U.S. patent application number 12/552063 was filed with the patent office on 2011-03-03 for downhole telescoping tool with radially expandable members.
This patent application is currently assigned to ENVENTURE GLOBAL TECHNOLOGY. Invention is credited to Douglas Glenn Durst.
Application Number | 20110048741 12/552063 |
Document ID | / |
Family ID | 43623138 |
Filed Date | 2011-03-03 |
United States Patent
Application |
20110048741 |
Kind Code |
A1 |
Durst; Douglas Glenn |
March 3, 2011 |
DOWNHOLE TELESCOPING TOOL WITH RADIALLY EXPANDABLE MEMBERS
Abstract
A downhole axial expansion or telescoping tool includes radially
expandable tubular members. The tubular members are relatively
moveable before and after radial expansion, and include an
intermediate layer therebetween of a non-metal or non-cladding
material. The intermediate layer may provide any one or more of
lubricity, load transfer, sealing, and shape retention during and
after radial expansion.
Inventors: |
Durst; Douglas Glenn; (Katy,
TX) |
Assignee: |
ENVENTURE GLOBAL TECHNOLOGY
Houston
TX
|
Family ID: |
43623138 |
Appl. No.: |
12/552063 |
Filed: |
September 1, 2009 |
Current U.S.
Class: |
166/384 ;
166/207 |
Current CPC
Class: |
E21B 17/07 20130101 |
Class at
Publication: |
166/384 ;
166/207 |
International
Class: |
E21B 29/00 20060101
E21B029/00; E21B 43/10 20060101 E21B043/10 |
Claims
1. A downhole telescoping tool comprising: a first metal tubular
member; a second metal tubular member disposed in the first metal
tubular member and reciprocal therein; and a non-metal layer
disposed between the first and second tubular members; wherein the
first and second tubular members are radially expandable to a
plastically deformed position.
2. The telescoping tool of claim 1 wherein the first and second
tubular members are radially expanded and plastically deformed.
3. The telescoping tool of claim 2 wherein the non-metal layer
transfers the radial expansion load from the second tubular member
to the first tubular member.
4. The telescoping tool of claim 2 wherein the second tubular
member is reciprocal in the first tubular member before and after
radial expansion.
5. The telescoping tool of claim 2 wherein the non-metal layer is
lubrication between the reciprocal second tubular member and the
first tubular member.
6. The telescoping tool of claim 2 wherein the non-metal layer
seals between the second tubular member and the first tubular
member.
7. The telescoping tool of claim 1 further comprising an outer
tubular housing receiving the first and second tubular members.
8. The telescoping tool of claim 7 wherein the outer tubular
housing is radially expandable.
9. The telescoping tool of claim 7 wherein the outer tubular
housing engages a portion of the non-metal layer.
10. The telescoping tool of claim 7 wherein the outer tubular
housing is coupled to at least one of the first tubular member and
the second tubular member.
11. The telescoping tool of claim 7 wherein the outer tubular
housing is coupled to an upper tubular string.
12. The telescoping tool of claim 11 wherein the upper tubular
string is radially expandable.
13. The telescoping tool of claim 1 wherein the second tubular
member is coupled to a lower tubular string.
14. The telescoping tool of claim 13 wherein the lower tubular
string is radially expandable.
15. A downhole telescoping tool comprising: a first tubular member
slidably coupled with a second tubular member; and an intermediate
layer of non-cladding material disposed between the slidably
coupled first and second tubular members; wherein the first tubular
member, the second tubular member, and the intermediate layer are
radially expanded and plastically deformed; wherein the first
tubular member and the second tubular member are relatively
slidable before and after radial expansion and plastic
deformation.
16. The telescoping tool of claim 15 further comprising splines
disposed between the first and second tubular members to prevent
rotation while allowing axial translation of the first and second
tubular members.
17. The telescoping tool of claim 15 wherein after radial expansion
and plastic deformation the intermediate layer provides at least
one of load transfer, lubrication and sealing.
18. A method of radially expanding a telescoping tool comprising:
disposing a layer of material between an inner tubular member
slidably coupled to an outer tubular member; radially expanding and
plastically deforming the inner tubular member into the layer of
material; transferring the radial expansion load to the outer
tubular member using the layer of material to radially expand and
plastically deform the outer tubular member; and after radial
expansion and plastic deformation of the inner and outer tubular
members, sliding the inner and outer tubular members relative to
each other.
19. The method of claim 18 further comprising using the layer of
material to prevent cladding of the inner and outer tubular members
in response to the radial expansion and plastic deformation.
20. The method of claim 18 further comprising moving an expansion
device through the inner and outer tubular members.
Description
BACKGROUND
[0001] This disclosure relates generally to hydrocarbon exploration
and production, and in particular to forming well bore tubular
strings and connections to facilitate hydrocarbon production or
downhole fluid injection.
[0002] During hydrocarbon exploration and production, a well bore
typically traverses a number of zones within a subterranean
formation. A tubular system may be established in the well bore to
create flow paths from the multiple producing zones to the surface
of the well bore. Efficient production is highly dependent on the
inner diameter of the tubular production system, with greater inner
diameters producing more hydrocarbons or allowing inserted
equipment with appropriate pressure ratings to be used in well
completions. Existing apparatus and methods for producing
hydrocarbons include a complex set of tubulars, connections, liner
hangers, sand control devices, packers and other equipment which
tend to constrict the inner diameter of the production system
available for production.
[0003] The tubular system implemented during the treatment,
completion and production of subterranean oil and gas wells may
also include a packer set at a preselected location above a
production zone. In the case of wells of substantial depth, and
particularly wells where the downhole temperatures are
substantially in excess of or below the surface temperatures,
problems have been encountered due to excessive expansion or
contraction of the elongated tubing string. For example, in the
treatment or stimulation of the well, it is common to introduce
fluids at surface ambient temperature into the tubing string. In
some cases, the fluid is introduced as steam at elevated
temperatures. When the major portions of the tubing string are at a
much higher temperature initially, this inherently results in a
cooling, and hence a substantial contraction of the tubing string,
resulting in the production of a substantial tensile stress in the
tubing string between its surface connection and the set packer.
Similarly, in the production phase of such wells, the production
fluid is normally at a temperature substantially in excess of the
temperature of the majority of the tubing string, resulting in a
substantial expansion of the tubing string and the production of a
substantial compressive force on the tubing string. Additionally,
changes in fluid pressure inside and outside the tubing string play
a major role in the development of substantial tension or
compressive forces in the tubing string.
[0004] In other systems, a tubing hanger assembly is disposed at a
relatively elevated downhole position within the well to suspend
the production tubing extending to the production zones from such
tubing hanger. Intermediate the tubing hanger and the top of the
well there is commonly provided one or more production tubing
strings commonly referred to as a "space-out section" which extends
to a well surface hanger which is utilized to suspend the tubing
string weight intermediate the downhole hanger and the surface
hanger. The tubing strings coupled to the hangers undergo similar
expansion or contraction forces as described.
[0005] To address the described expansion or contraction of the
downhole tubulars, an expansion joint is disposed in the tubing
string. The expansion joint may be located between the bottom of
the tubing string and the packer. The expansion joint may be
located between the surface hanger and the downhole hanger, or in
the space-out section. The expansion joint is an axially moveable
or telescoping device or component designed to enable relative
movement between two fixed assemblies in the event of thermal
expansion or contraction. Expansion joints within the completion
assembly prevent any movement or forces being transmitted to fixed
components such as packers or tubing hangers. Such expansion joints
may, for example, comprise an elongated seal bore receptacle
attached to the packer or hanger within which there is sealingly
telescopically mounted a mandrel connected at its upper end to the
tubing string and relatively movable with respect to the seal bore
of the receptacle in response to the changes in tension or
compression in the tubing string. A telescoping joint disposed in a
space-out section may be capable of expansion or contraction to
absorb temperature produced variations in length of the space-out
section or dimensional differences between the planned and actual
location of the surface hanger with respect to the downhole hanger.
Further, the telescoping joint may have rotational or torque
transmitting capability so that rotation can be accomplished
through the joint to the right or to the left in order to perform
required operations on various pieces of apparatus carried by the
tubing string.
[0006] The principles of the present disclosure are directed to
overcoming one or more of the limitations of the existing apparatus
and processes for increasing fluid injection or hydrocarbon
production during treatment, completion and production of
subterranean wells.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For a more detailed description of the embodiments of the
present disclosure, reference will now be made to the accompanying
drawings, wherein:
[0008] FIG. 1 is a schematic view of an expandable tubular string
disposed in a borehole, the string including expandable tubular
members coupled together by connections or joints;
[0009] FIG. 2A is an enlarged, partial cross-section view of one of
the tubular connections of FIG. 1, including the radial expansion
and plastic deformation of a portion of the first tubular
member;
[0010] FIG. 2B shows the radial expansion and plastic deformation
of the tubular members and connection of FIG. 2A;
[0011] FIG. 3 is a schematic representation of an operating
environment for a basic exemplary completion or production
apparatus;
[0012] FIG. 4 is a partial, cross-section view of an expandable
tubular telescoping tool in accordance with the principles herein,
showing the various components of the tool assembly in an axially
contracted position;
[0013] FIG. 5 is a full cross-section view of the upper guide
member of FIG. 4;
[0014] FIG. 6 is the telescoping tool assembly of FIG. 4 shown in
an axially expanded position;
[0015] FIG. 7 is a partial, cross-section view of another
embodiment of an expandable tubular telescoping tool in accordance
with the principles herein, showing the various components of the
tool assembly in an axially contracted position;
[0016] FIG. 8 is the telescoping tool assembly of FIG. 7 shown in
an axially expanded position;
[0017] FIG. 9 is a full cross-section view of the upper guide
member of FIGS. 7 and 8;
[0018] FIG. 10 is a side perspective view of the upper guide member
of FIGS. 7-9;
[0019] FIG. 11 is a side perspective view of the lower guide member
of FIGS. 7 and 8;
[0020] FIG. 12 is a radial section view of the telescoping tool
assembly at section 12 of FIG. 7;
[0021] FIG. 13 is a radial section view of the upper guide member
at section 13 of FIGS. 9 and 10;
[0022] FIG. 14 is a radial section view of the lower guide member
at section 14 of FIG. 11;
[0023] FIG. 15 is a radial section view of the telescoping tool
assembly at section 15 of FIG. 7;
[0024] FIG. 16 is a radial section view of the telescoping tool
assembly at section 16 of FIG. 7; and
[0025] FIG. 17 is a radial section view of the telescoping tool
assembly at section 17 of FIG. 7.
DETAILED DESCRIPTION
[0026] In the drawings and description that follow, like parts are
typically marked throughout the specification and drawings with the
same reference numerals. The drawing figures are not necessarily to
scale. Certain features of the invention may be shown exaggerated
in scale or in somewhat schematic form and some details of
conventional elements may not be shown in the interest of clarity
and conciseness. The present disclosure is susceptible to
embodiments of different forms. Specific embodiments are described
in detail and are shown in the drawings, with the understanding
that the present disclosure is to be considered an exemplification
of the principles of the invention, and is not intended to limit
the invention to that illustrated and described herein. It is to be
fully recognized that the different teachings of the embodiments
discussed below may be employed separately or in any suitable
combination to produce desired results.
[0027] Unless otherwise specified, any use of any form of the terms
"connect", "engage", "couple", "attach", or any other term
describing an interaction between elements is not meant to limit
the interaction to direct interaction between the elements and may
also include indirect interaction between the elements described.
In the following discussion and in the claims, the terms
"including" and "comprising" are used in an open-ended fashion, and
thus should be interpreted to mean "including, but not limited to .
. . ". The terms "pipe," "tubular member," "casing" and the like as
used herein shall include tubing and other generally cylindrical
objects. In addition, in the discussion and claims that follow, it
may be sometimes stated that certain components or elements are in
fluid communication. By this it is meant that the components are
constructed and interrelated such that a fluid could be
communicated between them, as via a passageway, tube, or conduit.
The various characteristics mentioned above, as well as other
features and characteristics described in more detail below, will
be readily apparent to those skilled in the art upon reading the
following detailed description of the embodiments, and by referring
to the accompanying drawings.
[0028] Referring initially to FIG. 1, a string 14 of coupled
tubular members is disposed in a well bore 10 drilled through the
formation 12, creating an annulus 13. The string 14 comprises a
series of connected tubular members, such as casing joints 15, 16,
17 and 18, having a centerline or axis 19. In some embodiments, the
casing joints are secured by connections 15a, 16a and 17a as
indicated to form an elongate string that extends to the well
surface. The casing string 14 is illustrated as being made up of
individual casing joints of approximately 40 feet in length, for
example, with a joint connection between the adjoining casing
joints. In accordance with the principles of the present
disclosure, the casing string 14 is to be radially expanded and
plastically deformed into engagement with the surrounding well bore
10 using a forging device or expansion mandrel that passes
internally through the casing string 14 and the connections 15a,
16a, and 17a. In other embodiments, the well bore 10 is cased and
the string 14 is expanded toward the casing.
[0029] Referring now to FIG. 2A, the connection 15a of FIG. 1 is
shown enlarged and in partial cross-section about the axis 19. The
first tubular member 16 includes an internal connection surface 22
at an end portion 24. In some embodiments, the internal surface 22
includes threads. An external connection surface 28 of an end
portion 26 of the second tubular member 15 is coupled to the
internal connection 12 of the end portion 14 of the first tubular
member 10. In some embodiments, the external surface 28 includes
threads such that the surfaces 22, 28 are threadedly engaged. The
first and second tubulars 16, 15 abut at locations 30, 32. In an
exemplary embodiment, the internally threaded connection 22 of the
end portion 24 of the first tubular member 16 is a box connection,
and the externally threaded connection 28 of the end portion 26 of
the second tubular member 15 is a pin connection.
[0030] In an exemplary embodiment, as illustrated in FIGS. 2A and
2B, the first and second tubular members 16, 15 may then be
positioned within another structure 10 such as, for example, a
wellbore, and radially expanded and plastically deformed, for
example, by moving an expansion device or cone 34 through the
interiors of the first and second tubular members. The movement of
the expansion cone 34 through the interiors of the first and second
tubular members 16, 15 may be from top to bottom or from bottom to
top. As shown, the tubular members 15, 16 are radially expandable
from a first unexpanded position to a final plastically deformed
position.
[0031] In the embodiments just described, and throughout the
disclosure herein, the wellbore or borehole described may be
uncased or cased. The expandable tubulars may be radially expanded
and plastically deformed toward the uncased borehole, or toward a
casing already in place in the borehole.
[0032] Referring to FIG. 3, a schematic representation of an
operating environment for a basic exemplary completion or
production apparatus 100 is shown. The apparatus 100 is an
exemplary embodiment, and various other embodiments of the
apparatus 100 consistent with the teachings herein are included. As
depicted, a drilling rig 110 is positioned on the earth's surface
105 and extends over and around a well bore 120 that penetrates a
subterranean formation F for the purpose of recovering
hydrocarbons. The well bore 120 may be drilled into the
subterranean formation F using conventional (or future) drilling
techniques. The well bore 120 may extend substantially vertically
away from the surface 105 over a vertical portion 122, or may
deviate at any angle from the surface 105 over a lateral well bore
portion 124. In some instances, all or portions of the well bore
120 may be vertical, deviated, horizontal, and/or curved.
[0033] At least a portion of the vertical well bore 122 may be
lined with casing 125 that may be cemented 127 into position
against the formation F in a conventional manner. A lower portion
128 of the well bore 122 may also be lined with cemented casing
125. In some instances, the operating environment for the apparatus
100 includes a substantially uncased, open hole well bore 120. The
well bore may also include the uncased, open hole lateral well bore
portion 124. The lateral well 124 may include various hydrocarbon
producing zones 80, 82, 84, 86, 88, 90. The drilling rig 110
includes a derrick 112 with a rig floor 114 through which a tubing
or work string 118 extends downwardly from the drilling rig 110
into the well bore 120. The tubing string 118 suspends a
representative downhole production apparatus 100 to a predetermined
depth within the well bore 120 to perform a specific operation,
such as perforating a casing, expanding a fluid path therethrough,
fracturing the formation F, producing the formation F, or other
completion or production operation. The tubing string 118 may also
be known as the entire conveyance above and coupled to the
apparatus 100. The drilling rig 110 is conventional and therefore
includes a motor driven winch and other associated equipment for
extending the tubing string 118 into the well bore 120 to position
the apparatus 100 at the desired depth.
[0034] While the exemplary operating environment depicted in FIG. 3
refers to a stationary drilling rig 110 for lowering and setting
the apparatus 100 within a land-based well bore 120, one of
ordinary skill in the art will readily appreciate that mobile
workover rigs, well servicing units, such as coiled tubing units,
and the like, could also be used to lower the apparatus 100 into
the well bore 120. It should be understood that the apparatus 100
may also be used in other operational environments, such as within
an offshore well bore.
[0035] The production apparatus 100, disposed partially in cased
hole 122 and substantially in open hole 124, includes an upper end
having a liner hanger 132, a lower end 136, and a tubing section
134 extending therebetween. The lower end 136 may include devices
138, 140 such as a guide shoe, a float shoe or a float collar of a
type known in the art, and other tubing conveyed devices 142, 144.
The borehole 124 and the tubing section 134 define an annulus 146
therebetween. The tubing section 134 includes an interior 148 that
defines a flow passage 150 therethrough. The tubing section 134 may
include an inner string 152 with a lower end 154 that extends into
a polished bore receptacle 144. The inner string 152 may be used to
carry out preliminary operations, such as perforating or jetting.
Alternatively, the tubing section 134 does not include the inner
string 152 such that the flow passage 150 is the main flowbore
through the apparatus 100. A plurality of devices 158 are connected
in the tubing section 134 and provide operational interaction with
the various hydrocarbon producing zones 180, 182, 184, 186, 188.
The completion or production devices 158 may include seals,
packers, subs, screens, blast joints and other devices used in
completion or production strings.
[0036] Referring to FIG. 4, an assembly 200 for axial expansion and
contraction of a tubular string is shown. As will be shown and
described herein, tubular members of the assembly 200 are
configured for relative axial movement while coupled to allow for
expansion and contraction of the overall tubular string. Thus, the
assembly 200 may also be referred to as an axial expansion tool or
telescoping tool. In some embodiments, one or more of the tubular
members in the telescoping tool is radially expandable, as will be
described more fully herein. In certain embodiments, the tubular
members are radially expandable to a plastically deformed
position.
[0037] In FIG. 4, the telescoping tool assembly 200 is shown in an
axially contracted position. An upper half of the telescoping tool
assembly 200 is shown in cross-section, including an outer housing
220, an internal upper guide member 210 and a lower guide and seal
assembly 230. The outer housing 220 is a tubular member including
an upper end 222 and a lower end 224. The internal upper guide
member 210 is a tubular member including an upper end 212 and a
lower end 214. As shown in FIG. 5, an inner surface 215 of the
upper guide 210 includes one or more slots 216 extending from an
intermediate portion of the upper guide 210 to the end 214. In some
embodiments, the slots 216 are milled. In some embodiments, an
axial length 218 of the slots 216 is approximately 6 feet to 10
feet, though this range is exemplary only and other lengths are
contemplated.
[0038] Still referring to FIG. 4, the lower guide 230 is a tubular
member including an upper end 232 and a lower end 234. The upper
end 232 includes outer slots 236 and ribs or splines 237 for
slidably mating with the slots 216, creating the telescoping
arrangement between the upper guide 210 and the lower guide 230
wherein these members reciprocate relative to each other. In some
embodiments, the slots 236 are milled resulting in the splines 237.
In some embodiments, the axial length of the slots 236 and splines
237 is similar to the length 218 such that a stroke 238 is created
between the mating splines 237 and slots 216. The mating splines
237 and slots 216, 236 may also be referred to as anti-rotation
splines. The splines and slots are an interlocking mechanism for
axial movement and anti-rotation. In other embodiments, the
positions of the splines 237 and the slots 216 are reversed,
wherein the splines 237 are disposed on the upper guide 210 and
instead extend into the slots 216 disposed on the lower guide 230.
In some embodiments, other interlocking mechanisms are used between
the telescoping and reciprocal upper guide 210 and lower guide 230
for axial movement and simultaneous prevention of relative rotation
between these two members. While rotation between the two tubular
members 210, 230 in the tool 200 is prevented, it should be
understood that the overall tool 200 may be rotated as part of the
larger tubular string into which the tool 200 is coupled. Thus,
rotating or torquing through the tool 200 is possible via the
anti-rotation mechanism that prevents relative rotation inside the
tool 200.
[0039] The slidably coupled and reciprocating guide members 210,
230 are disposed inside the outer housing 220. Disposed between the
guide members 210, 230 and the outer housing 220 is a sleeve or
layer 270. A portion of the sleeve 270 is disposed between the
guide members 210, 230 over the length of the interlocked splines
and slots. Another portion of the sleeve 270 is disposed between
the lower guide 230 and the outer housing 220. One or more sealing
members or bands 239 may be disposed between the lower guide 230
and the outer housing 220.
[0040] In some embodiments, the sleeve 270 is a layer of non-metal
material disposed between the metal tubulars 210, 230 and metal
tubular 220 to prevent metal to metal contact between these
tubulars. For example, the sleeve 270 comprises a layer of high
strength, high modulus material. In exemplary embodiments, the
sleeve 270 comprises a polyurethane material. In still other
embodiments, the sleeve 270 is a layer of a spray on material, a
bonded on (to one tubular or the other) material, a wrapped on
material, or a combination thereof. In some embodiments, the sleeve
270 is a nano material. In some embodiments, the sleeve 270 is a
composite material. The sleeve 270 is a lubricous, or becomes a
lubricous, material that provides lubricity between the metal
tubular members. The sleeve 270 is a non-cladding material, wherein
bonding or other permanent attachment between the metal tubular
members is prevented. As will be further described herein, the
lubricous material 270 allows relative axial movement of the guide
members 210, 230 and the outer housing 220 of the telescoping tool
assembly 200, both before and after radial expansion and plastic
deformation of the tool assembly. In some embodiments, the sleeve
270 also radially expands to transfer radial expansion loads
between the tubular member 210, 230, and between the tubular
members 220, 230, and act as a seal.
[0041] In some embodiments, the upper end 222 of the outer housing
220 is attached to the upper end 212 of the upper guide member 210,
such as via a hanger connection, a threaded connection or a weld.
In some embodiments, the connection between the outer housing 220
and the upper guide 210 is permanent. The upper end 222 of the
outer housing 220 includes a connector coupled with a connector end
242 of a tubular member 240. The connectors may be threaded to form
a threaded connection 225. In some embodiments, the tubular member
240 is a non expandable oilfield casing or tubing string with a
premium connection. In some embodiments, the tubular member 240 is
expandable. In some embodiments, the outer housing 220 is an
expandable member with a premium connection to form the connection
225.
[0042] The lower end 234 of the lower guide member 230 includes a
connector coupled with a connector end 252 of a tubular member 250.
The connectors may be threaded to form a threaded connection 235.
In some embodiments, the tubular member 250 is a non expandable
oilfield casing or tubing string with a premium connection. In some
embodiments, the tubular member 250 is expandable. In some
embodiments, the lower guide member 230 is an expandable member
with a premium connection to form the connection 235. In some
embodiments, the upper guide member is expandable. A shear
connection 260, such as a shear ring or shear pin, extends through
the outer housing end 224 and the lower guide end 234 to secure the
assembly 200 in the contracted or closed position shown in FIG. 4.
The contracted position may be maintained by the shear connection
260 while the assembly 200 is being lowered into its operating
position such that the assembly 200 does not expand or open before
it is in place.
[0043] In FIG. 4, the expansion tool 200 is shown in the contracted
or closed position. When tensile and/or compressive forces are
created in one or both of the tubing strings 240, 250 due to
thermal or pressure effects therein, the expansion tool is
configured to axially expand or open as shown in FIG. 6. Upon
application of the axial forces from the tubing strings 240, 250,
the shear connection 260 is sheared to release the lower assembly,
comprising the lower guide member 230 coupled to the tubular member
250, from the upper assembly, comprising the upper guide member 210
coupled to the outer housing 220 which is coupled to the tubular
member 240. The lower assembly is then allowed to move axially
relative to the upper assembly, as shown in FIG. 6 and represented
by the strokes 238, 258. More particularly, the lower guide 230
moves axially relative to the upper guide 210, with the
interlocking splines 237 and slots 216, 236 sliding axially against
each other while preventing relative rotation. The non-metal sleeve
or layer 270 prevents metal to metal contact between the
interlocking and sliding splines and slots while also providing one
or more of load transfer, sealing and lubricity. Axial forces
applied in the opposite direction will force the assembly 200 back
toward the contracted position of FIG. 4. Movement between the
contracted and expanded positions of the assembly 200 will absorb
the axial forces that may be detrimental to fixed components of the
well completion system, such as packers, tubing hangers or tubing
anchors.
[0044] In some embodiments, the shear connection 260 is placed at
variable axial positions from that shown. Further, in some
embodiments, the original sheared run-in position of the assembly
200 can be any of various positions between the contracted position
of FIG. 4 and the expanded position of FIG. 6. The pinned, run-in
position may be closed, open, or partially open.
[0045] Referring next to FIG. 7 another embodiment is shown
including a telescoping tool assembly 300 with radially expandable
members. An upper assembly includes an upper guide member 310
coupled to an outer housing 320 which is coupled to an upper
tubular string 340. A lower assembly includes a lower guide member
330 coupled to a lower tubular string 350. The two assemblies are
sheared connected at 360. In some embodiments, the shear connection
360 is located at other axial positions along the assembly 300, to
provide various closed, open, or partially open run-in positions.
Sealing members 339 are coupled between the lower guide 330 and the
outer housing 320. A non-metal sleeve or layer 370 includes axial
lengths disposed between the lower guide 330 and the outer housing
320, and between the lower guide 330 and the upper guide 310 at an
interlocking and sliding anti-rotation mechanism 390. As shown in
FIG. 8, axial forces in the tubing strings 340, 350 will cause the
connection 360 to shear and the upper and lower assemblies to move
axially relative to each other by sliding of the lower guide
splines, as shown in FIG. 11, in the upper guide slots 316, as
shown in FIG. 9. In some embodiments, the splines and slots are
located on opposite members, and other interlocking arrangements
are used to allow reciprocating translation of the upper and lower
guides while preventing rotation. Such an arrangement allows
rotation and torque to be transferred through the tool 300.
[0046] Referring to FIGS. 10 and 11, an end 314 of the upper guide
member 310 (FIG. 10) is configured to received an end 332 of the
lower guide member 330 (FIG. 11). The lower guide member 330
include alternating splines 337 and slots 336. The splines 337
mates with slots 316 milled into the inner surface 315 of the upper
guide member 310. A sealing band 339 is provided on the lower guide
330 for sealing with the upper guide 310. A non-metal sleeve or
layer 370 is provided on the lower guide 330 to each contact with
and transfer loads between the lower guide 330 and the upper guide
310 and outer housing 320.
[0047] Referring now to FIG. 12, a radial cross-section is shown of
the assembly 300 of FIG. 7. The inner, lower guide member 330 is
surrounded by the upper guide member 310. Disposed between the
interlocking splines and slots, as previously described, is the
layer 370. The radial cross-section of the upper guide member 310
of FIGS. 9 and 10, as shown in FIG. 13, illustrates the slots 316
in the inner surface 315. The radial cross-section of the lower
guide member 330 of FIG. 11, as shown in FIG. 14, illustrates the
splines 337 separated by the reduced diameter outer surfaces 336.
FIGS. 15-17 are additional radial cross-sections of the assembly
300 of FIG. 7. In FIG. 15, the lower guide member 330 is surrounded
by the upper guide member 310, with the intervening layer 370
disposed therebetween at the spline/slot arrangements. The outer
housing 320 surrounds and contains the upper guide member 310. In
FIG. 16, a different portion of the layer 370 is shown disposed
between the inner guide member 330 and the outer housing 320. In
FIG. 17, the outer housing 320 is shown surrounding and containing
the upper part of the guide member 310. As previously noted, the
upper end of the outer housing 320 may be attached to the upper end
of the upper guide member 310 via a hanger connection, a threaded
connection or a weld.
[0048] In the expansion tool assemblies 200, 300, an expansion
device may be coupled thereto. An expansion device, such as the
expansion cone 34, may be coupled to the assemblies 200, 300 or to
the tubing strings 240, 250, 340, 350. Other expansion devices are
known and contemplated herein. Before activation of the expansion
device, the telescoping tools may be sheared from their run-in
positions (any one of open, closed, or partially open) and the
tubular guide members may be reciprocated relative to the other
guide member and the outer housing to accommodate axial loads in
the tubing strings. In further embodiments, upon application of a
hydraulic or mechanical driving force, the expansion device is
moved or displaced through the assemblies 200, 300 to radially
expand and plastically deform portions thereof. As described
herein, certain components and connections of the assemblies 200,
300 may be expandable while others are not. These components may be
radially expandable to a plastically deformed position. The tubing
strings 240, 250, 340, 350 may be expandable or non-expandable. In
some embodiments, the assemblies 200, 300 include seals or other
members bonded or attached to the outer surfaces such that the
radially expanded assemblies 200, 300 engage the seals with an
existing exterior structure and provide an anchor hanger. If all or
some of the tubing strings 240, 250, 340, 350 are expanded, the
assemblies 200, 300 may be expanded independently of the tubing
strings or concurrently with the tubing strings. Different
combinations of expandable and non-expandable components and
connections may be used to produce desired results.
[0049] Thus, in the pre-expanded position, the assemblies 200, 300
can support axial tension and compression loads in the tubular
strings. Further, when all or portions of the telescoping tool
assemblies 200, 300 are radially expanded, the assemblies can
continue to accommodate axial tension and compression loads in the
tubular strings by allowing the moveable guide member to telescope
or reciprocate relative to the other guide member and the outer
housing. The radially expanded and plastically deformed tool
assemblies 200, 300 retain their axial expansion or telescoping
functionality. The layers 270, 370 are provided to facilitate the
retained telescoping functionality. The layers 270, 370 provide
lubricity between the moveable joint components, such as between
the moveable guide member and the other guide member and outer
housing. The layers 270, 370 comprise non-cladding materials such
that the moveable guide members are not bonded upon radial
expansion. The layers 270, 370 transfer loads between the assembly
components, such as radial expansion loads from the inner tubular
members to the outer tubular members. The layers 270, 370 provide
sealing characteristics after radial expansion. The layers 270, 370
help maintain component and tool shape after radial expansion. The
tools 200, 300 are re-shaped by radial expansion, and the layers
270, 370 provide a medium for retaining geometric shape after
expansion while also maintaining functionality and operability of
the relatively axially moveable members.
[0050] The assemblies 200, 300, whether radially expanded or not,
by being axially moveable limit or remove axial load constraints
within the tubular or casing string they are coupled to, such as
the strings 240, 250, 340, 350. The assemblies 200, 300 also
support pressures in both the pre- and post-expanded positions.
[0051] In all embodiments, radial expansion and plastic deformation
of at least portions of the assemblies 200, 300 increases the
effective flow area of the system to enable higher injection or
production rates, and decreases restrictions, particularly at the
liner hanger, for the passage of work strings and tools. Upon
radial expansion, the assemblies 200, 300 are still capable of
accommodating axial expansion or contraction loads in the tubular
strings via the relatively moveable guide members. Further, the
sleeves or layers 270, 370 transfer the radial expansion loads from
the inner tubular members to the outer tubular members, in addition
to providing sealing and lubricating characteristics.
[0052] While the disclosure is susceptible to various modifications
and alternative forms, specific embodiments thereof are shown by
way of example in the drawings and description. It should be
understood, however, that the drawings and detailed description
thereto are not intended to limit the disclosure to the particular
form disclosed, but on the contrary, the intention is to cover all
modifications, equivalents and alternatives falling within the
spirit and scope of the present disclosure.
* * * * *