U.S. patent application number 12/788688 was filed with the patent office on 2011-12-01 for system and method for straightening tubing.
Invention is credited to Doug Pipchuk, David P. Smith.
Application Number | 20110289994 12/788688 |
Document ID | / |
Family ID | 45004485 |
Filed Date | 2011-12-01 |
United States Patent
Application |
20110289994 |
Kind Code |
A1 |
Smith; David P. ; et
al. |
December 1, 2011 |
SYSTEM AND METHOD FOR STRAIGHTENING TUBING
Abstract
A technique enables extending the useful life of tubing deployed
in a wellbore. The technique involves routing a damaged or
distorted tubing through a straightening device. The tubing
straightening device bends and counter bends the tubing along
predetermined axes as it passes through the tubing straightening
device. The bending and counter bending are selected so the tubing
exits the straightening device with a predetermined form.
Inventors: |
Smith; David P.; (Sugar
Land, TX) ; Pipchuk; Doug; (Calgary, CA) |
Family ID: |
45004485 |
Appl. No.: |
12/788688 |
Filed: |
May 27, 2010 |
Current U.S.
Class: |
72/164 ;
72/369 |
Current CPC
Class: |
E21B 41/00 20130101;
E21B 19/22 20130101; E21B 19/00 20130101; E21B 17/003 20130101;
E21B 17/206 20130101; B21F 1/02 20130101; E21B 17/1035
20130101 |
Class at
Publication: |
72/164 ;
72/369 |
International
Class: |
B21D 3/02 20060101
B21D003/02 |
Claims
1. A system for facilitating reuse of a communication line carrier,
comprising: a chassis having a carrier tubing inlet and a carrier
tubing outlet through which a carrier tubing passes; a first wheel
set having at least one adjustable wheel which is selectively
positioned to bend the carrier tubing in a first Y-axis direction
after the carrier tubing enters through the carrier tubing inlet; a
second wheel set having at least one adjustable wheel which is
selectively positioned to bend the carrier tubing in a first X-axis
direction; a third wheel set having at least one adjustable wheel
which is selectively positioned to bend the carrier tubing in a
second Y-axis direction generally opposite the first Y-axis
direction; and a fourth wheel set having at least one adjustable
wheel which is selectively positioned to bend the carrier tubing in
a second X-axis direction generally opposite the first X-axis
direction, wherein the degree of bending is selected such that the
carrier tubing exiting the carrier tubing outlet is substantially
straight.
2. The system as recited in claim 1, wherein the carrier tubing
inlet is sized to receive a fiber carrier tubing.
3. The system as recited in claim 1, wherein the bending force
exerted on the carrier tubing by the first wheel set is greater
than the bending force exerted by the third wheel set.
4. The system as recited in claim 3, wherein the bending force
exerted on the carrier tubing by the second wheel set is greater
than the bending force exerted by the fourth wheel set.
5. The system as recited in claim 1, wherein each of the first,
second, third and fourth wheel sets comprises three wheels in which
two of the three wheels are stationary and one of the three wheels
is adjustable.
6. The system as recited in claim 1, wherein each of the at least
one adjustable wheels is manually adjustable.
7. The system as recited in claim 1, wherein each of the at least
one adjustable wheels is automatically adjustable via a control
system.
8. The system as recited in claim 1, wherein each of the at least
one adjustable wheels comprises a circumferential groove sized to
receive the carrier tubing.
9. The system as recited in claim 1, further comprising a shaping
wheel which removes ovality from the carrier tubing.
10. A method of extending the useful life of a carrier tubing,
comprising: selecting a carrier tubing having distortions along its
length; routing the carrier tubing through a tubing straightening
device; and bending and counter bending the carrier tubing along a
plurality of axes as it passes through the tubing straightening
device until the carrier tubing exits the tubing straightening
device with the distortions removed.
11. The method as recited in claim 10, wherein bending and counter
bending comprises bending and counter bending an optical fiber
carrier tubing in both a Y-axis and a substantially perpendicular
X-axis.
12. The method as recited in claim 10, wherein bending and counter
bending comprises routing the carrier tubing through a plurality of
wheel sets, each wheel set having cooperating wheels positioned to
apply a bending force to the carrier tubing.
13. The method as recited in claim 12, further comprising adjusting
at least one wheel of each wheel set to apply the desired bending
force.
14. The method as recited in claim 13, wherein adjusting comprises
of adjusting the at least one wheel of each wheel set such that the
bending force applied during bending is greater than during counter
bending in each of the axes.
15. The method as recited in claim 10, wherein bending and counter
bending comprise substantially straightening the carrier
tubing.
16. The method as recited in claim 15, wherein bending and counter
bending comprise reducing ovality of the carrier tubing.
17. A method, comprising: bending a tubing in directions along a
first axis and along a second axis as the tubing moves through a
tubing straightening device; counter bending the tubing in
directions along the first axis and along the second axis as the
tubing moves through the tubing straightening device; and selecting
the amount of bending and counter bending to provide the tubing
with a predetermined form upon exiting the tubing straightening
device.
18. The method as recited in claim 17, wherein bending comprises
bending the tubing in directions along a Y-axis and along an X-axis
perpendicular to the Y-axis.
19. The method as recited in claim 18, wherein counter bending
comprises counter bending the tubing with less force than applied
during bending.
20. The method as recited in claim 19, wherein counter bending
comprises counter bending after first bending the tubing along both
the Y-axis and the X-axis.
21. The method as recited in claim 17, wherein bending comprises
bending a fiber carrier tubing with a diameter equal to or less
than 0.25 inch.
22. The method as recited in claim 17, wherein bending comprises
bending a fiber carrier tubing having a diameter equal to or less
than 0.1 inch.
23. The method as recited in claim 17, further comprising injecting
the tubing into a coiled tubing string and deploying the coiled
tubing string in a wellbore.
24. The method as recited in claim 17, wherein selecting comprises
providing the tubing with a reduced ovality.
Description
BACKGROUND
[0001] The statements in this section merely provide background
information related to the present disclosure and may not
constitute prior art. In many types of well related operations,
various types of tubing are deployed downhole into a wellbore.
Smaller diameter tubing, e.g. control lines, may be used in
conjunction with larger diameter tubing, e.g. production or coiled
tubing. For example, control lines may be deployed within or along
a coiled tubing string to facilitate the transmission of signals
along the wellbore. In some applications, control lines utilize a
carrier tubing for enclosing a signal carrier, such as an optical
fiber. However, many of these types of tubing are susceptible to
being bent or otherwise deformed during operations and/or during
movement into and out of the wellbore. If sufficiently bent or
otherwise damaged, the tubing may not be available for reuse.
SUMMARY
[0002] In general, the present disclosure provides a system and
method for extending the useful life of tubing deployed in a
wellbore. Initially, a damaged or distorted tubing is selected, and
the tubing is routed through a straightening device. The tubing
straightening device bends and counter bends the tubing along
predetermined axes as it passes through the tubing straightening
device. The bending and counter bending are selected so the tubing
exits the straightening device with a predetermined form, e.g. a
straightened form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] Certain embodiments of the invention will hereafter be
described with reference to the accompanying drawings, wherein like
reference numerals denote like elements, and:
[0004] FIG. 1 is a schematic illustration of one embodiment of a
tubing straightening device;
[0005] FIG. 2 is a schematic illustration similar to that of FIG. 1
but with additional features;
[0006] FIG. 3 is a schematic representation of a bending regimen
useful in straightening certain types of tubing;
[0007] FIG. 4 is an illustration of one embodiment of a
straightening station wheel acting on tubing passing through the
tubing straightening device; and
[0008] FIG. 5 is a flowchart providing one example of a procedure
which may be employed to straighten tubing with the tubing
straightening device.
DETAILED DESCRIPTION
[0009] In the following description, numerous details are set forth
to provide an understanding of the present invention. However, it
will be understood by those of ordinary skill in the art that the
present invention may be practiced without these details and that
numerous variations or modifications from the described embodiments
may be possible.
[0010] The present disclosure generally relates to a system and
method for extending the useful life of certain types of tubing
employed in downhole applications. For example, the technique
enables returning control line tubing, e.g. fiber carrier tubing,
to a form which allows continued use in subsequent downhole
applications. In many well related operations, deployment and use
of tubing downhole creates bends or other distortions in the
tubing, and those distortions can be substantially removed by
employing the methodology described herein.
[0011] In one embodiment, a tubing straightening device is used to
return a distorted length of tubing to its original shape by
re-straightening the distorted length of tubing. The technique may
be designed to correct many types of distortions in several types
of tubing, e.g. control line tubing. One embodiment employs the
tubing straightening device to straighten optical fiber carrier
tubing, such as fiber carrier tubing formed from Inconel.TM. or
from a variety of other materials, including other metal tubing
materials. Once straightened, the fiber carrier tubing can be
reinjected into a coiled tubing string and reused as opposed to
purchasing a new spool of fiber carrier tubing for injection into
the coiled tubing string.
[0012] According to one application, the tubing straightening
device comprises a series of stations mounted along a rigid
chassis. Each of the stations is designed to bend the tubing in a
direction along a predetermined axis as the tubing is moved through
the tubing straightening device. In one specific embodiment, the
series of stations comprises a series of roller or wheel sets which
subject the tubing to a sequence of bending cycles and cause the
tubing to straighten before exiting the tubing straightening
device. The series of wheel sets may comprise a series of four
wheel sets which bend and counter bend the tubing along two
distinct axes, e.g. a Y-axis and an X-axis. The wheel sets are
adjustable to bend and counter bend the tubing in the desired
sequence of directions regardless of how the tubing enters the
tubing straightening device. In some applications, the final two
wheel sets are employed to "set the bend" which results in a
straight tube upon exit.
[0013] Referring generally to FIG. 1, one embodiment of a system 20
for straightening a tubing 22 is illustrated. In this embodiment,
system 20 comprises a tubing straightening device 24 which returns
the tubing 22 to a desired form as the tubing 22 is passed through
device 24. By way of example, tubing 22 enters the tubing
straightening device 24 as a distorted, e.g. bent, tubing (as
represented by reference character 26) and exits tubing
straightening device 24 in a desired form, e.g. a straight tube (as
represented by reference character 28). The tubing 22 may be
control line tubing, such as a communication line carrier. In one
embodiment, tubing 22 is a small diameter communication line
carrier in the form of an optical fiber carrier tubing.
[0014] In the embodiment illustrated, tubing straightening device
24 comprises a chassis 30 having a tubing inlet 32 through which
tubing 22 enters and a tubing outlet 34 through which tubing 22
exits the tubing straightening device. Tubing straightening device
24 further comprises a plurality of stations 36 which are designed
to manipulate the tubing 22 in a manner that removes the undesired
distortions, e.g. bends and/or remove local deformations on the
tubing 22. The number, arrangement and type of stations 36 can be
altered according to the type of tubing 22 being reconditioned.
However, in one embodiment of the tubing straightening device 24,
the stations 36 each comprise a roller or wheel set 38.
[0015] Each wheel set 38 comprises a plurality of wheels 40 through
which tubing 22 is passed. The wheels 40 are positioned to bend the
tubing 22 to a desired degree and in a desired direction. The
desired bending at each sequential wheel set 38 may be achieved by
forming at least one of the wheels 40 as an adjustable wheel 42
while the other wheels 40 are mounted in a stationary position on
chassis 30. In the illustrated embodiment, the desired bending is
achieved at each wheel set 38 by utilizing one adjustable wheel 42
which acts on the tubing 22 between two stationary wheels 40 as the
tubing 22 is passed through that specific wheel set 38.
[0016] The adjustable wheel 42 may be moved toward or away from the
cooperating stationary wheels 40 to apply a greater or lesser
bending force for reconditioning the tubing 22. Movement of each
adjustable wheel 42 may be accomplished by a corresponding actuator
44 which may be a manual or powered actuator. In one example, each
actuator 44 is a mechanical actuator, such as a ball and screw
actuator or a stepper motor actuator.
[0017] In the embodiment illustrated in FIG. 1, the actuators 44
are oriented in different directions relative to each other to
apply desired bending forces to the tubing 22, via wheels 42, in
corresponding directions. By way of example, the actuators 44 and
wheel sets 38 may be positioned to enable bending and counter
bending of the tubing 22 along a plurality of different axes. In
the specific example illustrated, tubing 22 moves into the first
station 36 and a bending force is applied to the tubing 22 in a
direction along a first axis. From the first station 36, the tubing
22 is directed through a second station 36 which applies a bending
force to the tubing 22 in a direction along a second axis, e.g. a
perpendicular axis. From the second station 36, the tubing 22 is
directed to a third station 36 which applies a counter bending
force to the tubing 22 in an opposite direction along the first
axis. Subsequently, the tubing 22 is directed from the third
station to a fourth station 36 which applies a counter bending
force to the tubing 22 in an opposite direction along the second
axis. In this example, the sequential and controlled bending of
tubing 22 creates a straight tube which exits tubing straightening
device 24 through tubing outlet 34.
[0018] Movement of tubing 22 through tubing straightening device 24
may be facilitated by a feeder mechanism 46, as illustrated in FIG.
2. The feeder mechanism 46 is employed to guide the deformed tubing
26 into tubing inlet 32 of tubing straightening device 24. A puller
mechanism 48 also may be used to provide a pulling force which
helps move tubing 22 through tubing straightening device 24. In
some applications, actuators 44 may be in the form of automated
actuators controlled by a control system 50. For example, control
system 50 may be a processor based control system which may be
programmed to automatically adjust the actuators 44 to apply
desired bending forces to the tubing 22 at each sequential station
36.
[0019] In one specific embodiment, the tubing 22 undergoes bending
and counter bending in directions along both a Y-axis and an
X-axis, as illustrated in FIG. 3. In this embodiment, the distorted
tubing, e.g. distorted carrier tubing, is fed into tubing
straightening device 24 through tubing inlet 32 and routed through
the first wheel set 38. The first wheel set bends the tubing 22 in
a direction along the -Y axis relatively aggressively, as
represented by arrow 52. This bending action pre-forms the tubing
22 in the -Y axis direction, thereby removing any opposing Y axis
residual bend it may have had before entering tubing straightening
device 24. The bending at the first wheel set 38 pre-shapes the
Y-axis of the tubing 22.
[0020] Subsequently, tubing 22 is routed through the second wheel
set 38 between the adjustable and stationary wheels 40. The second
wheel set bends the tubing 22 in a direction along the -X axis
relatively aggressively, as represented by arrow 54. This bending
action pre-forms the tubing 22 in the -X axis direction, removing
any opposing X axis residual bend it may have had before entering
tubing straightening device 24.
[0021] The tubing 22 is then routed through the third wheel set 38,
which is oriented and adjusted to counter bend tubing 22 in a
direction along the +Y axis, as represented by arrow 56. The
tension or bending force applied by the third wheel set 38 may be
somewhat less than applied by the first and second wheel sets 38.
Because the residual bend of the tubing 22 is known at this point
in the tubing straightening device 24, the tension/bending force
applied by the third wheel set 38 is selected to neutralize the Y
axis residual bend of the tubing 22.
[0022] After leaving the third wheel set 38, tubing 22 is routed
through the fourth wheel set 38, which is oriented and adjusted to
counter bend tubing 22 in a direction along the +X axis, as
represented by arrow 58. The tension or bending force applied by
the fourth wheel set 38 also may be somewhat less than applied by
the first and second wheel sets 38. Because the residual bend along
this axis of the tubing 22 also is known at this point in the
tubing straightening device 24, the tension/bending force applied
by the fourth wheel set 38 is selected to neutralize the X axis
residual bend of the tubing 22. As a result, a straightened tubing
22 or 28 having a generally linear form is delivered through tubing
outlet 34. The operation of the stations 36 and/or wheel sets 38 of
straightening device 24 also advantageously removes local
deformations from the tubing 22. The straightened tubing can be
reinjected into coiled tubing or otherwise reused in a downhole
application.
[0023] Although a variety of wheels, e.g. rollers, and other
devices may be used to apply desired bending forces to tubing 22 in
directions along predetermined axes, one embodiment of a suitable
wheel 40 is illustrated in FIG. 4. In this embodiment, each wheel
40 comprises a circumferential groove 60 along its face. Groove 60
is sized to receive tubing 22 and, in some applications, maybe
slightly larger than the tubing 22 being straightened (or being
returned to another desired form). The groove 60 aids in
maintaining the tubing 22 in a desired alignment during the
straightening process.
[0024] One or more of the wheels 40 also may be used in cooperation
with a shaping mechanism 62, such as a shaping wheel. The shaping
mechanism 62 works in concert with the wheel 40 to provide a
desired cross-sectional shape to the tubing 22. For example, the
shaping mechanism 62 may be in the form of a wheel having a shaping
groove 64 to correct any undesired ovality of the tubing 22. If,
for example, the tubing 22 has been deformed to an undesirable oval
shape, the tubing 22 may be passed along or through an appropriate
shaping mechanism 62 to return the tubing 22 to a more circular
cross-sectional shape. In some applications, the shaping mechanism
62 works in cooperation with one or more of the wheels 40, or is
constructed as a separate opposing wheel set, to provide sufficient
force for reshaping the tubing 22 and returning it toward its
original round shape.
[0025] Referring generally to the flowchart of FIG. 5, one example
of an operational procedure for straightening tubing, e.g. fiber
carrier tubing, is illustrated. In this particular embodiment, a
control line tubing 22, such as a fiber carrier tubing, is
initially selected for straightening, as represented by block 66.
The tubing 22 is then fed into straightening device 24 through
tubing inlet 32, as represented by block 68. The tubing is moved
through the first station 36 and is bent in a first direction along
a first axis, as represented by block 70.
[0026] The tubing 22 is then routed through the second station 36
which bends the tubing in a second direction along a second axis,
as represented by block 72. As the tubing continues to move through
straightening device 24, it is routed through the third station 36
which counter bends the tubing in an opposite direction along the
first axis, as represented by block 74. Similarly, the tubing 22 is
passed through the fourth station 36 which also counter bends the
tubing but in an opposite direction along the second axis, as
represented by block 76. After the fourth station, the tubing 22 is
discharged through tubing outlet 34 as a straightened tubing for
reuse, as represented by block 78.
[0027] The tubing straightening device 24 may be employed to
recondition and remove local deformations from a variety of tubing
types for use in many well related applications. The tubing
straightening device 24 is particularly amenable for use in
straightening and/or removing location deformations from relatively
small tubes of formable material, e.g. metallic material. For
example, control lines are often formed of metal with relatively
small diameters, e.g. diameters equal to or less than 0.25 inch.
Fiber carrier tubing often is formed from materials that may be
shaped, e.g. metal materials and metal alloys, e.g. Inconel.TM.,
having small diameters of, for example, less than 0.10 inch. In
some applications, the straightening device 24 also may be employed
to reconditioned tubes having larger diameters.
[0028] Additionally, tubing straightening device 24 may be
constructed in alternate configurations depending on various
factors, such as tubing size, tubing material, type of distortion,
and desired finished form. For example, the number of stations
mounted along the chassis may be adjusted to accommodate the
reconditioning requirements of a given tubing. Wheels or other
mechanisms may be employed to provide the bending forces used to
bend the tubing along desired axes as the tubing moves through the
straightening device. The tubing also may undergo bending/counter
bending in negative and/or positive directions along two or more
axes. Various feeders and pulling mechanisms may be used in
combination with the straightening device to enable controlled
movement of the tubing through the straightening device.
Additionally, various types of mechanical and/or automated
actuators may be used to apply the desired bending forces to the
tubing at each station. In many applications, the applied bending
force varies between stations and is selected according to the
types of tubing and types of distortions being reconditioned.
[0029] Accordingly, although only a few embodiments of the present
invention have been described in detail above, those of ordinary
skill in the art will readily appreciate that many modifications
are possible without materially departing from the teachings of
this invention. Such modifications are intended to be included
within the scope of this invention as defined in the claims.
* * * * *