U.S. patent application number 12/598826 was filed with the patent office on 2010-04-15 for apparatus and methods for expanding tubular elements.
This patent application is currently assigned to Dynamic Dinosaurs B.V.. Invention is credited to Wilhelmus Christianus Maria Lohbeck.
Application Number | 20100088879 12/598826 |
Document ID | / |
Family ID | 38198721 |
Filed Date | 2010-04-15 |
United States Patent
Application |
20100088879 |
Kind Code |
A1 |
Lohbeck; Wilhelmus Christianus
Maria |
April 15, 2010 |
APPARATUS AND METHODS FOR EXPANDING TUBULAR ELEMENTS
Abstract
A method for expanding a tubular in a wellbore uses an expansion
apparatus that includes an expansion body disposed on a tool body.
The expansion apparatus is positioned in the tubular. The method
further includes compressing the expansion body such that an outer
surface radially expands the tubular permanently and axially
translating the compressed body within the tubular.
Inventors: |
Lohbeck; Wilhelmus Christianus
Maria; (Rijswijk, NL) |
Correspondence
Address: |
Conley Rose, P.C
P.O. Box 3267
Houston
TX
77253-3267
US
|
Assignee: |
Dynamic Dinosaurs B.V.
Rijswijk
NL
|
Family ID: |
38198721 |
Appl. No.: |
12/598826 |
Filed: |
May 2, 2008 |
PCT Filed: |
May 2, 2008 |
PCT NO: |
PCT/EP08/55443 |
371 Date: |
December 29, 2009 |
Current U.S.
Class: |
29/523 |
Current CPC
Class: |
E21B 43/105 20130101;
Y10T 29/4994 20150115 |
Class at
Publication: |
29/523 |
International
Class: |
B21D 39/08 20060101
B21D039/08 |
Foreign Application Data
Date |
Code |
Application Number |
May 4, 2007 |
GB |
0708624.2 |
Claims
1. (canceled)
2. The method as claimed in claim 18, wherein the expansion body
comprises one or more rings.
3. The method as claimed in claim 18, wherein the expansion body
comprises a cylinder.
4. The method as claimed in claim 18, wherein the expansion body is
mounted coaxially on a longitudinal axis of the tool body.
5. (canceled)
6. The method as claimed in claim 18, wherein the expansion body
comprises polyurethane.
7. The method as claimed in claim 18, wherein the expansion body is
comprised of more than one section.
8. (canceled)
9. (canceled)
10. The method as claimed in claim 60, wherein the upper shoulder
and the lower shoulder are substantially perpendicular to a
longitudinal axis of the tool body.
11. The method as claimed in claim 60, wherein the upper shoulder
and the lower shoulder are at different angles to a longitudinal
axis of the tool body.
12. The method as claimed in claim 18, wherein the tool body
comprises a cylinder in which a piston is slidably located, and
wherein one of the upper shoulder and the lower shoulder is
moveable with the piston.
13. The method as claimed in claim 12, wherein the cylinder is
provided with a supply of pressurised fluid for causing movement of
the piston.
14. The method as claimed in claim 12, wherein the cylinder has a
mechanical arrangement for causing movement of the piston.
15. The method as claimed in claim 12, wherein the upper shoulder
is fixed to the tool body by means of an axial shaft around which
the expansion body and piston are mounted.
16. (canceled)
17. (canceled)
18. A method for expanding a tubular in a wellbore, comprising:
positioning an expansion apparatus in the tubular, wherein the
expansion apparatus comprises an expansion body disposed on a tool
body; compressing the expansion body such that an outer surface
radially expands the tubular permanently; and axially translating
the compressed expansion body within the tubular.
19. (canceled)
20. The method as claimed in claim 18, further comprising releasing
the expansion body from compression such that it returns to its
uncompressed shape and moving the expansion apparatus to another
location in the wellbore.
21. The method as claimed in claim 20, further comprising repeating
expansion of the tubular element at the other location.
22-59. (canceled)
60. The method of claim 18, wherein the compressing of the
expansion body comprises axially moving at least one of an upper
shoulder and a lower shoulder towards the other.
61. A method for expanding a tubular in a wellbore, comprising:
positioning an expansion apparatus the tubular, wherein the
expansion apparatus comprises a polyurethane expansion section
disposed on a tool body; axially compressing the polyurethane
expansion section to radially expand the tubular into permanent
contact with the wellbore; and axially translating the expansion
apparatus within the tubular while the polyurethane expansion
section is axially compressed.
62. A method for expanding a tubular in a wellbore, comprising:
positioning an expansion apparatus the tubular, wherein the
expansion apparatus comprises a polyurethane expansion section
disposed on a tool body between an upper shoulder and a lower
shoulder; axially translating at least one of the upper shoulder
and the lower shoulder towards the other shoulder to axially
compress the polyurethane expansion section, wherein the axial
compression of the polyurethane expansion section radially expands
the tubular; and axially translating the expansion apparatus within
the tubular while the polyurethane expansion section is axially
compressed.
Description
TECHNICAL FIELD
[0001] This invention relates to apparatus and methods for
expanding tubular elements that are suitable for installation in a
well such as an oil or gas well, or tubulars of surface, subsea or
subsurface pipelines. Even further the invention relates to systems
which employ such and apparatus and methods for expanding tubular
elements.
BACKGROUND ART
[0002] Tubular elements such as casing and completion tubing,
screens and other such devices are well known in the field of oil
and gas wells. In order for them to be installed in the well, it is
necessary that they have an outer diameter that is less than the
inner diameter of the borehole in which they are to be installed.
In fact, since the inner diameter of the borehole can vary and the
trajectory of the borehole is often not straight, the maximum
possible diameter can be significantly less than that of the
borehole at any point.
[0003] When a borehole is being drilled, it is usually necessary to
stop drilling after a certain depth and stabilise the borehole by
placing a steel tubular casing in the well and filling the annulus
between the outside of the casing and the borehole wall with
cement. This operation may need to be repeated several times during
the drilling of the well, each successive casing being necessarily
smaller than the inside diameter of the preceding casing. This in
turn leads to progressive reduction of the inner open diameter of
the well which in turn places limitations on the maximum depth of
the well and on the quantities of fluids that can flow along the
well.
[0004] To overcome this problem, it has been previously proposed to
expand the casing in the well to reduce the annular space. Also,
expansion of subsequent casings to match the diameter of the
previous casing has also been proposed to avoid the progressive
diameter reduction found with conventional casing techniques.
[0005] Expansion is typically achieved using a cone shaped
expanding tool which has a maximum diameter that is greater than
the inside diameter of the casing to be expanded. Forcing the
expanding tool through the casing (for example by mechanically
pushing or pulling or by pumping a fluid) causes it to expand. One
difficulty in this operation is that because the outer diameter of
the expansion tool is greater than the inner diameter of the
casing, it is not possible to position the expanding tool in the
casing; it must either start at the top or bottom and be moved
either to the other end or back to its starting place to be removed
from the casing (or left in the well). To address this, expanding
tools/cones have been proposed that are initially positioned in a
contracted state and then are reconfigured into their (larger)
operational configuration before being moved through the casing.
However, since the outer diameter is still greater than the inner
diameter of the casing, this must be done in an open section of the
well or in a section of wider diameter. A recent alternative
proposal is for the tool to apply enough force during deployment to
expand the casing.
[0006] It is an object of this invention to provide a method by
which expansion can be initiated in a section of the casing or
other tubular in its unexpanded state and so can create either a
compete expansion, or a chamber/expanded section in which a
conventional expanding tool can be deployed. This invention
achieves this object by the use of a flexible sleeve and an
expanding tool that can fit in the unexpanded tubular element.
[0007] It is further an object of this invention to provide various
applications of the expansion apparatus, some of which reduce the
need for the use of cementing in wells.
DISCLOSURE OF THE INVENTION
[0008] One aspect of this invention provides a method of expanding
a tubular element suitable for installation in a well, comprising:
[0009] installing an expander tool in the tubular element, the
expander tool comprising: [0010] a flexible sleeve having an outer
diameter less than or equal to the inner diameter of the tubular
element, and being made from a flexible material of predetermined
thickness; [0011] a cone expander section on which the sleeve is
mounted, a first cone having a first narrow end that fits inside
the sleeve and which increases from the first narrow end to a
maximum at a base that is greater than the inner diameter of the
sleeve but less than the inner diameter of the tubular element; and
[0012] a first elongate mandrel extending from the end of the cone
expander section on the opposite side to the first narrow end;
[0013] positioning the expander tool including the sleeve at a
predetermined location in the tubular element to be expanded;
[0014] fixing the position of the sleeve at the predetermined
location; [0015] urging the expander section through the sleeve
from one end to the other so as to expand the sleeve against the
inside of the tubular member and cause it in turn to expand, the
expander being urged through the (preferably lubricated) sleeve
until it exits the other end of the sleeve; [0016] allowing the
sleeve to contract around the first mandrel such that the outer
diameter of the sleeve is less than the unexpanded inner diameter
of the tubular element; and [0017] moving the expander tool with
the sleeve located around the first mandrel away from the expanded
location.
[0018] Another aspect of the invention provides apparatus for
expanding a tubular element in a well, comprising: [0019] a
flexible sleeve having an outer diameter less than or equal to the
inner diameter of the tubular element, and being made from a
flexible material of predetermined thickness; [0020] a cone
expander section on which the sleeve is mounted, a first cone
having a first narrow end that fits inside the sleeve and which
increases from the first narrow end to a maximum at a base that is
greater than the inner diameter of the sleeve but less than the
inner diameter of the tubular element; and [0021] a first elongate
mandrel extending from the end of the cone expander section on the
opposite side to the first narrow end.
[0022] This invention allows expansion of the tubular element
starting from its normal diameter without the need to provide a
local expansion or oversized portion to allow deployment of an
expansion tool.
[0023] In one embodiment, the step of fixing the position of the
sleeve at the predetermined location in the tubular element
comprises activating an anchoring mechanism on the expander tool.
In another, it comprises a compressible ring, such as a ring made
from polyurethane, mounted on the expander tool (for example, at
its nose-end), activation of the anchoring mechanism comprising
compressing the ring axially so as to cause its outer diameter to
increase and locally expand the sleeve against the tubular member
to anchor it. It is also possible that expansion of the ring also
causes local expansion of the tubular element, in which case a
shifting element may be required to allow the cone to move while
the sleeve remains stationary.
[0024] In an alternative embodiment, the step of fixing the
position of the sleeve at the predetermined location in the tubular
element comprises forcing the sleeve against a locating formation
on the inside of the tubular member.
[0025] In a further embodiment of the invention, the expander tool
comprises a second cone at the other end of the expander section,
the middle of the expander section defining the base of the first
and second cones, the first mandrel extending from the narrow end
of the second cone and the second elongate mandrel extending from
the narrow end of the first cone; the method comprising: [0026]
positioning the expander tool at a first predetermined location in
the tubular element to be expanded; [0027] fixing the position of
the sleeve at the first predetermined location; [0028] urging the
expander section through the sleeve from one end to the other so as
to expand the sleeve against the inside of the tubular member and
cause it in turn to expand, the expander being urged through the
sleeve until it exits the other end of the sleeve; [0029] allowing
the sleeve to contract around the first mandrel such that the outer
diameter of the sleeve is less than the unexpanded inner diameter
of the tubular element; and [0030] moving the expander tool with
the sleeve located around the first mandrel away from the expanded
location to a second predetermined location; [0031] fixing the
position of the sleeve at the second predetermined location; [0032]
urging the expander section back through the sleeve from one end to
the other so as to expand the sleeve against the inside of the
tubular member and cause it in turn to expand, the expander being
urged through the sleeve until it exits the other end of the
sleeve; [0033] allowing the sleeve to contract around the second
mandrel such that the outer diameter of the sleeve is less than the
unexpanded inner diameter of the tubular element; and [0034] moving
the expander tool with the sleeve located around the first mandrel
away from the expanded location.
[0035] This allows multiple expansion operations to be performed at
different locations throughout the well.
[0036] Preferably, the sleeve is made from a flexible/elastic
material of predetermined thickness which includes elongate
reinforcing members running axially though the sleeve. This resists
the tendency of the sleeve to lengthen as it is compressed rather
than expand outwardly.
[0037] Another aspect of the invention comprises a method of
expanding a tubular element suitable for installation in a well,
comprising: [0038] installing a flexible sleeve at a predetermined
location in the tubular element to be expanded, the sleeve having
an outer diameter less than or equal to the inner diameter of the
tubular element, and being made from a flexible material of
predetermined thickness which includes elongate reinforcing members
running axially though the sleeve; [0039] installing an expander in
the tubular element adjacent to the sleeve, the expander having one
end closest to the sleeve that is smaller than the inner diameter
of the sleeve, the outer diameter of the expander increasing from
the one end to a maximum that is greater than the inner diameter of
the sleeve but less than the inner diameter of the tubular element;
[0040] urging the expander through the sleeve so as to expand the
sleeve against the inside of the tubular member and cause it in
turn to expand.
[0041] The reinforcing members preferably comprise steel rods or
aramide fibres twalon/keflar which run for substantially the whole
length of the sleeve or are formed in loops.
[0042] The sleeve is typically made from polyurethane.
[0043] An application of the apparatus of the invention may be for
a device to produce one or more areas of isolation. The areas may
be in the annulus of a well or the areas may be selected areas in a
tubular of a well. The method of producing these areas of isolation
is attained by the expansion of tubular elements in the areas of
interest.
[0044] Another aspect of the invention provides for a liner hanger
including an apparatus for expanding tubular elements as described
above.
[0045] Another aspect of the invention provides for a fishing tool
including an apparatus for expanding tubular elements as described
above. The fishing tool may further include a conduit. This conduit
may allow for circulation through the fishing tool. The conduit may
further allow for circulation through the article to be fished.
[0046] Another aspect of the invention provides for a wellhead
including an apparatus for expanding tubular elements as described
above. The apparatus may be used to expand more than one concentric
tubular element.
[0047] Another aspect of the invention provides for an abandonment
plug including an apparatus for expanding tubular elements as
described above. The apparatus may be used to expand a tubular
element in a well to be abandoned. This tubular element may be an
additional tubular element inside the casing or liner. The
expansion body may be left in an expanded state in the expanded
tubular element to form the abandonment plug. The additional
tubular element may be expanded so as to close the micro-annulus
around the casing or liner.
[0048] Another aspect of the invention provides for an expandable
sand screen including an apparatus for expanding tubular elements
as described above.
[0049] Another aspect of the invention provides for a well pressure
tester including an apparatus for expanding tubular elements as
described above. The apparatus for expanding tubular elements in
the well pressure tester preferably uses expansion of a
compressible expansion body substantially to form a seal against
the tubular element.
[0050] Another aspect of the invention provides for a pile expander
including an apparatus for expanding tubular elements as described
above.
[0051] Another aspect of the invention provides for a bridge plug
including an apparatus for expanding tubular elements as described
above. The bridge plug may be permanent or it may be retrievable.
This tubular element to be expanded may be an additional tubular
element inside the casing or liner. The apparatus for expanding
tubular elements in the well pressure tester preferably uses
expansion of a compressible expansion body substantially to form a
seal against the tubular element.
[0052] Another aspect of the invention provides for a packer
including an apparatus for expanding tubular elements as described
above. This tubular element to be expanded may be an additional
tubular element inside the casing or liner. The apparatus for
expanding tubular elements in the well pressure tester preferably
uses expansion of a compressible expansion body substantially to
form a seal against the tubular element.
[0053] Another aspect of the invention provides for a pipe
connector including an apparatus for expanding tubular elements as
described above. Preferably the pipe connector is a swage type pipe
connector.
[0054] Another aspect of the invention provides for a selective
chemical placement tool including an apparatus for expanding
tubular elements as described above. The selective chemical
placement tool may be slidably displaceable.
[0055] Another aspect of the invention provides for an anchor
device including an apparatus for expanding tubular elements as
described above. The anchor device may be used to anchor a tubular
element or other equipment against the formation or another tubular
element.
[0056] Another aspect of the invention provides for a bellow
expander including an apparatus for expanding tubular elements as
described above. The bellow expander may be used to relieve
buckling or axial stresses in the tubular element.
[0057] Another aspect of the invention provides for a downhole
patching system including an apparatus for expanding tubular
elements as described above. The downhole patching system may be
used to repair casing or liner damage, or leaking connectors. It
may further include a sealing element.
[0058] Another aspect of the invention provides for a perforation
shut off patch system including an apparatus for expanding tubular
elements as described above. The perforation shut off patch may
further include a sealing element.
[0059] Another aspect of the invention provides for a telescopic
liner expansion system including an apparatus for expanding tubular
elements as described above.
[0060] Other uses will be apparent from the description below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] FIG. 1 shows a schematic side view of apparatus for
expanding tubular elements according to a first embodiment of the
invention;
[0062] FIG. 2 shows a schematic side view of apparatus for
expanding tubular elements of the embodiment of FIG. 1 in situ in a
well casing;
[0063] FIG. 3 shows a schematic side view of apparatus for
expanding tubular elements the embodiment of FIG. 2 after partial
expansion;
[0064] FIG. 4 shows a schematic side view of apparatus for
expanding tubular elements of the embodiment of FIG. 1 after
expansion has been completed;
[0065] FIG. 5 shows detail of an anchor mechanism for use in the
present invention;
[0066] FIG. 6 shows a schematic side view of the anchor mechanism
of FIG. 5 deployed in a casing;
[0067] FIG. 7 shows a schematic side view of apparatus for
expanding tubular elements according to a further embodiment of the
invention;
[0068] FIG. 8 shows a schematic side view of a liner lap expansion
application of the apparatus of the invention in situ in a
wellbore;
[0069] FIG. 9 shows a schematic side view of an application of the
apparatus of the invention used to pressure test a liner lap and
then used to pressure test the liner in situ in a wellbore;
[0070] FIG. 10 shows a schematic side view of a pressure tester
application of the apparatus of the invention in situ in a
wellbore; and
[0071] FIG. 11 shows schematic side view of a liner bottom
expansion application of the apparatus of the invention in situ in
a wellbore.
MODE(S) FOR CARRYING OUT THE INVENTION
[0072] FIG. 1 shows a schematic diagram of a tool according to a
first embodiment of the invention, comprising a cone expander
section 10 having a cone 12 which expands from a narrow end to a
base in the middle of the section 10. An elongate mandrel 14
extends from the base part of the section 10 on the opposite side
to the cone 12 and optionally has a retainer 16 located at its
other end.
[0073] A flexible sleeve 18 is seated on the cone 12, the sleeve 18
having internally flared end portions 20, the flares having a
complementary angle to the cone 12 (both typically about 7 degr).
The sleeve is formed from a flexible material, polyurethane being
particularly preferred. Elongate steel reinforcing wires 21 run
through the interior of the material making up the sleeve 18. The
outer diameter of the sleeve 18 is substantially the same as that
of the base of the cone in the expander section. The inner diameter
of the sleeve 18 is less than this such that the cone section 10 is
not free to move through the sleeve 18.
[0074] A further elongate mandrel 22 extends from the narrow end of
the cone 12 through the middle of the sleeve 18 and has a further
retainer 24 at its free end. In the configuration shown in FIG. 1,
the sleeve is held on the cone 12 which projects into the flared
end 20 of the sleeve 18, the retainer 24 preventing accidental
disengagement. In this configuration, the tool can be moved through
a casing 26 in a well such as an oil or gas well. The outer
diameter of the cone section 10 and sleeve 18 being marginally
smaller than the inner diameter of the casing 26 (see FIG. 2).
[0075] In use, the tool described above is lowered to a position of
interest (FIG. 2). The sleeve 18 is then anchored in the casing 26
(as is described below) to prevent further downward movement.
[0076] Once the tool/sleeve is anchored in position, the cone 12 is
forced into the end of the sleeve 18 which is forced to expand
until the base can fit inside the sleeve 18. Expansion of the
sleeve 18 radially outwardly in turn causes the casing 26 to expand
in a corresponding manner and deform permanently 28 (FIG. 3). The
reinforcing wires 21 act to restrict lengthening of the sleeve by
longitudinal extrusion rather than expanding radially.
[0077] The cone 12 is forced down the sleeve 18 until it exits the
far end, at which point the sleeve is allowed to relax back to its
original dimensions around the mandrel 14, its outer diameter
returning to its approximate original value (see FIG. 4). The tool
can then be withdrawn from the well with the sleeve 18 on the
mandrel 14 leaving only the expanded portion of the casing 28 ready
for use.
[0078] The tool/cone expander can be pushed/pulled down through the
sleeve by any suitable means. For example, it can be pumped down
using pressurised fluid and an appropriate arrangement of seals
above the sleeve 18. Alternatively, a mechanical drive can be
connected to the top of the tool, extending either from the surface
or from an anchored point in the casing above. The tool is
typically connected to the surface via a cable and/or tubing to
provide power and data communication for control, and supply any
working fluids that may be needed.
[0079] It will be understood that tubular element to be expanded
may be any one of a number of tubular elements used in oil or gas
wells such as, for example, a casing, a liner, a pipeline, or the
like. The tubular element to be expanded may also be one of a
number of types of tubulars used in surface, subsea or subsurface
pipelines. It will also be understood that the tubular element may
be of a solid, slotted or perforated type.
[0080] The anchoring mechanism can comprise extendible anchors
(slips, dogs, etc.). These can be incorporated into the retainer 24
or provided separately. The anchoring mechanism is operated to act
on the sleeve when the tool is in position and lock it to the
casing. Thus the tool can be positioned at any point in the casing.
Another form of anchor comprises an expanding ring as is shown in
FIGS. 5 and 6. In this embodiment, the mandrel 22 is provided with
power and control electronics, a pump and hydraulic fluid supply
(or a connection to a corresponding supply at the surface) and
sensors (not shown). An operational head section 30 is provided at
the lower end of the mandrel 22. The head section 30 which
comprises a main head part 32 which is connected to the mandrel 22
and defines a cylinder 34 open at its lower end. An axial shaft 36
extends from the base of the cylinder 34 and has an end plate 38
connected thereto. A piston 40 is slidably mounted in the cylinder
34 around the shaft 36. The head 42 of the piston 40 has a large
diameter than the part 44 received in the cylinder bore 34, the
outer diameter of the head 42 corresponding approximately to the
outer diameter of the mandrel 22. A polyurethane ring 46 is mounted
around the shaft 36 between the piston head 42 and the end plate
38. This too has an outer diameter corresponding approximately to
the outer diameter of the mandrel 22. The working space 48 in the
cylinder 34 below the piston 40 is connected to a supply of
pressurised fluid (not shown) in the mandrel 22.
[0081] When the tool is positioned at the desired position in the
casing, pressurised fluid is admitted to the working space 48. This
forces the piston 40 out of the cylinder 34 so as to squeeze the
ring 46 between the head 42 and end plate 38. This squeezing action
causes the ring 46 to bulge around its periphery 50 so as to
project beyond the outer diameter of the rest of the mandrel 22.
The peripheral bulge 50 of the ring 46 causes the sleeve 18 to be
pushed out (against the casing to lock the sleeve in place (as the
anchor ring must slide over the inside of the sleeve, low friction
is required).
[0082] The casing 26 is in turn is deformed as is shown in FIG. 6.
Thus the sleeve 18 is trapped between the ring bulge 50 and the
casing 26 and cannot move as the cone 12 is forced through it. To
operate in this manner, it is necessary that the cone 12 can slide
over the mandrel 22. At the end of the expansion, the cone can be
withdrawn and the ring 46 released to allow the sleeve 18 to
contract around the mandrel 22 and be moved to another position
away from the expanded section of the casing.
[0083] It will be noted that in other embodiments of the invention
instead of having a ring 46 there may be a thick walled cylinder
mounted around the shaft 36 between the piston head 42 and the end
plate 38, and this cylinder may serve as an expansion body in tool
10. The material from which the ring 46 or the cylinder is made may
be other kinds of flexible and elastic material other than
polyurethane such as, for example, rubber. Further, the ring 46 or
the cylinder may be comprised of more than one section, which may
form separate segments. These segments may be housed in
compartments specifically shaped therefore in the area around the
shaft 36, between the piston head 42 and the end plate 38.
[0084] In another embodiment, as is shown in FIG. 7, a second cone
52 is provided at on the expander section 10 on the same side as
the first mandrel 14. In use, the tool is first used in the manner
as described above in relation to FIGS. 1 to 4. The (double sided
cone) tool is them moved in the casing to another position, at
which the sleeve is again anchored and then expanded by moving the
expander section upwards, using the second cone 52 to expand the
sleeve 18 in the same manner. At the end of this operation, the
sleeve is again located around the mandrel 22 and ready to be moved
to another position and operated as before.
[0085] Other changes within the scope of the apparatus and methods
of the invention will be apparent. For example, in one embodiment,
anchoring is achieved by providing bumps (not shown) on the inside
of the casing 26 against which the free end of the sleeve 18
abuts.
[0086] The expansion provided by the apparatus and methods of the
invention can be used in the manner of previously proposed
expansions, for example, to avoid cementing and progressive
reduction in the flow diameter of the well, connection of sections
of casing, forming of expanded sections for insertion of a
succeeding casing section, expansion of a patch over open borehole
or existing casing, etc.
[0087] There are further various applications of the apparatus of
the invention which may be used in tubular elements in oil and gas
wells, or in tubular elements used in surface, subsea or subsurface
pipelines.
[0088] Another application of the apparatus of the invention is for
a downhole anchor device. The anchor device may be used to anchor a
tubular element or other equipment against the formation or another
tubular element at selected locations in the wellbore.
[0089] The invention may be applied to expansion of tubular
elements against the borehole wall or against another casing. In
this way the invention can extend to a telescopic liner expansion
system which includes the apparatus for expanding tubular elements
as described above. Three liners, for example, can be run down a
hole at the same time, one inside the other. Each liner can then be
extended and the apparatus for expanding tubular elements used to
expand each of them.
[0090] The invention may also be used to form a bell or expanded
section, known as a chamber in the art, in which another expansion
tool can be deployed for further expansion of the tubular. The bell
or expanded section, or chamber, may be used for other purposes as
well in drilling or completion operations in oil or gas wells.
Expanded section 40 shown in FIG. 5 is an example of such a
chamber. The shape of the bell or expanded section, or chamber that
is formed may be symmetrical or asymmetrical. Asymmetrical
expansion may be accomplished by using a ring 34 which has an
asymmetrical shape such as an oval shape. In this case the piston
head 30 and the end plate 26 must first be centralised, so that the
ring 34 does not move into a position to give symmetrical expansion
during use. One of the ways in which asymmetrical expansion is
beneficial is when it is used to create a weak point or a specific
crack in the casing so that a side passage can be put into the
casing at that point.
[0091] The bell or expanded section could be used to locate
anything that would otherwise cause a restriction downhole. The
apparatus would have to be centralised firmly when used in this
way. It could thus, for example, be used to house a sub-surface
safety valve, pump, separator, etc.
[0092] Another application of the apparatus for expansion of
tubular elements can be to clad a relatively thin steel tube (with
or without seals on the outside) against the inside of a
deteriorated old tubing, casing, leaking connector, perforation,
etc. Substantially smaller sections or larger sections of tubular
can be clad by the apparatus. The cladding may, for example, be
used to store carbon dioxide gas in a depleted reservoir, enlarge
production tubing or repair leaks.
[0093] A further similar application of the apparatus is that it
can be used to create a patch or pad downhole for holding sensors
that are focused in one direction close to a borehole wall. Similar
applications of the apparatus are for a downhole patching system
and a perforation shut off patch system. The downhole patching
system may be used to repair casing or liner damage, or leaking
connectors. The patching system may further include a sealing
element, such as an o-ring on the outer diameter (OD).
[0094] The apparatus may also be used in the expansion of tubular
elements to produce areas of isolation. These areas may be in the
annulus of a well or these areas may be at selected zones of a
well. These zonal areas of isolation, for example, can be used to
squeeze off selective sections for shut off, acid injections,
chemical sand consolidation, or the like.
[0095] Another application of the apparatus is for a sand
screen.
[0096] A further application of the apparatus is for a pile
expander. The advantage of such a pile expander is that it can
improve pile bearing capacity and thus shorter piles may be
used.
[0097] A further application of the apparatus of the invention is
for a liner hanger. The liner hanger may be for use with liners,
casing or tubing, as the case may be. In this application the
apparatus is preferably used with a sleeve in combination with a
sealing element such as an o-ring on the OD.
[0098] In FIG. 8 a similar application for use in expanding an
expandable liner lap 54 is illustrated in a wellbore 55.
[0099] Another application of the apparatus of the invention is for
an expandable fishing tool. The expandable fishing tool may include
a conduit through its body. This allows for circulation through the
fishing tool. The conduit also allows for circulation through the
article to be fished. In this case the article is preferable the
tubular element and the conduit thus allows circulation through the
whole of the tubular element including its bottom end in the
wellbore. The expandable fishing tool has the advantage of
including a larger surface area, which may even create a recess,
and thus there is a better grip for the fish, or article to be
fished.
[0100] Another application of the apparatus is for an expandable
wellhead. The apparatus may be used to expand more than one
concentric tubular element at the wellhead. Preferably there may be
four or five concentric elements at the wellhead which are expanded
by the apparatus of the invention. The advantage of this expandable
wellhead is that it is then more rigid or robust than
conventionally formed wellheads, particularly those used offshore.
A further advantage is that a wellhead with a smaller OD can be
made.
[0101] The apparatus of the invention may also be used in an
abandonment plug. The tubular element that is expanded in the
abandonment plug may be an additional tubular element inside the
casing or liner. Such an abandonment plug may comprise a tube with
one open end and one closed end with or without seals around its OD
that is expanded against the casing or liner to shut in the well
and simultaneously close the micro-annulus. The expansion used
against the casing may be minor and is used to close off the
micro-annulus. The apparatus may be used to expand the additional
tubular element in a well to be abandoned and the expansion body
may be left in an expanded state in the expanded tubular element.
The abandonment plug may also include a steel sleeve which is also
expanded against the casing together with one or more rings 34. The
abandonment plug may be used with or without cement and may be
deployed by wireline, coiled tubing or other conduit.
[0102] Another application of the apparatus of the invention is for
an expandable sand screen. Similarly the apparatus may also be used
in perforated or slotted liner and in casing expansions.
[0103] As shown in FIGS. 9 and 10, a further application of the
apparatus of the invention is for a well pressure tester. The well
pressure tester can be used to pressure test various parts of oil
or gas wells such as, for example, a liner lap, the drill pipe, or
the formation cementation. The apparatus for expanding tubular
elements in the well pressure tester preferably uses expansion of
an expansion body substantially to form a seal against the tubular
element and not to expand the tubular element beyond its original
shape. The apparatus of the invention in this application may
include a plurality of rings 46 as shown in FIG. 10. In this
example of a pressure tester 56 some of the rings 46 may be used
for a packer application to isolate the area of interest and others
may be used to expand against the area of interest so as to perform
the actual pressure test. A pump or pressure intensifier may also
be included downhole with the pressure tester 56 to provide the
pressure used in the test. The pressure may also be supplied by an
integrated pressure multiplier, or by other means of supplying
pressure.
[0104] A packer itself is yet another application of the apparatus
of the invention. The packer may be a permanent installation in the
wellbore or may be retrievable and it is used to seal the wellbore
either permanently or temporarily. The tubular element to be
expanded by the expansion apparatus of the packer may be an
additional tubular element inside the casing or liner. The
apparatus for expanding tubular elements in the well pressure
tester preferably uses expansion of a compressible expansion body
substantially to form a seal against the tubular element and not to
expand the tubular element beyond its original shape. The packer
may be used in production or for testing, and may be used in cased
wellbores or in open wellbores. Typically the packer is used in
most completions to isolate the annulus from the production
conduit, enabling controlled production, injection or treatment of
the wellbore.
[0105] The well pressure tester 56 may also be used as a leakoff
test device to test the strength or fracture pressure of the open
formation. A section of the wellbore can be sealed off using the
apparatus and the pressure tester 56 can then be used along with
fluid under pressure in the section to test the maximum fluidic
pressure which the well can withstand in that particular section.
The leakoff test device may also be used at the liner bottom
58.
[0106] The apparatus of the invention may also be used to expand
the liner bottom 58 to seal the annulus, as illustrated in FIG.
11.
[0107] Another application of the apparatus of the invention is for
a bridge plug which is used to isolate the lower part of a
wellbore. The bridge plug may be permanent, enabling the lower part
of the wellbore to be permanently sealed off from production, or it
may be retrievable enabling the lower part of the wellbore to be
temporarily isolate from the treatment conducted on an upper zone
of the wellbore. The tubular element expanded by the bridge plug
may be an additional tubular element inside the casing or liner.
The apparatus for expanding tubular elements in the well pressure
tester preferably uses expansion of a compressible expansion body
substantially to form a seal against the tubular element and not to
expand the tubular element beyond its original size. The advantage
of the bridge plug is that it may be able to hold more pressure
when it is expanded to a level just below the yield of the tubular
element. The result is that it will thus will then have more
holding force.
[0108] The apparatus may also be used in a pipe connector.
Typically a pipe, or tubing or casing is expanded to fit
substantially tightly against another pipe, tubing or casing, as
the case may be, which has been fitted over it and it is then
connected using known pipe connection methods. The pipe connector
may also be used to connect tubing to casing or to connect a
lateral pipe to a central pipe. Preferably the pipe connector is a
swage type pipe connector.
[0109] Another application of the apparatus of the invention is for
a selective chemical placement tool. The selective chemical
placement tool is typically deployed downhole by coiled tubing,
workstring or other conduit. The selective chemical placement tool
may be slidably displaceable. In use the selective chemical
placement tool is deployed to a particular area of interest and
then expansion takes place by the expanding apparatus so that the
tool is anchored in the casing or liner across an area to be
treated. Chemical fluid is then injected into the body of the tool
between its two outer sections and this chemical fluid may then be
able to enter areas outside of the casing or liner, that is in the
annulus, by squeezing to perform various chemical treatments such
as, for example, sand consolidation and chemical shut-off. Once the
chemical treatment has been performed, the selective chemical
placement tool may then be slidably displaced to another location
and then be anchored at that position so that another chemical
treatment may be performed at this location. In this way the
selective chemical placement tool may be moved sequentially down
the wellbore to perform sequential chemical treatments where
required.
[0110] The apparatus may also be used as part of a bellow expander.
The bellow expander may be used to relieve buckling or axial
stresses in a tubular element. It may further also be used to
convert global buckling of a pipe or casing to localised
buckling.
[0111] It will be understood that the apparatus and methods of the
invention as well as the applications which include them can thus
be used in oil and gas wells for holes which are drilled with drill
string and which are subsequently lined or cased, as well as in oil
or gas wells which are drilled with liners or casings.
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