U.S. patent application number 12/422603 was filed with the patent office on 2010-10-14 for resilient anchor.
This patent application is currently assigned to Enventure Global Technology, LLC. Invention is credited to Harsh Chowdhary, Bruce H. Storm, JR..
Application Number | 20100257913 12/422603 |
Document ID | / |
Family ID | 42933255 |
Filed Date | 2010-10-14 |
United States Patent
Application |
20100257913 |
Kind Code |
A1 |
Storm, JR.; Bruce H. ; et
al. |
October 14, 2010 |
Resilient Anchor
Abstract
Methods and apparatus for radially expanding and plastically
deforming an expandable tubular member using an expansion device
for radially expanding and plastically deforming the expandable
tubular member, an actuator coupled to the expansion device, and an
anchor coupled to the actuator. The anchor includes a resilient
member that is selectively deformable between a first position
wherein the resilient member does not engage the expandable tubular
member and a second position wherein the resilient member engages
the expandable tubular member so as to releasably couple the anchor
to the expandable tubular member.
Inventors: |
Storm, JR.; Bruce H.;
(Houston, TX) ; Chowdhary; Harsh; (Houston,
TX) |
Correspondence
Address: |
Conley Rose, P.C
P.O. Box 3267
Houston
TX
77253-3267
US
|
Assignee: |
Enventure Global Technology,
LLC
Houston
TX
|
Family ID: |
42933255 |
Appl. No.: |
12/422603 |
Filed: |
April 13, 2009 |
Current U.S.
Class: |
72/370.06 ;
72/393 |
Current CPC
Class: |
E21B 23/01 20130101;
B21D 39/20 20130101; E21B 43/103 20130101; B21D 41/02 20130101 |
Class at
Publication: |
72/370.06 ;
72/393 |
International
Class: |
B21D 39/08 20060101
B21D039/08; B21D 41/02 20060101 B21D041/02 |
Claims
1. An apparatus for radially expanding and plastically deforming an
expandable tubular member, comprising: an expansion device operable
to radially expand and plastically deform the expandable tubular
member as said expansion device is axially displaced relative to
the expandable tubular member; an actuator coupled to said
expansion device and operable to axially displace said expansion
device relative to the expandable tubular member; and an anchor
coupled to said actuator, wherein said anchor comprises a resilient
member selectively deformable between a first position wherein said
resilient member does not engage the expandable tubular member and
a second position wherein said resilient member engages the
expandable tubular member so as to releasably couple said anchor to
the expandable tubular member.
2. The apparatus of claim 1 wherein said resilient member is
deformed from the first position to the second position by axially
compressing said resilient member.
3. The apparatus of claim 2 wherein said anchor further comprises a
compression flange operable to axially compress said resilient
member.
4. The apparatus of claim 1 wherein said resilient member is
deformed from the first position to the second position by radial
expansion.
5. The apparatus of claim 4 wherein said anchor further comprises a
mandrel operable to radially expand said resilient member.
6. The apparatus of claim 1 wherein said resilient member further
comprises reinforcement members embedded therein.
7. A method comprising: coupling an anchor comprising a resilient
member to a first end of an actuator; coupling an expansion device
to a second end of the actuator; disposing the anchor into an
expandable tubular member; applying a force to the resilient member
so as to deform the resilient member from a first position wherein
the resilient member does not engage the expandable tubular member
to a second position wherein the resilient member engages the
expandable tubular member so as to releasably couple the anchor to
the expandable tubular member; and radially expanding and
plastically deforming the expandable tubular member by activating
the actuator so as to axially displace the expansion device
relative to the expandable tubular member.
8. The method of claim 7, further comprising: removing the force
from the resilient member so as to allow the resilient member to
deform from the second position to the first position; axially
displacing the anchor relative to the expansion device; applying a
force to the resilient member so as to deform the resilient member
from the first position to the second position; and radially
expanding and plastically deforming the expandable tubular member
by activating the actuator so as to axially displace the expansion
device relative to the expandable tubular member.
9. The method of claim 7, wherein the force applied to the
resilient member is an axial compressive force.
10. The method of claim 7, wherein the force applied to the
resilient member is a radial expansion force.
11. The method of claim 7, wherein the force applied to the
resilient member is generated by a pressurized fluid.
12. The method of claim 7, wherein deforming the resilient member
to the second position does not plastically deform the expandable
tubular member.
13. The method of claim 7, wherein deforming the resilient member
to the second position plastically deforms the expandable tubular
member.
14. A method comprising: coupling an anchor and an expansion device
to an actuator to form an expansion assembly, wherein the anchor
comprises a resilient member; disposing the expansion assembly at
least partially within an expandable tubular member that is
disposed within a wellbore; deforming the resilient member from a
first position wherein the resilient member does not engage the
expandable tubular member to a second position wherein the
resilient member engages the expandable tubular member so as to
releasably couple the anchor to the expandable tubular member; and
radially expanding and plastically deforming the expandable tubular
member by activating the actuator so as to axially displace the
expansion device relative to the expandable tubular member.
15. The method of claim 14, further comprising: returning the
resilient member to the first position from the second position;
axially displacing the anchor relative to the expansion device;
deforming the resilient member from the first position to the
second position; and radially expanding and plastically deforming
the expandable tubular member by activating the actuator so as to
axially displace the expansion device relative to the expandable
tubular member.
16. The method of claim 14, wherein the resilient member is
deformed from the first position to the second position by applying
a force to the resilient member and returns to the first position
when the force is removed.
17. The method of claim 16, wherein the force applied to the
resilient member is an axial compressive force.
18. The method of claim 16, wherein the force applied to the
resilient member is a radial expansion force.
19. The method of claim 14, wherein deforming the resilient member
to the second position does not plastically deform the expandable
tubular member.
20. The method of claim 14, wherein deforming the resilient member
to the second position plastically deforms the expandable tubular
member.
Description
BACKGROUND
[0001] In the oil and gas industry, expandable tubing is often used
for casing, liners and the like. To create a casing, for example, a
tubular member is installed in a wellbore and subsequently expanded
by displacing an expansion cone through the tubular member. The
expansion cone may be pushed or pulled using mechanical means, such
as by a support tubular coupled thereto, or driven by hydraulic
pressure. As the expansion cone is displaced axially within the
tubular member, the expansion cone imparts radial force to the
inner surface of the tubular member. In response to the radial
force, the tubular member plastically deforms, thereby permanently
increasing both its inner and outer diameters. In other words, the
tubular member expands radially. Expandable tubulars may also be
used to repair, seal, or remediate existing casing that has been
perforated, parted, corroded, or otherwise damaged since
installation.
SUMMARY OF INVENTION
[0002] In one aspect, the present disclosure relates to methods and
apparatus for radially expanding and plastically deforming an
expandable tubular member using an expansion device, an actuator
coupled to the expansion device, and an anchor coupled to the
actuator. The anchor includes a resilient member that is
selectively deformable between a first position wherein the
resilient member does not engage the expandable tubular member and
a second position wherein the resilient member engages the
expandable tubular member so as to releasably couple the anchor to
the expandable tubular member.
[0003] Other aspects and advantages of the invention will be
apparent from the following description and the appended
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a fragmentary cross-sectional illustration of an
apparatus for installing an expandable tubular member within a
preexisting structure.
[0005] FIG. 2 is a fragmentary cross-sectional illustration of the
apparatus of FIG. 1 after displacing the expansion device within
the expandable tubular member.
[0006] FIG. 3 is a fragmentary cross-sectional illustration of the
apparatus of FIG. 2 after displacing the actuator and anchor
relative to the expansion device and the expandable tubular
member.
[0007] FIG. 4 is a fragmentary cross-sectional illustration of the
apparatus of FIG. 3 after displacing the expansion device within
the expandable tubular member.
[0008] FIG. 5A-5B are partial schematic illustrations of an anchor
activated by axial compression in accordance with one
embodiment.
[0009] FIG. 6A-6B are partial schematic illustrations of an anchor
activated by radial expansion in accordance with another
embodiment.
[0010] FIG. 7 is a cross-section of an anchor in accordance with
one embodiment.
[0011] FIGS. 8A-8C are detailed isometric views of a resilient
member for use with the anchor shown in FIG. 7 in accordance with
one embodiment.
[0012] FIG. 9 is a fragmentary cross-sectional illustration of an
apparatus for anchoring a workstring to a tubular member.
[0013] FIG. 10 is a fragmentary cross-sectional illustration of the
apparatus of FIG. 9 with the workstring anchored to the tubular
member.
DETAILED DESCRIPTION
[0014] The present disclosure relates to apparatus and methods for
anchoring a workstring within a tubular member such that a process
can be performed on the tubular member. In some embodiments, the
anchored workstring is used to move the tubular member within a
wellbore. In other embodiments, the anchored workstring includes an
expansion apparatus operable to radially expand the tubular member
within a wellbore.
[0015] Referring to FIG. 1, an embodiment of an expansion apparatus
10 for radially expanding and plastically deforming a tubular
member 12 includes a tubular support member 14 that is coupled to
an end of an anchor 16 for controllably engaging the tubular member
via resilient member 26. Another end of the anchor 16 is coupled to
a tubular support member 18 that is coupled to an end of an
actuator 20. Another end of the actuator 20 is coupled to a tubular
support member 22 that is coupled to an end of an expansion device
24 for radially expanding and plastically deforming the tubular
member 12. The anchor 16, the tubular support member 18, the
actuator 20, and the tubular support member 22 are positioned
within the tubular member 12.
[0016] In one embodiment, the expansion apparatus 10 is positioned
within a preexisting structure 30 such as, for example, a wellbore
that traverses a subterranean formation 32. Once tubular member 12
and expansion apparatus 10 are disposed at a desired location
within structure 30, anchor 16 is activated. The activation of
anchor 16 causes resilient member 26 to deform and engage tubular
member 12 so as to releasably couple anchor 16 to tubular member
12. As a result, the axial position of anchor 16 is fixed relative
to tubular member 12, as shown in FIG. 2. The activation of anchor
16 is further detailed below in reference to FIGS. 5A-5B and 6A-6B.
Once anchor 16 is releasably coupled to tubular member 12, actuator
20 can be activated to axially displace the expansion device 24
relative to tubular member 12. The axial displacement of expansion
device 24 radially expands and plastically deforms a portion of the
tubular member 12.
[0017] Once actuator 20 has displaced expansion device 24, as
illustrated in FIG. 3, the anchor 16 is then deactivated, which
disengages resilient member 26 from the tubular member 12. With
anchor 16 released, the tubular support member 14, the anchor 16,
the tubular support member 18, and the actuator 20 can be displaced
axially relative to the expansion device 24. The axial displacement
of anchor 16 and actuator 20 may be effectuated by pulling support
member 14 upward or through a reversal of the activation of
actuator 20.
[0018] As illustrated in FIG. 4, the anchor 16 is again releasably
coupled to tubular member 12 by deforming resilient member 26 into
engagement with tubular member 12. Actuator 20 is activated to
further axially displace expansion device 24 relative to tubular
member 12. As expansion device 24 is displaced by the actuator 20,
another portion of tubular member 12 is radially expanded and
plastically deformed. The operations of FIGS. 3 and 4 can then be
repeated until the desired length of the tubular member 12 is
radially expanded and plastically deformed. The process of
anchoring and releasing may be repeated many times to allow
repeated expansion steps. The strains imposed on the resilient
members may be limited to avoid any permanent deformation of
resilient member 26 and allow virtually unlimited actuation of the
anchor 26.
[0019] For example, in the embodiments shown in FIGS. 1-4, the
actuator 20 may be configured for a stroke length of 3 feet and
3000 feet of tubular member 12 may be expanded. The anchor 16 could
be actuated to anchor the support member 14, the actuator 20 then
stroked 3 feet to expand a portion of tubular member 12 with
expansion device 24, followed by release of the anchor 16. Pulling
up on the support member 14 resets the actuator 20 and allows a
repeat of the anchoring and expansion in the 3 foot intervals until
the tubular member 12 is expanded.
[0020] It is understood that expansion apparatus 10 is only one
embodiment of a system utilizing an anchor, actuator, and expansion
device and other such systems may be contemplated or are known in
the art. For example, the expansion device may be a solid mandrel
having a fixed outer diameter, an adjustable or collapsible mandrel
with a variable outer diameter, a roller-type expansion device, or
any other device used to expand a tubular. Still further, although
illustrated in FIG. 1 as having all initial position external to
the expandable tubular member and configured for upward expansion,
in certain embodiments, the expansion device may have an initial
position within the tubular and/or be configured for downward
expansion. Expansion apparatus 10 may also utilize any actuator
that provides sufficient force to axially displace the expansion
device through the expandable tubular. The actuator may be driven
by hydraulic pressure, mechanical forces, electrical power, or any
other suitable power source.
[0021] FIGS. 5A and 5B schematically illustrate one embodiment of
an anchor 112 comprising a resilient member 126 that is deformed by
the application of an axial force on the resilient member.
Resilient member 126 is a substantially cylindrical body disposed
about a support member 134. Resilient member 126 is axially
constrained on one end by flange 128. Piston 130 is disposed
adjacent to the other end of resilient member 126. When anchor 112
is activated, piston 130 moves toward flange 128 and axially
compresses resilient member 126.
[0022] The axial compression of resilient member 126 increases the
outside diameter of the resilient member according to the material
properties, such as Poisson's ratio, of the resilient material. For
example, a urethane formulated for a downhole environment may have
a Poisson's ratio of about 0.50. As a result of the axial
compression, the outside of the resilient member 126 comes into
contact with, and develops a normal force on, the inner diameter of
the tubular member 132. Further axial compression of the resilient
member 126 adds to the normal force, which provides the anchoring
force for the anchor 112. The anchoring force is approximately the
product of the normal force applied to the inner diameter of the
tubular member 132 and the coefficient of friction between the
tubular member 132 and the resilient member 126.
[0023] In certain embodiments, resilient member 126 may exert a
force on tubular member 132 that is sufficient to cause deformation
of the tubular member 132. This localized deformation of tubular
member 132 may further increase the anchoring force generated by
resilient member 126 as the resilient member would have to be
sheared or compressed in order to exit the area that has been
deformed.
[0024] FIGS. 6A and 6B schematically illustrate another embodiment
of an anchor 212 comprising a resilient member 226 that is deformed
by radially expanding the resilient member using a tapered mandrel
228. Resilient member 226 is a substantially cylindrical body
disposed about a support member 230. Tapered mandrel 228 is also
disposed about support member 230 and is axially moveable relative
thereto. Resilient member 226 is axially constrained on one end by
flange 232. When anchor 212 is activated, tapered mandrel 228 is
moved toward flange 232.
[0025] The axial movement of tapered mandrel 228 forces resilient
member 226 to radially expand outward over the tapered mandrel and
into contact with tubular member 234. As a result of the radial
expansion, the outside of the resilient member 226 comes into
contact with, and develops a normal force on the inner diameter of
the tubular member 234. Further radial expansion of the resilient
member 226 adds to the normal force, which provides the anchoring
force for the anchor 212. The anchoring force is approximately the
product of the normal force applied to the inner diameter of the
tubular member 234 and the coefficient of friction between the
tubular member 234 and the resilient member 226.
[0026] In certain embodiments, resilient member 226 may exert a
force on tubular member 234 that is sufficient to cause deformation
of the tubular member. This localized deformation of tubular member
234 may further increase the anchoring force generated by resilient
member 226 as the resilient member would have to be sheared or
compressed in order to exit the area that has been deformed.
[0027] In FIG. 7, an anchor in accordance with one embodiment is
shown. The anchor uses resilient members 702a and 702b disposed
around an anchor body 701 to selectively engage the inside of
tubular member 12 to anchor support member 14 with respect to
tubular member 12. Engagement of the resilient members 702a and
702b is controlled by axially compressing the resilient members
702a and 702b, which increases the outside diameter of the
resilient members 702a and 702b according to the material
properties of the particular material, such as Modulus of
Elasticity, and Poisson's ratio. As a result of the axial
compression, the outside of the resilient members 702a and 702b
come into contact with the inside of the tubular member 12, which
develops a normal force on the inner diameter of the tubular member
12. Further axial stress on the resilient members 702a and 702b
adds to the normal force, which provides the anchoring force for
the anchor. The anchoring force is approximately the product of the
normal force applied to the inner diameter of the tubular member 12
and the coefficient of friction between the tubular member 12 and
the resilient members 702a and 702b.
[0028] The form and function of the anchor shown in FIG. 7 will now
be described in greater detail. Those having ordinary skill in the
art will appreciate that many modifications may be made to the
embodiment shown in FIG. 7 in accordance with the teachings herein.
At one end, the anchor body 701 includes a connection, such as a
threaded connection, to the support member 14. The opposing end of
the anchor body 701 is connected to other components of the
expansion apparatus, such as an actuator (not shown). The anchor
includes two resilient members 702a and 702b that are generally
cylindrical in shape and disposed on the anchor body 701. In the
relaxed or undocked state, as shown in FIG. 7, the outside diameter
of the resilient members 702a and 702b is less than the inside
diameter of the tubular member 12 to allow movement of the
expansion apparatus.
[0029] The resilient members 702a and 702b are axially trapped by a
top compression flange 720 and a bottom compression flange 721,
respectively. The resilient members 702a and 702b are separated by
a center wedge 715. The surfaces of center wedge 715 and
compression flanges 720 and 721 that contact the ends of resilient
members 702a and 702b are curved, which helps to force the
resilient members radially outward as they are axially compressed
by the compression flanges. The resilient members 702a and 702b may
further include reinforcement members, such as anti-extrusion
inserts 703a-d to reduce or eliminate axial extrusion. The
anti-extrusion inserts 703a-d are formed from less flexible
material, such as Teflon.RTM. or Nylon.RTM., and may be separate or
integrally bonded with the resilient members 702a and 702b.
[0030] In the embodiment shown in FIG. 7, the top compression
flange 720 and the bottom compression flange 721 act as
pressure-driven pistons to axially compress and radially expand the
resilient members 702a and 702b. The respective piston areas are
defined by the inside diameters of an upper retainer 701 and a
lower retainer 711 and the outside diameter of a mandrel portion
705 of the anchor body 701. O-rings or any other sealing
arrangement may be used to seal between the respective inside and
outside diameters of the top compression flange 720, the bottom
compression flange 721, the mandrel portion 705 of the anchor body
701, the upper retainer 701, and the lower retainer 711. To anchor
the support member 14, pressure from the inside of the anchor is
transmitted through ports 730a to actuate the top compression
flange 720 and through ports 730b to actuate the bottom compression
flange 721. The pressure differential between the inside of the
anchor and the annulus between the tubular member 12 and the anchor
body 701 axially moves the top compression flange 720 and the
bottom compression flange 721 towards each other, thereby axially
compressing the resilient members 702a and 702b. The resulting
radial strain brings the outside of the resilient members 702a and
702b into contact with the inside of the tubular member 12.
Releasing pressure causes the resilient members 702a and 702b to
radially contract and axially extend to return to the relaxed state
and release the anchor, thereby allowing movement of the support
member 14 relative to the tubular member 12.
[0031] Although a pressure actuated embodiment is shown in FIG. 7,
those having ordinary skill in the art will appreciate that the
anchor could be actuated using other means, such as an electric
motor with a linear actuator. Furthermore, the present disclosure
is not limited to any number of resilient members. In some
embodiments, a single resilient member may provide sufficient
anchoring force. Those having ordinary skill in the art will
appreciate that the amount of anchoring force needed will depend on
many factors, such as the material strength, diameter, and
thickness of the tubular member being expanded.
[0032] FIGS. 8A-8C illustrate a resilient member 802 that may be
used with the anchor shown in FIG. 7. In this embodiment, the
resilient member 802 is generally cylindrical, but includes
azimuthally arranged cuts or grooves 801 on the exterior to relieve
hoop stress in the resilient member 802. Grooves 801 also allow
fluid bypass, which may be desirable for pressure equalization or
fluid transfer across resilient member 802. Extrusion inserts 803
are at opposing ends of each section of the resilient member 802,
Because of the grooves 801, the extrusion inserts 803 will
experience less strain during actuation of the resilient member
802, which prevents or minimizes the risk of plastic deformation of
the extrusion inserts 803. Extrusion inserts 803 are one example of
a reinforcement member that may be used to improve the performance
of resilient member 802. Other reinforcement members may include
wire mesh, fibers, balls, and/or other materials combined with the
resilient material.
[0033] Referring now to FIGS. 9 and 10, workstring 310 comprises
anchor device 316 that is coupled to support member 314. Workstring
310 is disposed within tubular member 312 that may be at the
surface or may be disposed within wellbore 330. Anchor device 316
includes resilient member 326 that is operable to engage tubular
member 312. Workstring 310 is disposed within tubular member 312
with resilient member 326 in a first position, as shown in FIG. 9,
where the resilient member does not contact the tubular member.
Once workstring 310 is positioned within tubular member 312,
resilient member 326 is selectively deformed to a second position,
as shown in FIG. 10, by the activation of anchor device 316.
[0034] The activation of anchor device 316 couples workstring 310
to tubular member 316. Workstring 310 can then be used to move
tubular member 312 within wellbore 330. For example, workstring 310
may be installed within tubular member 312 at the surface and then
be used to lower the tubular member into wellbore 330, such as
during casing running or liner drilling operations. Workstring 310
may also be installed within a tubular member 312 that is already
in wellbore 330 to enable the tubular member to be removed from the
wellbore, such as during fishing operations. As described above in
relation to FIGS. 1 and 2, workstring 310 may also be used to
engage tubular member 312 to perform a radial expansion operation.
In certain embodiments, anchor device 316 may be operable to
transmit torque from workstring 310 to tubular member 316, so that
the tubular member can be rotated.
[0035] Anchors utilizing resilient members as disclosed herein
provide an anchor that is less sensitive than other anchoring
systems to variations in the inside diameter of the tubular member
being expanded. Eccentricity and surface flaws are forgiven by the
resilient members pressed against the inside of the tubular member
because the resilient members conform to whatever surface they are
pressed against. Additionally, the anchors can be configured to
anchor within a range of internal diameters to take advantage of
the range of radial strain tolerated by the resilient members.
Unlike slips or pawls used in other anchoring systems, anchors
utilizing resilient members do not gouge or otherwise damage the
inside surface of the tubular member, which avoids creating stress
concentrations in the tubular member when that portion is later
expanded. Additionally, anchors utilizing resilient members are
able to be constructed from a relatively few components, thus
providing a less complicated and less expensive anchoring
device.
[0036] Although this detailed description has shown and described
illustrative embodiments of the invention, this description
contemplates a wide range of modifications, changes, and
substitutions. In some instances, one may employ some features of
the present invention without a corresponding use of the other
features. Accordingly, it is appropriate that readers should
construe the appended claims broadly, and in a manner consistent
with the scope of the invention.
* * * * *