by applying an upward axial force to the upper end of the
tubular support member.
[0038] After completing the radial expansion and plastic
deformation of the third expandable tubular member 30, the tubular
support member 12 and the tubular expansion cone 14 are removed
from the wellbore 100.
[0039] In an exemplary embodiment, as illustrated in FIG. 1f, the
lower central portion of the shoe 18 is then removed using a
conventional milling device.
[0040] Thus, during the operation of the system 10, the
intermediate non pre-expanded portions, 16c, 24c, and 30c, of the
expandable tubular members, 16, 24, and 30, respectively, are
radially expanded and plastically deformed by the pressurization of
the interior passages, 18a, 16b, 20b, 22b, 24b, 26b, 28b, and 30b,
of the shoe 18, the expandable tubular member 16, the tubular
members, 20 and 22, the expandable tubular member 24, the tubular
members, 26 and 28, and the expandable tubular member 30,
respectively, below the tubular expansion cone 14. As a result, the
sealing members, 16e, 24e, and 30e, are displaced in the radial
direction into engagement with the wellbore casing 104 thereby
coupling the shoe 18, the expandable tubular member 16, the tubular
members, 20 and 22, the expandable tubular member 24, the tubular
members, 26 and 28, and the expandable tubular member 30 to the
wellbore casing. Furthermore, as a result, the expandable
connections between the expandable tubular members, 16, 24, and 30,
the shoe 18, and the tubular members, 20, 22, 26, and 28, do not
have to be expandable connections thereby providing significant
cost savings. Furthermore, in the system 10, the tubular members
20, 22, 26, and 28 are interleaved among the expandable tubular
members, 16, 24, and 30. As a result, because only the intermediate
non pre-expanded portions, 16c, 24c, and 30c, of the expandable
tubular members, 16, 24, and 30, respectively, are radially
expanded and plastically deformed, the tubular members, 20, 22, 26,
and 28 can be conventional tubular members thereby significantly
reducing the cost and complexity of the system 10. Moreover,
because only the intermediate non pre-expanded portions, 16c, 24c,
and 30c, of the expandable tubular members, 16, 24, and 30,
respectively, are radially expanded and plastically deformed, the
number and length of the interleaved tubular members, 20, 22, 26,
and 28 can be much greater than the number and length of the
expandable tubular members. In an exemplary embodiment, the total
length of the intermediate non pre-expanded portions, 16c, 24c, and
30c, of the expandable tubular members, 16, 24, and 30, is
approximately 200 feet, and the total length of the tubular
members, 20, 22, 26, and 28, is approximately 3800 feet.
Consequently, in an exemplary embodiment, a liner having a total
length of approximately 4000 feet is coupled to a wellbore casing
by radially expanding and plastically deforming a total length of
only approximately 200 feet.
[0041] Furthermore, the sealing members 16e, 24e, and 30e, of the
expandable tubular members, 16, 24, and 30, respectively, are used
to couple the expandable tubular members and the tubular members,
20, 22, 26, and 28 to the wellbore casing 104, the radial gap
between the tubular members, the expandable tubular members, and
the wellbore casing 104 may be large enough to effectively
eliminate the possibility of damage to the expandable tubular
members and tubular members during the placement of the system 10
within the wellbore casing.
[0042] In an exemplary embodiment, after the sealing member 16e of
the expandable tubular member 16 has been radially expanded into
engagement with the wellbore casing 104, the expandable tubular
members, 24 and 30, are radially expanded and plastically deformed
by injecting the fluidic material 106 and applying an upward axial
force to the tubular support member 12 and tubular expansion cone
14. In this manner, radial expansion and plastic deformation of the
expandable tubular members, 24 and 30, may be enhanced.
[0043] In an exemplary embodiment, after the sealing member 16e of
the expandable tubular member 16 has been radially expanded into
engagement with the wellbore casing 104, the expandable tubular
members, 24 and 30, are radially expanded and plastically deformed
by only applying an upward axial force to the tubular support
member 12 and tubular expansion cone 14. In this manner, radial
expansion and plastic deformation of the expandable tubular
members, 24 and 30, may be provided without the further continued
injection of the fluidic material 106.
[0044] In an exemplary embodiment, the pre-expanded ends, 16a, 16d,
24a, 24d, 30a, and 30d, of the expandable tubular members, 16, 24,
and 30, respectively, and the tubular members, 20, 22, 26, and 28,
have outside diameters and wall thicknesses of 8.375 inches and
0.350 inches, respectively; prior to the radial expansion, the
intermediate non pre-expanded portions, 16c, 24c, and 30c, of the
expandable tubular members, 16, 24, and 30, respectively, have
outside diameters of 7.625 inches; the tubular members, 20, 22, 26,
and 28, have inside diameters of 7.675 inches; after the radial
expansion, the inside diameters of the intermediate portions, 16c,
24c, and 30c, of the expandable tubular members, 16, 24, and 30,
are equal to 7.675 inches; and the wellbore casing 104 has an
inside diameter of 8.755 inches in an exemplary embodiment, the
pre-expanded ends, 16a, 16d, 24a, 24d, 30a, and 30d, of the
expandable tubular members, 16, 24, and 30, respectively, and the
tubular members, 20, 22, 26, and 28, have outside diameters and
wall thicknesses of 4.500 inches and 0.250 inches, respectively;
prior to the radial expansion, the intermediate non pre-expanded
portions, 16c, 24c, and 30c, of the expandable tubular members, 16,
24, and 30, respectively, have outside diameters of 4.000 inches;
the tubular members, 20, 22, 26, and 28, have inside diameters of
4.000 inches; after the radial expansion, the inside diameters of
the intermediate portions, 16c, 24c, and 30c, of the expandable
tubular members, 16, 24, and 30, are equal to 4.000 inches; and the
wellbore casing 104 has an inside diameter of 4.892 inches.
[0045] In an exemplary embodiment, the system 10 is used to form or
repair a wellbore casing, a pipeline, or a structural support.
[0046] Referring now to FIG. 2, an exemplary embodiment of an
expandable tubular member 200 will now be described. The tubular
member 200 defines an interior region 200a and includes a first end
200b including a first threaded connection 200ba, a first tapered
portion 200c, an intermediate portion 200d, a second tapered
portion 200e, and a second end 200f including a second threaded
connection 200fa. The tubular member 200 further preferably
includes an intermediate sealing member 200g that is coupled to the
exterior surface of the intermediate portion 200d.
[0047] In an exemplary embodiment, the tubular member 200 has a
substantially annular cross section. The tubular member 200 may be
fabricated from any number of conventional commercially available
materials such as, for example, Oilfield Country Tubular Goods
(OCTG), 13 chromium steel tubing/casing, or L83, J55, or P110 API
casing.
[0048] In an exemplary embodiment, the interior 200a of the tubular
member 200 has a substantially circular cross section. Furthermore,
in an exemplary embodiment, the interior region 200a of the tubular
member includes a first inside diameter D.sub.1, an intermediate
inside diameter D.sub.INT, and a second inside diameter D.sub.2. In
an exemplary embodiment, the first and second inside diameters,
D.sub.1 and D.sub.2, are substantially equal. In an exemplary
embodiment, the first and second inside diameters, D.sub.1 and
D.sub.2, are greater than the intermediate inside diameter
D.sub.INT.
[0049] The first end 200b of the tubular member 200 is coupled to
the intermediate portion 200d by the first tapered portion 200c,
and the second end 200f of the tubular member is coupled to the
intermediate portion by the second tapered portion 200e. In an
exemplary embodiment, the outside diameters of the first and second
ends, 200b and 200f, of the tubular member 200 is greater than the
outside diameter of the intermediate portion 200d of the tubular
member. The first and second ends, 200b and 200f, of the tubular
member 200 include wall thicknesses, t.sub.1 and t.sub.2,
respectively. In an exemplary embodiment, the outside diameter of
the intermediate portion 200d of the tubular member 200 ranges from
about 75% to 98% of the outside diameters of the first and second
ends, 200a and 200f. The intermediate portion 200d of the tubular
member 200 includes a wall thickness t.sub.INT.
[0050] In an exemplary embodiment, the wall thicknesses t.sub.1 and
t.sub.2 are substantially equal in order to provide substantially
equal burst strength for the first and second ends, 200a and 200f,
of the tubular member 200. In an exemplary embodiment, the wall
thicknesses, t.sub.1 and t.sub.2, are both greater than the wall
thickness t.sub.INT in order to optimally match the burst strength
of the first and second ends, 200a and 200f, of the tubular member
200 with the intermediate portion 200d of the tubular member
200.
[0051] In an exemplary embodiment, the first and second tapered
portions, 200c and 200e, are inclined at an angle, .alpha.,
relative to the longitudinal direction ranging from about 0 to 30
degrees in order to optimally facilitate the radial expansion of
the tubular member 200. In an exemplary embodiment, the first and
second tapered portions, 200c and 200e, provide a smooth transition
between the first and second ends, 200a and 200f, and the
intermediate portion 200d, of the tubular member 200 in order to
minimize stress concentrations.
[0052] The intermediate sealing member 200g is coupled to the outer
surface of the intermediate portion 200d of the tubular member 200.
In an exemplary embodiment, the intermediate sealing member 200g
seals the interface between the intermediate portion 200d of the
tubular member 200 and the interior surface of a wellbore casing
205 after the radial expansion and plastic deformation of the
intermediate portion 200d of the tubular member 200. In an
exemplary embodiment, the intermediate sealing member 200g has a
substantially annular cross section. In an exemplary embodiment,
the outside diameter of the intermediate sealing member 200g is
selected to be less than the outside diameters of the first and
second ends, 200a and 200f, of the tubular member 200 in order to
optimally protect the intermediate sealing member 200g during
placement of the tubular member 200 within the wellbore casings
205. The intermediate sealing member 200g may be fabricated from
any number of conventional commercially available materials such
as, for example, thermoset or thermoplastic polymers. In an
exemplary embodiment, the intermediate sealing member 200g is
fabricated from thermoset polymers in order to optimally seal the
radially expanded intermediate portion 200d of the tubular member
200 with the wellbore casing 205. In several alternative
embodiments, the sealing member 200g includes one or more rigid
anchors for engaging the wellbore casing 205 to thereby anchor the
radially expanded and plastically deformed intermediate portion
200d of the tubular member 200 to the wellbore casing.
[0053] Referring to FIGS. 3, and 4a to 4d, in an exemplary
embodiment, the tubular member 200 is formed by a process 300 that
includes the steps of: (1) upsetting both ends of a tubular member
in step 305; (2) expanding both upset ends of the tubular member in
step 310; (3) stress relieving both expanded upset ends of the
tubular member in step 315; (4) forming threaded connections in
both expanded upset ends of the tubular member in step 320; and (5)
putting a sealing material on the outside diameter of the
non-expanded intermediate portion of the tubular member in step
325.
[0054] As illustrated in FIG. 4a, in step 305, both ends, 400a and
400b, of a tubular member 400 are upset using conventional
upsetting methods. The upset ends, 400a and 400b, of the tubular
member 400 include the wall thicknesses t.sub.1 and t.sub.2. The
intermediate portion 400c of the tubular member 400 includes the
wall thickness t.sub.INT and the interior diameter D.sub.INT. In an
exemplary embodiment, the wall thicknesses t.sub.1 and t.sub.2 are
substantially equal in order to provide burst strength that is
substantially equal along the entire length of the tubular member
400. In an exemplary embodiment, the wall thicknesses t.sub.1 and
t.sub.2 are both greater than the wall thickness t.sub.INT in order
to provide burst strength that is substantially equal along the
entire length of the tubular member 400, and also to optimally
facilitate the formation of threaded connections in the first and
second ends, 400a and 400b.
[0055] As illustrated in FIG. 4b, in steps 310 and 315, both ends,
400a and 400b, of the tubular member 400 are radially expanded
using conventional radial expansion methods, and then both ends,
400a and 400b, of the tubular member are stress relieved. The
radially expanded ends, 400a and 400b, of the tubular member 400
include the interior diameters D.sub.1 and D.sub.2. In an exemplary
embodiment, the interior diameters D.sub.1 and D.sub.2 are
substantially equal in order to provide a burst strength that is
substantially equal. In an exemplary embodiment, the ratio of the
interior diameters D.sub.1 and D.sub.2 to the interior diameter
D.sub.INT ranges from about 100% to 120% in order to faciliate the
subsequent radial expansion of the tubular member 400.
[0056] In a preferred embodiment, the relationship between the wall
thicknesses t.sub.1, t.sub.2, and t.sub.INT of the tubular member
400; the inside diameters D.sub.1, D.sub.2 and D.sub.INT of the
tubular member 400; the inside diameter D.sub.wellbore of the
wellbore casing that the tubular member 400 will be inserted into;
and the outside diameter D.sub.cone of the expansion cone that will
be used to radially expand the tubular member 400 within the
wellbore casing is given by the following expression: Dwellbore - 2
* t 1 .gtoreq. D 1 .gtoreq. 1 t 1 .function. [ ( t 1 - t INT ) * D
cone + t INT * D INT ] ( 1 ) ##EQU1## where t.sub.1=t.sub.2; and
D.sub.1=D.sub.2.
[0057] By satisfying the relationship given in equation (1), the
expansion forces placed upon the tubular member 400 during the
subsequent radial expansion process are substantially equalized.
More generally, the relationship given in equation (1) may be used
to calculate the optimal geometry for the tubular member 400 for
subsequent radial expansion and plastic deformation of the tubular
member 400 for fabricating and/or repairing a wellbore casing, a
pipeline, or a structural support.
[0058] As illustrated in FIG. 4c, in step 320, conventional
threaded connections, 400d and 400e, are formed in both expanded
ends, 400a and 400b, of the tubular member 400. In an exemplary
embodiment, the threaded connections, 400d and 400e, are provided
using conventional processes for forming pin and box type threaded
connections available from Atlas-Bradford.
[0059] As illustrated in FIG. 4d, in step 325, a sealing member
400f is then applied onto the outside diameter of the non-expanded
intermediate portion 400c of the tubular member 400. The sealing
member 400f may be applied to the outside diameter of the
non-expanded intermediate portion 400c of the tubular member 400
using any number of conventional commercially available methods. In
a preferred embodiment, the sealing member 400f is applied to the
outside diameter of the intermediate portion 400c of the tubular
member 400 using commercially available chemical and temperature
resistant adhesive bonding.
[0060] In an exemplary embodiment, the expandable tubular members,
16, 24, and 30, of the system 10 are substantially identical to,
and/or incorporate one or more of the teachings of, the tubular
members 200 and 400.
[0061] Referring to FIG. 5, an exemplary embodiment of tubular
expansion cone 500 for radially expanding the tubular members 16,
24, 30, 200 and 400 will now be described. The expansion cone 500
defines a passage 500a and includes a front end 505, a rear end
510, and a radial expansion section 515.
[0062] In an exemplary embodiment, the radial expansion section 515
includes a first conical outer surface 520 and a second conical
outer surface 525. The first conical outer surface 520 includes an
angle of attack .alpha..sub.1 and the second conical outer surface
525 includes an angle of attack .alpha..sub.2. In an exemplary
embodiment, the angle of attack .alpha..sub.1 is greater than the
angle of attack .alpha..sub.2. In this manner, the first conical
outer surface 520 radially overexpands the intermediate portions,
16c, 24c, 30c, 200d, and 400c, of the tubular members, 16, 24, 30,
200, and 400, and the second conical outer surface 525 radially
overexpands the pre-expanded first and second ends, 16a and 16d,
24a and 24d, 30a and 30d, 200b and 200f, and 400a and 400b, of the
tubular members, 16, 24, 30, 200 and 400. In an exemplary
embodiment, the first conical outer surface 520 includes an angle
of attack .alpha..sub.1 ranging from about 8 to 20 degrees, and the
second conical outer surface 525 includes an angle of attack
.alpha..sub.2 ranging from about 4 to 15 degrees in order to
optimally radially expand and plastically deform the tubular
members, 16, 24, 30, 200 and 400. More generally, the expansion
cone 500 may include 3 or more adjacent conical outer surfaces
having angles of attack that decrease from the front end 505 of the
expansion cone 500 to the rear end 510 of the expansion cone
500.
[0063] Referring to FIG. 6, another exemplary embodiment of a
tubular expansion cone 600 defines a passage 600a and includes a
front end 605, a rear end 610, and a radial expansion section 615.
In an exemplary embodiment, the radial expansion section 615
includes an outer surface having a substantially parabolic outer
profile thereby providing a paraboloid shape. In this manner, the
outer surface of the radial expansion section 615 provides an angle
of attack that constantly decreases from a maximum at the front end
605 of the expansion cone 600 to a minimum at the rear end 610 of
the expansion cone. The parabolic outer profile of the outer
surface of the radial expansion section 615 may be formed using a
plurality of adjacent discrete conical sections and/or using a
continuous curved surface. In this manner, the region of the outer
surface of the radial expansion section 615 adjacent to the front
end 605 of the expansion cone 600 may optimally radially overexpand
the intermediate portions, 16c, 24c, 30c, 200d, and 400c, of the
tubular members, 16, 24, 30, 200, and 400, while the region of the
outer surface of the radial expansion section 615 adjacent to the
rear end 610 of the expansion cone 600 may optimally radially
overexpand the pre-expanded first and second ends, 16a and 16d, 24a
and 24d, 30a and 30d, 200b and 200f, and 400a and 400b, of the
tubular members, 16, 24, 30, 200 and 400. In an exemplary
embodiment, the parabolic profile of the outer surface of the
radial expansion section 615 is selected to provide an angle of
attack that ranges from about 8 to 20 degrees in the vicinity of
the front end 605 of the expansion cone 6800 and an angle of attack
in the vicinity of the rear end 610 of the expansion cone 600 from
about 4 to 15 degrees.
[0064] In an exemplary embodiment, the tubular expansion cone 14 of
the system 10 is substantially identical to the expansion cones 500
or 600, and/or incorporates one or more of the teachings of the
expansion cones 500 and/or 600.
[0065] In several alternative embodiments, a conventional rotary
expansion system such as, for example, those commercially available
from Weatherford International may be substituted for, or used in
combination with the expansion cones 14, 500, and/or 600 above.
[0066] In several alternative embodiments, conventional expansion
systems may be substituted for, or used in combination with the
expansion cones 14, 500, and/or 600 above.
[0067] A system for lining a wellbore casing has been described
that includes a tubular support member defining a first passage, a
tubular expansion cone defining a second passage fluidicly coupled
to the first passage coupled to an end of the tubular support
member and comprising a tapered end, a tubular liner coupled to and
supported by the tapered end of the tubular expansion cone, and a
shoe defining a valveable passage coupled to an end of the tubular
liner, wherein the tubular liner includes one or more expandable
tubular members that each include a tubular body comprising an
intermediate portion and first and second expanded end portions
coupled to opposing ends of the intermediate portion, and a sealing
member coupled to the exterior surface of the intermediate portion,
and one or more other tubular members coupled to the expandable
tubular members, wherein the inside diameters of the other tubular
members are greater than or equal to the outside diameter of the
tubular expansion cone. In an exemplary embodiment, the wall
thicknesses of the first and second expanded end portions are
greater than the wall thickness of the intermediate portion. In an
exemplary embodiment, each expandable tubular member further
includes a first tubular transitionary member coupled between the
first expanded end portion and the intermediate portion, and a
second tubular transitionary member coupled between the second
expanded end portion and the intermediate portion, wherein the
angles of inclination of the first and second tubular transitionary
members relative to the intermediate portion ranges from about 0 to
30 degrees. In an exemplary embodiment, the outside diameter of the
intermediate portion ranges from about 75 percent to about 98
percent of the outside diameters of the first and second expanded
end portions. In an exemplary embodiment, the burst strength of the
first and second expanded end portions is substantially equal to
the burst strength of the intermediate tubular section. In an
exemplary embodiment, the ratio of the inside diameters of the
first and second expanded end portions to the interior diameter of
the intermediate portion ranges from about 100 to 120 percent. In
an exemplary embodiment, the relationship between the wall
thicknesses t.sub.1, t.sub.2, and t.sub.INT of the first expanded
end portion, the second expanded end portion, and the intermediate
portion, respectively, of the expandable tubular members, the
inside diameters D.sub.1, D.sub.2 and D.sub.INT of the first
expanded end portion, the second expanded end portion, and the
intermediate portion, respectively, of the expandable tubular
members, and the inside diameter D.sub.wellbore of the wellbore
casing that the expandable tubular member will be inserted into,
and the outside diameter D.sub.cone of the expansion cone that will
be used to radially expand the expandable tubular member within the
wellbore casing is given by the following expression: Dwellbore - 2
* t 1 .gtoreq. D 1 .gtoreq. 1 t 1 .function. [ ( t 1 - t INT ) * D
cone + t INT * D INT ] ; ##EQU2## wherein t.sub.1=t.sub.2; and
wherein D.sub.1=D.sub.2. In an exemplary embodiment, the tapered
end of the tubular expansion cone includes a plurality of adjacent
discrete tapered sections. In an exemplary embodiment, the angle of
attack of the adjacent discrete tapered sections increases in a
continuous manner from one end of the tubular expansion cone to the
opposite end of the tubular expansion cone. In an exemplary
embodiment, the tapered end of the tubular expansion cone includes
an paraboloid body. In an exemplary embodiment, the angle of attack
of the outer surface of the paraboloid body increases in a
continuous manner from one end of the paraboloid body to the
opposite end of the paraboloid body. In an exemplary embodiment,
the tubular liner includes a plurality of expandable tubular
members, and the other tubular members are interleaved among the
expandable tubular members.
[0068] A method of lining a wellbore casing has also been described
that includes positioning a tubular liner within the wellbore
casing, and radially expanding one or more discrete portions of the
tubular liner into engagement with the wellbore casing. In an
exemplary embodiment, a plurality of discrete portions of the
tubular liner are radially expanded into engagement with the
wellbore casing. In an exemplary embodiment, the remaining portions
of the tubular liner are not radially expanded. In an exemplary
embodiment, the discrete portions of the tubular liner are radially
expanded by injecting a fluidic material into the tubular liner. In
an exemplary embodiment, the tubular liner includes a plurality of
tubular members; and wherein one or more of the tubular members are
radially expanded into engagement with the wellbore casing and one
or more of the tubular members are not radially expanded into
engagement with the wellbore casing. In an exemplary embodiment,
the tubular members that are radially expanded into engagement with
the wellbore casing include a portion that is radially expanded
into engagement with the wellbore casing and a portion that is not
radially expanded into engagement with the wellbore casing. In an
exemplary embodiment, the tubular liner includes one or more
expandable tubular members that each include a tubular body
comprising an intermediate portion and first and second expanded
end portions coupled to opposing ends of the intermediate portion,
and a sealing member coupled to the exterior surface of the
intermediate portion, and one or more other tubular members coupled
to the expandable tubular members, wherein the inside diameters of
the other tubular members are greater than or equal to the maximum
inside diameters of the expandable tubular members. In an exemplary
embodiment, the tubular liner includes a plurality of expandable
tubular members, and the other tubular members are interleaved
among the expandable tubular members.
[0069] A system for lining a wellbore casing has also been
described that includes means for positioning a tubular liner
within the wellbore casing, and means for radially expanding one or
more discrete portions of the tubular liner into engagement with
the wellbore casing. In an exemplary embodiment, a plurality of
discrete portions of the tubular liner are radially expanded into
engagement with the wellbore casing. In an exemplary embodiment,
the remaining portions of the tubular liner are not radially
expanded. In an exemplary embodiment, the discrete portions of the
tubular liner are radially expanded by injecting a fluidic material
into the tubular liner. In an exemplary embodiment, the tubular
liner includes a plurality of tubular members; and wherein one or
more of the tubular members are radially expanded into engagement
with the wellbore casing and one or more of the tubular members are
not radially expanded into engagement with the wellbore casing. In
an exemplary embodiment, the tubular members that are radially
expanded into engagement with the wellbore casing comprise a
portion that is radially expanded into engagement with the wellbore
casing and a portion that is not radially expanded into engagement
with the wellbore casing.
[0070] An apparatus has also been described that includes a
subterranean formation defining a borehole, a casing positioned in
and coupled to the borehole, and a tubular liner positioned in and
coupled to the casing at one or more discrete locations. In an
exemplary embodiment, the tubular liner is coupled to the casing at
a plurality of discrete locations. In an exemplary embodiment, the
tubular liner is coupled to the casing by a process that includes
positioning the tubular liner within the casing, and radially
expanding one or more discrete portions of the tubular liner into
engagement with the casing. In an exemplary embodiment, a plurality
of discrete portions of the tubular liner are radially expanded
into engagement with the casing. In an exemplary embodiment, the
remaining portions of the tubular liner are not radially expanded.
In an exemplary embodiment, the discrete portions of the tubular
liner are radially expanded by injecting a fluidic material into
the tubular liner. In an exemplary embodiment, the tubular liner
includes a plurality of tubular members; and wherein one or more of
the tubular members are radially expanded into engagement with the
casing and one or more of the tubular members are not radially
expanded into engagement with the casing. In an exemplary
embodiment, the tubular members that are radially expanded into
engagement with the casing comprise a portion that is radially
expanded into engagement with the casing and a portion that is not
radially expanded into engagement with the casing. In an exemplary
embodiment, the tubular liner includes one or more expandable
tubular members that each include a tubular body comprising an
intermediate portion and first and second expanded end portions
coupled to opposing ends of the intermediate portion, and a sealing
member coupled to the exterior surface of the intermediate portion,
and one or more other tubular members coupled to the expandable
tubular members, wherein the inside diameters of the other tubular
members are greater than or equal to the maximum inside diameters
of the expandable tubular members. In an exemplary embodiment, the
tubular liner includes a plurality of expandable tubular members,
and the other tubular members are interleaved among the expandable
tubular members.
[0071] It is understood that variations may be made in the
foregoing without departing from the scope of the invention. For
example, the system 10 may be used to form or repair a wellbore
casing, an underground pipeline, a structural support, or a tubing.
Furthermore, the system 10 may include one or more expandable
tubular members and one or more other tubular members. In addition,
the system 10 may include a plurality of expandable tubular
members, and the other tubular members may be interleaved among the
expandable tubular members.
[0072] 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.
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