U.S. patent application number 15/529394 was filed with the patent office on 2017-11-16 for method and system for installing a tubular element in a borehole.
The applicant listed for this patent is SHELL OIL COMPANY. Invention is credited to Walter STAM, Egbert Jan VAN RIET.
Application Number | 20170328184 15/529394 |
Document ID | / |
Family ID | 52146121 |
Filed Date | 2017-11-16 |
United States Patent
Application |
20170328184 |
Kind Code |
A1 |
STAM; Walter ; et
al. |
November 16, 2017 |
METHOD AND SYSTEM FOR INSTALLING A TUBULAR ELEMENT IN A
BOREHOLE
Abstract
A radially expandable tubular element (1) is installed in an
underground borehole by:--lowering the tubular element (1) into the
borehole a work string (2) and an anchor tool (16) to which the
tubular element (1) is connected via a dimple connection (32) to
increase the weight carrying capacity of the anchor tool
(16);--connecting an expander (14) to the work string (2) at a
position below the anchor tool (16); and--radially expanding the
tubular element (1) by pulling the expander (14) on the work string
(2) through the tubular element (1).
Inventors: |
STAM; Walter; (Rijswijk,
NL) ; VAN RIET; Egbert Jan; (Rijswijk, NL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SHELL OIL COMPANY |
Houston |
TX |
US |
|
|
Family ID: |
52146121 |
Appl. No.: |
15/529394 |
Filed: |
December 9, 2015 |
PCT Filed: |
December 9, 2015 |
PCT NO: |
PCT/EP2015/079155 |
371 Date: |
May 24, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B 23/01 20130101;
E21B 43/103 20130101; E21B 43/105 20130101 |
International
Class: |
E21B 43/10 20060101
E21B043/10; E21B 23/01 20060101 E21B023/01 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 12, 2014 |
EP |
14197684.5 |
Claims
1. A method of installing a radially expandable tubular element in
an underground borehole comprises the steps of: (a) positioning in
the tubular element an anchor tool having a cylindrical outer
surface provided with at least one dimple; (b) operating a pressing
device to press a respective wall portion of the tubular element
into the at least one dimple to create a dimple connection between
the tubular element and the anchor tool; (c) providing a work
string connected to the anchor tool; (d) operating a drive device
to lower the tubular element into the borehole on the work string
when the tubular element is connected to the anchor tool via the
dimple connection; (e) connecting an expander to the work string at
a position below the anchor tool; and (f) radially expanding the
tubular element by pulling the expander on the work string through
the tubular element.
2. The method of claim 1, wherein the step of operating the
pressing device comprises pressing a die member against said wall
portion of the tubular element, the die member having an end
portion with a shape similar to the shape of the dimple.
3. The method of claim 1, further comprising releasing the anchor
tool from the tubular element by inducing the drive device to move
the work string in at least one of axial and rotational direction
relative to the tubular element to deform each said wall portion to
a shape substantially similar to the shape of the wall portion
prior to the step of operating the pressing device.
4. A system for installing a radially expandable tubular element in
an underground borehole, the system comprising: (a) an anchor tool
adapted to be positioned in the tubular element and having a
cylindrical outer surface provided with at least one dimple; (b) a
pressing device for pressing a respective wall portion of the
tubular element opposite the at least one dimple into the dimple,
to create a dimple connection between the tubular element and the
anchor tool; (c) a work string connected to the anchor tool; (d) a
drive device for lowering the tubular element into the borehole on
the work string when the tubular element is connected to the anchor
tool via the dimple connection; (e) means for connecting an
expander to the work string at a position below the anchor tool;
and (f) means for radially expanding the tubular element by pulling
the expander on the work string through the tubular element.
5. The system of claim 4, wherein the at least one dimple has a
first surface and a second surface arranged opposite each other and
extending in circumferential direction of the anchor tool, said
first and second surfaces having mutually different inclination
angles relative to the cylindrical outer surface.
6. The system of claim 5, wherein the first surface extends at an
inclination angle .alpha.1 and the second surface at an inclination
angle .alpha.2 relative to the cylindrical outer surface, the first
surface facing upwardly in the borehole.
7. The system of claim 6, wherein .alpha.1>.alpha.2.
8. The system of claim 6, wherein a rounded transition surface
extends between the second surface and the cylindrical outer
surface.
9. The system of claim 5, wherein the dimple has a bottom surface
located between the first surface and the second surface, the
bottom surface extending substantially parallel to a longitudinal
axis of the anchor tool.
10. The system of claim 9, wherein the bottom surface has a
truncated V-shape.
11. The system of claim 4, wherein the cylindrical outer surface of
the anchor tool is provided with a plurality of said dimples spaced
in circumferential direction of the anchor tool.
12. The system of claim 4, wherein the pressing device includes a
die member having an end portion with a shape similar to the shape
of the dimple.
13. The system of claim 12, wherein the pressing device comprises
positioning means connectable to the anchor tool and adapted to
move the anchor tool relative to the die member so that the dimple
is located opposite the die member.
14. The system of claim 4, wherein the tubular element is a
radially expandable tubular element, and wherein the system further
comprises an expander for radially expanding the tubular element by
axially moving the expander through the tubular element, the
expander being connected to the work string at a position below the
anchor tool.
Description
[0001] The present invention relates to a system and a method for
installing a tubular element in a borehole extending into an earth
formation
[0002] Wellbores for the production of hydrocarbon fluid generally
are provided with steel casings and/or liners to provide stability
to the wellbore wall and to prevent undesired flow of fluid between
the wellbore and the surrounding earth formation. A casing
generally extends from surface into the wellbore, whereas a liner
may extend only a lower portion of the wellbore. However in the
present description the terms "casing" and "liner" are used
interchangeably and without such intended difference.
[0003] In a conventional wellbore, the wellbore is drilled in
sections whereby each section is drilled using a drill string that
has to be lowered into the wellbore through a previously installed
casing. In view thereof the wellbore and the subsequent casing
sections decrease in diameter with depth. The production zone of
the wellbore therefore has a relatively small diameter in
comparison to the upper portion of the wellbore. In view thereof it
has been proposed to drill a "mono diameter" wellbore whereby the
casing or liner to be installed is radially expanded in the
wellbore after lowering to the required depth. Subsequent wellbore
sections may therefore be drilled at a diameter larger than in the
conventional wellbore. If each casing section is expanded to the
same diameter as the previous section, the wellbore diameter may
remain substantially constant with depth.
[0004] US-2006/0065403-A1 discloses an assembly for expanding a
tubular element in a wellbore, whereby the tubular element is
suspended during running-in into the wellbore on a work string
having an expander at its lower end, and whereby the tubular
element passes through an existing casing in the wellbore. There is
a risk that the lower end of the tubular element is prematurely
expanded by the expander, for example if the weight of the tubular
element causes the tubular element to slip downward relative to the
work string. Such unintended expansion may hamper, or prevent,
lowering of the tubular element through the existing casing.
[0005] Other prior art anchoring systems are known from US patent
applications 2007/000669; 2008/041596 and 2006/196654 and
International patent application WO/196654, which have the risk
that the tubular element unintentially slips down and is
prematurely released from the work string.
[0006] It is an object of the invention to provide an improved
method and system for installing a tubular element in a borehole
extending into an earth formation, which overcome or alleviate
drawbacks of the prior art.
[0007] The invention provides a method of installing a radially
expandable tubular element in an underground borehole comprising
the steps of:
[0008] (a) positioning in the tubular element an anchor tool having
a cylindrical outer surface provided with at least one dimple;
[0009] (b) operating a pressing device to press a respective wall
portion of the tubular element into the at least one dimple to
create a dimple connection between the tubular element and the
anchor tool;
[0010] (c) providing a work string connected to the anchor
tool;
[0011] (d) operating a drive device to lower the tubular element
into the borehole on the work string when the tubular element is
connected to the anchor tool via the dimple connection;
[0012] (e) connecting an expander to the work string at a position
below the anchor tool; and
[0013] (f) radially expanding the tubular element by pulling the
expander on the work string through the tubular element.
[0014] The invention also provides a system for installing a
radially expandable tubular element in an underground borehole, the
system comprising:
[0015] (a) an anchor tool adapted to be positioned in the tubular
element and having a cylindrical outer surface provided with at
least one dimple;
[0016] (b) a pressing device for pressing a respective wall portion
of the tubular element opposite the at least one dimple into the
dimple, to create a dimple connection between the tubular element
and the anchor tool;
[0017] (c) a work string connected to the anchor tool;
[0018] (d) a drive device for lowering the tubular element into the
borehole on the work string when the tubular element is connected
to the anchor tool via the dimple connection;
[0019] (e) means for connecting an expander to the work string at a
position below the anchor tool; and
[0020] (f) means for radially expanding the tubular element by
pulling the expander on the work string through the tubular
element.
[0021] According to the method and system of the invention, the
weight carrying capacity of the work string is increased by virtue
of the dimple connection between the tubular element and the anchor
tool. The dimple connection carries at least a portion of the
weight of the tubular element during installation in the borehole.
Furthermore, the dimple connection may be released easily by
pulling up the work string, or pushing down the work string,
through the tubular element after installation in the borehole
whereby each wall portion is deformed back to substantially the
original shape.
[0022] Suitably, each dimple has first and second surfaces arranged
opposite each other and extending in circumferential direction of
the anchor tool, said surfaces having mutually different
inclination angles relative to the cylindrical outer surface. It is
thereby achieved that the dimple connection has a high load
carrying capacity in one axial direction and may be released easily
in the other axial direction. For example, the first surface may
extend at an inclination angle .alpha.1 and the second surface at
an inclination angle .alpha.2 relative to the cylindrical outer
surface, the first surface facing upwardly in the borehole, and
wherein .alpha.1>.alpha.2. Furthermore, the dimple connection
may be released more easily if a rounded transition surface extends
between the second surface and the cylindrical outer surface.
[0023] Suitably the dimple has a bottom surface located between
said first and second surfaces, the bottom surface extending
substantially parallel to a longitudinal axis of the anchor tool.
To increase the torque transmission capacity of the dimple
connection the bottom surface may have a truncated V-shape.
[0024] The cylindrical outer surface of the anchor tool is
advantageously provided with a plurality of said dimples spaced in
circumferential direction of the anchor tool.
[0025] Suitably the pressing device includes a die member having an
end portion with a shape similar to the shape of the dimple. To
accurately position the die member relative to the anchor tool, the
pressing device may comprise positioning means connectable to the
anchor tool and adapted to move the anchor tool relative to the die
member so that the dimple is located opposite the die member.
[0026] In an embodiment, the tubular element is a radially
expandable tubular element and the system further comprises an
expander for radially expanding the tubular element by axially
moving the expander through the tubular element, the expander being
connected to the work string at a position below the anchor
tool.
[0027] The anchor tool may be released from the tubular element by
inducing the drive device to move the work string in axial and/or
rotational direction relative to the tubular element so as to
deform each said wall portion to a shape substantially similar to
the shape of the wall portion prior to step (2) of the method.
[0028] The invention will be described hereinafter in more detail
and by way of example with reference to the accompanying schematic
drawings in which:
[0029] FIG. 1 shows an exemplary embodiment of the system of the
invention, partially in longitudinal section;
[0030] FIG. 2 shows a lower portion of an expansion string of the
exemplary embodiment, partially in longitudinal section;
[0031] FIG. 3 shows an anchor tool of the exemplary embodiment;
[0032] FIG. 4 shows cross-section 4-4 of FIG. 3;
[0033] FIG. 5 shows a pressing device used with the exemplary
embodiment;
[0034] FIG. 6 shows a perspective view of a die member of the
pressing device;
[0035] FIG. 7 shows the die member after pressing a wall portion of
the tubular element into a dimple of the anchor tool; and
[0036] FIG. 8 shows an alternative die member.
[0037] In the detailed description and the figures, like reference
numerals relate to like components.
[0038] FIGS. 1 and 2 show an assembly including a tubular element 1
adapted to be radially expanded in a wellbore (not shown) and a
work string in the form of expansion string 2 for radially
expanding the tubular element in the wellbore. The expansion string
2 includes from bottom to top: a mandrel 4, a far-cone centralizer
6, a debris catcher 7 and an on-off sub 8 having lower and upper
parts 8a, 8b. The on-off sub 8 connects the expansion string to the
lower end of a drill pipe 10 and is adapted to be disconnected by
rotation of the drill pipe 10 relative to the mandrel 4.
[0039] The mandrel 4 is provided with, from bottom to top: a lock
nut 12, an expander in the form of expansion cone 14, an anchor
tool 16 and a near-cone centralizer 18. The expansion cone 14, the
anchor tool 16 and the near-cone centralizer 18 have respective
central passages 19, 20, 21 through which the mandrel 4 extends.
The mandrel can slide through the passages 19 to 21.
[0040] The lock nut 12 is screwed to the mandrel 4 so as to lock
the assembly of expansion cone 14, anchor tool 16 and near-cone
centralizer 18 in place whereby the near-cone centralizer abuts
against a shoulder 22 of the mandrel 4. Furthermore, the expansion
cone 14 is rotationally locked to the anchor tool 16 by a
castellated connection 24, the anchor tool 16 is rotationally
locked to the near-cone centralizer 18 by a castellated connection
25, and the near-cone centralizer 18 is rotationally locked to the
shoulder 22 of mandrel 4 by a castellated connection 26.
[0041] Alternatively the anchor tool 16 may be directly
rotationally locked to the mandrel 4 by means of key slots formed
in the anchor tool 16 and mandrel 4, with keys fitting in such key
slots. This way the castellated connections 24, 25 may be
eliminated.
[0042] The expansion cone 14 has a nose portion of diameter
substantially equal to the inner diameter of the unexpanded tubular
element 1. The diameter of the expansion cone 14 gradually
increases from the nose portion in downward direction to a diameter
corresponding to a desired expansion ratio of the tubular element
1. The nose portion is provided with an annular seal 28 of
resilient material. Furthermore the tubular element 1 has an
outwardly flaring end section 29 adapted to receive the expansion
cone 14, with the largest outer diameter of the end section 29
being less than, or equal to, the largest outer diameter of the
expansion cone 14.
[0043] The anchor tool 16 has a cylindrical outer surface 30 of
diametrical size allowing the anchor tool 16 to snugly fit into the
tubular element 1. A plurality of dimples 32 are formed in the
cylindrical outer surface 30, the dimples being regularly spaced
along the circumference of the anchor tool. At each dimple 32, a
corresponding wall portion 34 of the tubular element 1 extends into
the dimple 32 so as to axially and rotationally lock the anchor
tool to the tubular element.
[0044] FIGS. 3, 4 show the anchor tool 16 in more detail. Each
dimple 32 has first and second surfaces 35a, 35b oppositely
arranged and extending in circumferential direction of the anchor
tool. The surfaces 35a, 35b are inclined relative to the
cylindrical outer surface 33 at respective inclination angles
.alpha.1, .alpha.2. A bottom surface 36 is located between the
first and second surfaces 35a, 35b, which bottom surface extends
substantially parallel to a longitudinal axis 37 of the anchor
tool. Rounded surface portions 38a, 38b extend at the transition
between the cylindrical outer surface 33 and the respective first
and second surfaces 35a, 35b. The surface portions 38a, 38b have
rounding radius R.
[0045] FIGS. 5 to 7 show a pressing device 40 for pressing, at each
dimple 32, the respective wall portion 34 of the tubular element 1
into the dimple 32 so as to create a dimple connection between the
tubular element 1 and the anchor tool 16. The pressing device 40
comprises a housing 44 having a longitudinal bore 46 into which a
lower section 47 of the tubular element 1 snugly fits. The pressing
device 40 further comprises a die member 48 positioned in a radial
bore 49 of the housing 44 in slidable manner. The die member 48 has
an end portion 50 facing the tubular element 1, with inclined
surfaces 52a, 52b and bottom surface 52c so as to have a shape
similar to the shape of the dimple 32. The anchor tool 16 is
arranged inside the tubular element 1 whereby the dimple 32 is
positioned opposite the end portion 50 of die member 48. The
pressing device 40 optionally further comprises a positioning
assembly including a plate 53 and a cylinder 54 to be arranged
inside the anchor tool 16. The cylinder 54 may be axially and
rotationally locked to the anchor tool 16 by a flange abutting one
end of the anchor tool and bolts 56 interconnecting the cylinder 54
and the plate 53.
[0046] FIG. 8 shows a die member 60 that is largely similar to the
die member 48, except that inclined surfaces 52a, 52b do not extend
parallel to each other so that bottom surface 52c has a truncated
V-shape.
[0047] During normal operation the anchor tool 16 is inserted into
the lower tubular section 47, and the assembly is then arranged in
the longitudinal bore 46 of the pressing device 40 whereby it is
ensured that the bottom surface 36 of the dimple is parallel to,
and in line with, the bottom surface 52c of the die member 48.
Optionally the cylinder 54, plate 53 and bolts 56 may be used to
accurately position the anchor tool 16 so that the dimple 32 is
exactly opposite the die member 48.
[0048] The pressing device 40 is then operated to induce die member
48 to press the wall portion 34 of the tubular element into the
dimple 32 until the inside of the wall portion 34 contacts the
bottom surface 36 of the dimple. This procedure is repeated for all
dimples 32 whereby each time the tubular element 1 with the anchor
tool 16 inside is rotated relative to the pressing device so as to
position the next dimple 32 opposite the die member 48. In this
manner a dimple connection is obtained between the lower tubular
section 47 and the anchor tool 16. Any suitable power source may be
used to operate the pressing device, for example hydraulic power,
electrical power or mechanical power. In a next step the lower
tubular section 47 is removed from the pressing device 40 and the
positing assembly, if used, is removed from the anchor tool 16.
[0049] The near-cone centralizer 18 is then fitted to the mandrel 4
so that the near-cone centralizer 18 abuts against shoulder 22 and
is rotationally locked to the mandrel 4 by castellated connection
26. Then the anchor tool 16, with the lower tubular section 47
connected thereto, is fitted to the mandrel 4 until the anchor tool
abuts the near-cone centralizer. Subsequently the expansion cone 14
is fitted to the mandrel 4 until the nose portion of the expansion
cone 14 abuts the anchor tool 16. Then the lock nut 12 is screwed
to the mandrel 4 so as to axially lock the expansion cone 14, the
anchor tool 16 and the near-cone centralizer 18 to the mandrel 4.
The mandrel 4 is then connected to the far-cone centralizer 6, the
debris catcher 7 and to the lower end of drill pipe 10 via on-off
sub 8 as shown in FIG. 1.
[0050] Subsequently the assembly is run into the wellbore whereby
drill pipes are added to form the expansion string 2, and tubular
joints are added to form the tubular element 1 in correspondence
with the depth of lowering.
[0051] During running-in the assembly into the wellbore the weight
of the tubular element 1 is transferred to the expansion string 2
via the dimple connection between the anchor tool 16 and the lower
tubular section 47, and via the contact between the outwardly
flaring end section 29 of tubular element 1 and the expansion cone
14. Rotary torque required for making-up the on-off sub 8, or for
reaming the wellbore while running-in is transferred from the
mandrel 4 via the castellated connection 26 to the near-cone
centralizer 18, then via the castellated connection 25 to the
anchor tool 16, and then via the dimple connection to the tubular
element 1.
[0052] If the tubular element needs to be pushed in downward
direction to overcome friction between the tubular element 1 and
the wellbore wall, for example in an inclined borehole section, the
required downward force is also transmitted to the tubular element
via the dimple connection.
[0053] After the tubular element 1 has reached the target depth in
the wellbore, the dimple connection between anchor tool 16 and
tubular element 1 is released. This may be done by moving the
expansion string 2 upward or downward while the tubular element 1
is kept stationary in the wellbore. In this manner each wall
portion 34 of the tubular element is moved out of the respective
dimple 32 whereby the wall portion is subjected to plastic and/or
elastic deformation. Such deformation is facilitated by the
inclined surfaces 35a, 35b and the rounded surface portions 38a,
38b. Generally, the dimple connection is released more easily for
smaller inclination angles .alpha.1 and .alpha.2 and/or for larger
values of R. Instead of, or in addition to, releasing the dimple
connection by axial movement of the expansion string 2 relative the
tubular element 1, the dimple connection may be released by
rotating the expansion string 2 relative the tubular element 1.
[0054] In the present example the inclination angles .alpha.1 and
.alpha.2 are equal. However the surfaces 35, 35b may have different
inclination angles. For example, since surface 35a must carry a
relatively large portion of the weight of the tubular element 1
during lowering into the wellbore, angle .alpha.1 may be selected
larger than angle .alpha.2 in order to increase the load carrying
capacity of surface 35a. In such application the inclination angle
.alpha.2 is relatively small, therefore the dimple connection may
be released relatively easy by moving the expansion string 2
downward while the tubular element 1 is kept stationary.
[0055] Once the dimple connection is released, radial expansion of
the tubular element 1 is started by pulling the expansion string 2
upwardly through the tubular element.
[0056] If the expansion cone 14 gets stuck in the tubular element 1
during the expansion process, for example with the expansion cone
in a section of overlap of the tubular element 1 with another
tubular element, the drill pipe has to be disconnected from the
expansion string 2 by breaking out the on-off sub 8. The required
break-out torque is transmitted from the drill pipe 10 via the
on-off sub 8 to the mandrel 4, then via the castellated connections
26, 25, 24 to the expansion cone 14, and finally via the face of
the expansion cone 14 to the tubular element 1.
[0057] The load carrying capacity of the dimple connection is
selected such that the force required to release the dimple
connection by upward movement of the anchor tool relative to the
tubular element exceeds the buoyant weight of the tubular element
in a vertical borehole. In this manner premature plastic
deformation of the tubular element is prevented.
[0058] Instead of the tubular shaped anchor tool 16 described
above, the anchor tool may be formed as a massive cylinder that is
integrally formed with the mandrel 4 or connected to the mandrel in
any suitable manner.
[0059] Design parameters for the anchor tool may be based on the
dimple length L, depth D, angle .alpha.1 and/or .alpha.2 and
round-off radius R (FIG. 4). For example, axial load capacity may
be increased by providing more dimples, increasing .alpha.1 and/or
.alpha.2, or increasing depth D. Torsional load capacity may be
increased by providing more dimples, increasing length L,
increasing depth D or using a dimple with a V-shaped bottom surface
(FIG. 8). Release forces required to release the dimple connection
may be reduced by less dimples, improved lubrication, decreased
.alpha.1 and/or .alpha.2 or lower depth D. Galling between the
anchor tool and the tubular element may be mitigated by increasing
the round-off radius R. Furthermore, a relatively sharp angle
.alpha.1 may increase the weight carrying capacity and a relatively
low angle .alpha.2 may reduce the release force of the dimple
connection.
[0060] The present invention is not limited to the embodiments as
described above, wherein various modifications are conceivable
within the scope of the appended claims. Features of different
embodiments may for instance be combined.
* * * * *