CA2624405A1 - Expansion system - Google Patents
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- CA2624405A1 CA2624405A1 CA002624405A CA2624405A CA2624405A1 CA 2624405 A1 CA2624405 A1 CA 2624405A1 CA 002624405 A CA002624405 A CA 002624405A CA 2624405 A CA2624405 A CA 2624405A CA 2624405 A1 CA2624405 A1 CA 2624405A1
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- expansion
- tubular member
- expansion device
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- member assembly
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Abstract
An apparatus for the radial expansion and plastic deformation of a tubular member.
Description
EXPANSION SYSTEM
BACKGROUND OF THE INVENTION
[0001] The present disclosure relates generally to wellbore casings, and in particular to wellbore casings that are formed using expandable tubing.
BRIEF DESCRIPTION OF THE DRAWINGS
BACKGROUND OF THE INVENTION
[0001] The present disclosure relates generally to wellbore casings, and in particular to wellbore casings that are formed using expandable tubing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] Figure ] is an illustration of a conventional method for drilling a borehole in a subterranean formation;
[0003] Figure 2 is a fragmentary cross sectional view of a device for coupling an expandable tubular member to an existing tubular member;
[0004] Figure 3 is a fragmentary cross sectional view of a hardenable fluidic sealing material being pumped down the device of Figure 2;
[0005] Figure 4 is a fragmentary cross sectional view of the expansion of an expandable tubular member using the expansion device of Figure 2.;
[0006] Figure 5 is a fragmentary cross sectional view of the completion of the radial expansion and plastic deformation of an expandable tubular member;
[0007] Figure 6 is a cross sectional view of an expandable tubular member expanded by a fixed expansion cone into contact with a casing with surface anomalies;
[0008] Figure 7 is a fragmentary cross sectional view of an expansion device with roller expansion elements;
[0009] Figure 8 is a cross sectional view of an expandable tubular member expanded by roller expansion elements;
[0010] Figure 9 is a fragmentary cross sectional view of a connection joint expanded by roller expansion elements;
[0011] Figure 10 is a side view of an exemplary embodiment of an expansion device with an expansion cone and roller expansion elements;
[0012] Figure 11 is a cross sectional view of the expansion device of Figure 10;
[0013] Figure 12 is a flow chart illustrating the operation of the expansion device of Figure 10;
[0014] Figure 13 is a fragmentary cross sectional view of the operation of the expansion device during the operation of the method of Figure 12;
[0015] Figure 14 is a cross sectional view of the expansion of an expandable tubular member into contact with a surrounding casing during the operation of the method of Figure 12;
224623.0 l /2725.24202 100161 Figure 15 is another fragmentary cross sectional view of the operation of the expansion device during the operation of the method of Figure 12;
[00171 Figure 16 is a cross sectional view of the expansion of an expandable tubular member solely with the expansion cone of the expansion device during the operation of the method of Figure 12;
[00181 Figure 17 is another fragmentary cross sectional of the expansion of an expandable tubular member during the operation of the method of Figure 12;
[00191 Figure 18 is a cross sectional view of the connection joint expanded in Figure 17;
[00201 Figure 19 is another fragmentary cross sectional view of the operation of the expansion device during the operation of the method of Figure 12;
[00211 Figure 20 is a cross sectional view of the expansion of an expandable tubular member with the combination of the expansion cone and the partially retracted roller expansion elements of the expansion device during the operation of the method of Figure 12;
[0022] Figure 21 is a cross sectional view of the connection joint expanded in Figure 19;
[00231 Figure 22 is a side view of an exemplary embodiment of an expansion device with roller expansion elements and a flexible shell;
[00241 Figure 23 is a cross sectional view of the expansion device of Figure 22;
[00251 Figure 24 is a fragmentary cross sectional view of the expansion of an expandable tubular member with the combination of roller expansion elements and a flexible shell of the expansion device of Figure 22;
[00261 Figure 25 is a cross sectional view of the expansion of an expandable tubular member with the combination of roller expansion elements and a flexible shell of the expansion device of Figure 22; and [00271 Figure 26 is a graphical illustration of the rate of increase of strain versus the rate of increase in stress.
DETAILED DESCRIPTION OF THE DRAWINGS
[00281 Referring initially to Figure 1, a conventional device 100 for drilling a borehole 102 in a subterranean formation 104 is shown. The borehole 102 may be lined with a casing 106 at the top portion of its length. An annulus 108 formed between the casing 106 and the formation 104 may be filled with a sealing material 110, such as, for example, cement. In an exemplary embodiment, the device 100 may be operated in a conventional manner to extend the length of the borehole 102 beyond the casing 106.
224623.01/2725.24202 [00291 Referring now to Figure 2, a device 200 for coupling an expandable tubular member 202 to an existing tubular member, such as, for example, the existing casing 106, is shown. The device 200 includes a shoe 206 that defines a centrally positioned valveable passage 206a adapted to receive, for example, a ball, plug or other similar device for closing the passage. An end of the shoe 206b is coupled to a lower tubular end 208a of a tubular launcher assembly 208 that includes the lower tubular end, an upper tubular end 208b, and a tapered tubular transition member 208c. The lower tubular end 208a of the tubular launcher assembly 208 has a greater inside diameter than the inside diameter of the upper tubular end 208b. The tapered tubular transition member 208c connects the lower tubular end 208a and the upper tubular end 208b. The upper tubular end 208b of the tubular launcher assembly 208 is coupled to an end of the expandable tubular member 202. One or more seals 210 are coupled to the outside surface of the other end of the expandable tubular member 202.
100301 An expansion device 212 is centrally positioned within and mates with the tubular launcher assembly 208. The expansion device 212 defines a centrally positioned fluid pathway 212a, and includes a lower section 212b, a middle section 212c, and an upper section 212d. The lower section 212b of the expansion device 212 defines an inclined expansion surface 212ba that supports the tubular launcher assembly 208 by mating with the tapered tubular transition member 208c of the tubular launcher assembly. The upper section 212d of the expansion device 212 is coupled to an end of a tubular member 218 that defines a fluid pathway 218a. The fluid pathway 218a of the tubular member 218 is fluidicly coupled to the fluid pathway 212a defined by the expansion device 212.
One or more spaced apart cup seals 220 and 222 are coupled to the outside surface of the tubular member 218 for sealing against the interior surface of the expandable tubular member 202. In an exemplary embodiment, cup seal 222 is positioned near a top end of the expandable tubular member 202. A top fluid valve 224 is coupled to the tubular member 218 above the cup seal 222 and defines a fluid pathway 226 that is fluidicly coupled to the fluid pathway 218a.
[00311 During operation of the device 200, as illustrated in Figure 2, the device 200 is initially lowered into the borehole 102. In an exemplary embodiment, during the lowering of the device 200 into the borehole 102, a fluid 228 within the borehole 102 passes upwardly through the device 200 through the valveable passage 206a into the fluid pathway 212a and 218a and out of the device 200 through the fluid pathway 226 defined by the top fluid valve 224.
[00321 Referring now to Figure 3, in an exemplary embodiment, a hardenable fluidic sealing material 300, such as, for example, cement, is then pumped down the fluid pathway 218a and 212a and out through the valveable passage 206a into the borehole 102 with the top fluid valve 224 in a 224623.01/2725.24202 closed position. The hardenable fluidic sealing material 300 thereby fills an annular space 302 between the borehole 102 and the outside diameter of the expandable tubular member 202.
100331 Refemng now to Figure 4, a plug 402 is then injected with a fluidic material 404. The plug thereby fits into and closes the valveable passage 206a to further fluidic flow. Continued injection of the fluidic material 404 then pressurizes a chamber 406 defined by the shoe 206, the bottom of the expansion device 212, and the walls of the launcher assembly 208 and the expandable tubular member 202. Continued pressurization of the chamber 406 then displaces the expansion device 212 in an upward direction 408 relative to the expandable tubular member 202 thereby causing radial expansion and plastic deformation of the launcher assembly 208 and the expandable tubular member.
[0034] Referring now to Figure 5, the radial expansion and plastic deformation of the expandable tubular member 202 is then completed and the expandable tubular member is coupled to the existing casing 106. The hardenable fluidic sealing material 300, such as, for example, cement fills the annulus 302 between the expandable tubular member 202 and the borehole 102.
The device 200 has been withdrawn from the borehole and a conventional device 100 for drilling the borehole 102 may then be utilized to drill out the shoe 206 and continue drilling the borehole 102, if desired.
[0035] Referring now to Figure 6, the use of a fixed diameter expansion cone with device 200 may not accommodate surface anomalies 600 on a casing 602 or wellbore and may leave one or more gaps 604 between the outside diameter 606 of an expandable tubular member 608 and the inside diameter 610 of the casing 602 or wel]bore.
[0036] Referring now to Figures 7 and 8, in an exemplary embodiment, a conventional expansion device 700 includes roller expansion elements 702 that radially expand and plastically deform an expandable tubular member 704 upon the rotation in a direction 706 of the expansion device within the expandable tubular member. The expansion device 700 may be rotated in the direction 706 with the use of a mud motor 708 or by rotation of the drill string 710, or rotated in another conventional manner. The roller expansion elements 702 may be displaced in a radial direction using hydraulic pressure in an conventional manner, such as, for example, in the commercially available products of Weatherford. In another exemplary embodiment, the roller expansion elements 702 may be tapered.
[0037] Referring now to Figure 9, the radial expansion and plastic deformation of expandable tubular member 704 at a connection joint 712 by the roller expansion elements 702 of the expansion device 700 can cause the connection joint to lose connection strength and sealing ability. As a result, the connection joint 712 may not provide a metal to metal seal and/or a fluid tight seal.
[0038] Referring now to Figure 10, in an exemplary embodiment, an expansion device 1000 includes an expansion cone 1002, a central roller section 1004, circumferentially spaced apart roller 224623.0 l /2725.24202 expansion elements 1006, and a]ower tubular end 1008. The expansion cone 1002 has a leading surface 1010 and an outer inclined surface 1012 that defines an angle al. The outer inclined surface 1012 and roller expansion elements 1006 together form the expansion surfaces 1014 that upon displacement of the expansion device 1000 relative to an expandable tubular member radially expand and plastically deform the expandable tubular member. The central roller section 1004 may be rotated in a direction 1016 by use of a mud motor 1018, rotation of the drill string 1020, or by rotation in another conventional manner. The roller expansion elements 1006 are displaced in a radial direction using hydraulic pressure in an conventional manner, such as, for example, in the commercially available products of Weatherford.
[0039] The expansion device 1000 includes a sensor 1022 that detects connection joints of an expandable tubular member and sends a signal to a controller 1024. In an exemplary embodiment, the sensor 1022 may, for example, be a conventional acoustic and/or magnetic sensor. The controller 1024 receives the signal from the sensor 1022 and retracts the roller expansion elements 1006 when the roller expansion elements are near the connection joints of an expandable tubular member. In this manner, an expandable tubular member is radially expanded and plastically deformed by the expansion cone 1002 and not by the roller expansion elements 1006 near the vicinity of the connection joints. Furthermore, the expandable tubular member between the connection joints and outside the vicinity of the connection joints is radially expanded and plastically deforrned by both the expansion cone 1002 and the roller expansion elements 1006. In another exemplary embodiment, the expansion cone 1002 has an adjustable diameter.
[0040] In an exemplary embodiment, the expansion device 212 consists of one or more of the expansion devices 700 and 1000.
[0041] Referring now to Figure 11, in an exemplary embodiment, the expansion device 1000 displaces the roller expansion elements 1006 in an outer radial direction from the central roller section 1004 using hydraulic pressure.
[0042] In an exemplary embodiment, a strain controlled expansion device may be substituted for the expansion cone 1002. A strain controlled expansion device is an expansion device in which the shape of the expansion device controls the amount of strain in the material that is expanded. In an exemplary embodiment, a stress controlled expansion device may be substituted for the roller expansion elements 1006. A stress controlled expansion device is an expansion device in which the contact pressure applied to the inside surface of the material to be expanded is controlled, thereby controlling the stress in the material to be expanded.
224623.01 /272 5.24202 (0043] Referring now to Figures 12, 13, and 14, in an exemplary embodiment, during the operation of the system 1000, the system implements a method 1200 in which in 1202 expansion of the expandable tubular member 1304 by the system is initiated by the expansion device 1000 being displaced in an upward direction 1300, by the injection of a fluidic material 1302, relative to the expandable tubular member 1304 thereby causing radial expansion and plastic deformation of the expandable tubular member into intimate contact with an outer casing member 1306. In an exemplary embodiment, in the initial expansion 1202, the expansion device 1000 is rotated in a direction 1016 by the use of a mud motor 1018, rotation of the drill string 1020, or other conventional manner of providing rotation, thereby causing radial expansion and plastic deformation of the expandable tubular member 1304 by the expansion cone 1002 and the roller expansion elements 1006. In an exemplary embodiment, the expandable tubular member 1304 may be comprised of individual sections coupled together with one or more connection joints 1308. In an exemplary embodiment, the connection joints 1308 include threaded connections.
[0044] In an exemplary embodiment, operation of the expansion device 1000 with roller expansion elements 1006 radially expands and plastically deforms the expandable tubing member 1304 into intimate contact with the outer casing member 1306 or wellbore and thereby may accommodate surface anomalies 1402 on the casing or wellbore and may also fill in any gaps between the outside diameter 1404 of the expandable tubing member and the inside diameter 1406 of the casing or wellbore.
[0045] Referring now to Figures 12, 15, and 16, in an exemplary embodiment, during continued operation of the system 1000, the sensor 1022 of the system continually determines if the roller expansion elements 1006 are within the vicinity of the connection joints 1308 in 1204. If the sensor 1022 of the system 1000 determines that the roller expansion elements 1006 are within the vicinity of the connection joints 1308 in 1204, then the system retracts the roller expansion elements 1006 within the central roller section 1004 in 1206. As a result, the continued operation of the system 1000 to radially expand and plastically deform the expandable tubular member 1304 is provided solely by the engagement of the expansion cone 1002 with the expandable tubular member during the relative displacement of the expansion cone with the expandable tubular member. No rotation of the drill string 1020 or operation of the mud motor 1018 is required when the roller expansion elements 1006 are allowed to fully retract within the central roller section 1004.
[0046] Referring now to Figures 12, 17 and 18, in an exemplary embodiment, during continued operation of the system 1000, the sensor 1022 of the system continually determines if the roller expansion elements 1006 are outside the vicinity of the connection joints 1308 in 1208. If the sensor 224623.01 /272 5.24202 1022 of the system 1000 determines that the roller expansion elements 1006 are outside the vicinity of the connection joints 1308 in 1208, then the system extends the roller expansion elements in a radially outward direction in 1210. As a result, the continued radial expansion and plastic deformation of the expandable tubular member 1304 is provided by the combination of the expansion cone 1002 and the roller expansion elements 1006 engaging the expandable tubular member 1304 during the relative displacement of the expansion cone and the roller expansion elements with the expandable tubular member.
[0047] In an exemplary embodiment, during operation of the system 1000 in accordance with the method 1200, as illustrated in Figure 18, the integrity of the connection joints 1308 may be maintained due to the expansion of the connection joints 1308 solely by the expansion cone 1002 in 1206. As a result, in an exemplary embodiment, the connection joint 1308, following the radial expansion and plastic deformation of the expandable tubular member 1304, provides a metal to metal and/or fluid tight seal.
[0048] Referring now to Figures 12, 19, 20, and 21, in an exemplary embodiment, during continued operation of the system 1000, the sensor 1022 of the system 1000 continually determines if the roller expansion elements 1006 are within the vicinity of the connection joints 1308 in 1204. If the sensor 1022 of the system 1000 determines that the roller expansion elements 1006 are within the vicinity of the connection joints 1308 in 1204, then the system retracts the roller expansion elements 1006 partially within the central roller section 1004 in 1206. As a result, the continued operation of the system 1000 to radially expand and plastically deform the expandable tubular member 1304 is provided by the combination of the expansion cone 1002 and the partially retracted roller expansion elements 1006 engaging the expandable tubular member 1304 during the relative displacement of the expansion cone and the roller expansion elements with the expandable tubular member. In an exemplary embodiment, the extent to which the roller expansion elements 1006 may be retracted in 1206 in order to maintain the integrity of the connection joints 1308 during and following the radial expansion and plastic deformation of the connection joints, may be determined using experimental empirical methods.
[0049] In an exemplary embodiment, the determination that the roller expansion elements 1006 are within the vicinity of the connection joints 1308, may be determined using empirical methods. The determination that the roller expansion elements 1006 are within the vicinity of the connection joints 1308 may be a function of, among other things, the type of connection joint, the metallurgy of the expandable tubular member, the geometry of the expansion device, the wall thickness of the 224623.01 /272 5.24202 expandable tubular member, and the amount the expandable tubular member is to be radially expanded and plastically deformed.
[0050] Referring now to Figure 22 and 23, in an exemplary embodiment, an expansion device 2200 is substantially identical to expansion device 1000, however a flexible shell 2202 is positioned around the outer circumference formed by the exterior surfaces of the roller expansion elements 1006 and the central roller section 1004. The flexible shell 2202 is attached at opposite ends of the upper and lower portions of the central roller section 1004.
[0051] Referring now to Figures 24 and 25, in an exemplary embodiment, during operation of the expansion device 2200, the roller expansion elements 1006 are displaced in an outward direction and the expansion device is rotated in a direction 1016, thereby causing radial expansion and plastic deformation of the expandable tubular member 1304 by the expansion cone 1002 and the flexible shell 2202. During operation, in an exemplary embodiment, the flexible shell 2202 positioned around the exterior circumference of the roller expansion elements 1006 and the central roller section 1004 distributes the stress applied by the roller expansion elements to the interior surface of expandable tubular member 1304. As a result, the use of the flexible shell 2202 decreases the stress concentrations in the connection joints 1308 of the expandable tubular member 1304 caused by the roller expansion elements and allows radial expansion and plastic deformation of the connection joints without loss of connection strength or sealing ability. As a result, the connection joint 1308 provides a metal to metal seal andlor a fluid tight seal during and after radial expansion and plastic deformation of the connection joint. In an exemplary embodiment, during operation of the expansion device 2200, the flexible shell 2202 is not plastically deformed by the roller expansion elements 1006 and conforms around the exterior of the central roller section 1004 when the roller expansion elements 1006 are fully retracted.
[0052] In an exemplary embodiment, the roller expansion elements 1006 may be displaced in a radially outwardly direction with the use of a variable compressibility fluid.
Variable compressibility can be achieved, for example, by the insertion into the fluid of frangible ceramic spheres that collapse above a certain pressure. The compressibility of the fluid may also be varied by the use of gaseous bubbles in the fluid. In an exemplary embodiment, the variable compressibility of the fluid used to displace the roller expansion elements 1006 into engagement with the expandable tubular member 1304 mitigates damage to the connection joint 1308. For example, the compressibility of the variable compressibility fluid may be controlled such that as the rate of strain of the tubular member increases, due to operation of the rollers, the contact stresses may not increase as fast, may be stable, or may decrease. Furthermore, for example, since the yield point of the connection joint 224623.01/2725.24202 1308 is typically different from the yield point of the remaining portions of the expandable tubular member 1304, the variable compressibility of the fluid may be designed using empirically experimental methods to provide a relationship as shown in Figure 26.
Referring to Figure 26, the graph 2600 indicates that as the rate of strain increases, the rate of increase in stress is designed to go down. The variable compressibility fluid is designed to account for this and permits the roller expansion elements 1006 to adjust to the connections joints 1308 and radially expand and plastically deform the connection joints and provide a metal to metal seal and/or a fluid tight seal during and after radial expansion and plastic deformation of the connection joint.
[0053] In an exemplary embodiment, during operation of the system 1000, the radial expansion and plastic deformation of the expandable tubular member 1304 may be provided by displacing the system 1000 in a top down or bottoms up configuration, pushing down or pulling up on a drillstring, or a combination of these methods.
[0054] In an exemplary embodiment, the expandable tubular member 202 consists of one or more of the expandable tubular members 704 and 1304.
[0055] An expansion device for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the mechanical joints of the tubular member assembly; and a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the non-mechanical joint portion of the tubular member assembly.
[0056] An expansion device for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes a first expansion device comprising a substantially continuous outer tapered surface for engaging an interior surface of the tubular member; and a second expansion device operably coupled to the first expansion device comprising one or more roller expansion elements for engaging the interior surface of the tubular member.
[0057] An expansion device for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes a first expansion device comprising a substantially continuous outer tapered surface for engaging an interior surface of the tubular member assembly; a second expansion device operably coupled to the first expansion device comprising one or more roller expansion elements for engaging the interior surface of the tubular member assembly; one or more sensors to sense 224623.01 /272 5.24202 connection joints of the tubular member assembly; and a controller operably coupled to the sensor and the second expansion device; wherein the controller retracts the roller expansion elements based on the vicinity of the expansion device to a connection joint of the tubular member assembly; and wherein the mechanical joints are threaded connections.
[0058] A method of radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes controllably straining the mechanical joint of the tubular member assembly; and controllably stressing and straining the non-mechanical joint portion of the tubular member assembly.
[0059] A method of radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the mechanical joints of the tubular member assembly; and operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the non-mechanical joint portion of the tubular member assembly.
[0060] A method of radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; and operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions.
[0061] A method of radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes: operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; operating one or more sensors to sense connection joints of the tubular member assembly; and operating a controller coupled to the sensor and the second expansion device. The controller retracts the roller expansion elements based on the vicinity of the 224623.01 /2725.24202 expansion device to a connection joint of the tubular member assembly; and the mechanical joints are threaded connections.
100621 A method of radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes: operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; operating one or more sensors to sense connection joints of the tubular member assembly; and operating a controller coupled to the sensor and the second expansion device. The controller retracts the roller expansion elements based on the vicinity of the expansion device to a connection joint of the tubular member assembly; wherein the mechanical joints are threaded connections; and determining the amount the roller expansion elements are retracted by empirical methods.
[00631 An expansion system for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes means for controllably straining the mechanical joint of the tubular member assembly; and means for controllably stressing and straining the non-mechanical joint portion of the tubular member assembly.
100641 An expansion system for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes means for operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the mechanical joints of the tubular member assembly; and means for operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the non-mechanical joint portion of the tubular member assembly.
[00651 An expansion system for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes: means for operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; and means for operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions.
224623.01/2725.24202 [0066] An expansion system for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes: means for operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; means for operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions;
means for operating one or more sensors to sense connection joints of the tubular member assembly;
means for operating a controller coupled to the sensor and the second expansion device; wherein the controller retracts the roller expansion elements based on the vicinity of the expansion device to a connection joint of the tubular member assembly; and wherein the mechanical joints are threaded connections.
[0067] An expansion system for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes: means for operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; means for operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions;
means for operating one or more sensors to sense connection joints of the tubular member assembly;
means for operating a controller coupled to the sensor and the second expansion device; wherein the controller retracts the roller expansion elements based on the vicinity of the expansion device to a connection joint of the tubular member assembly; wherein the mechanical joints are threaded connections; and determining the amount the roller expansion elements are retracted by empirical methods.
[0068] In an exemplary embodiment, other forms of strain controlled expansion devices may be used instead of or in addition to the expansion cone. In an exemplary embodiment, other forms of stress controlled expansion processes may be used instead of or in addition to the roller cones.
[0069] Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features, and some steps of the present invention may be executed without a corresponding execution of other steps. In some instances, some features of the present invention may be employed with a corresponding use of other features, and some steps of the present invention may be executed with a corresponding execution of other steps. Accordingly, all such modifications, changes and 224623.01/2725.24202 substitutions are intended to be included within the scope of this invention as defined in the following claims, and it is appropriate that the claims be construed broadly and in a manner consistent with the scope of the invention. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.
224623.01/2725.24202
224623.0 l /2725.24202 100161 Figure 15 is another fragmentary cross sectional view of the operation of the expansion device during the operation of the method of Figure 12;
[00171 Figure 16 is a cross sectional view of the expansion of an expandable tubular member solely with the expansion cone of the expansion device during the operation of the method of Figure 12;
[00181 Figure 17 is another fragmentary cross sectional of the expansion of an expandable tubular member during the operation of the method of Figure 12;
[00191 Figure 18 is a cross sectional view of the connection joint expanded in Figure 17;
[00201 Figure 19 is another fragmentary cross sectional view of the operation of the expansion device during the operation of the method of Figure 12;
[00211 Figure 20 is a cross sectional view of the expansion of an expandable tubular member with the combination of the expansion cone and the partially retracted roller expansion elements of the expansion device during the operation of the method of Figure 12;
[0022] Figure 21 is a cross sectional view of the connection joint expanded in Figure 19;
[00231 Figure 22 is a side view of an exemplary embodiment of an expansion device with roller expansion elements and a flexible shell;
[00241 Figure 23 is a cross sectional view of the expansion device of Figure 22;
[00251 Figure 24 is a fragmentary cross sectional view of the expansion of an expandable tubular member with the combination of roller expansion elements and a flexible shell of the expansion device of Figure 22;
[00261 Figure 25 is a cross sectional view of the expansion of an expandable tubular member with the combination of roller expansion elements and a flexible shell of the expansion device of Figure 22; and [00271 Figure 26 is a graphical illustration of the rate of increase of strain versus the rate of increase in stress.
DETAILED DESCRIPTION OF THE DRAWINGS
[00281 Referring initially to Figure 1, a conventional device 100 for drilling a borehole 102 in a subterranean formation 104 is shown. The borehole 102 may be lined with a casing 106 at the top portion of its length. An annulus 108 formed between the casing 106 and the formation 104 may be filled with a sealing material 110, such as, for example, cement. In an exemplary embodiment, the device 100 may be operated in a conventional manner to extend the length of the borehole 102 beyond the casing 106.
224623.01/2725.24202 [00291 Referring now to Figure 2, a device 200 for coupling an expandable tubular member 202 to an existing tubular member, such as, for example, the existing casing 106, is shown. The device 200 includes a shoe 206 that defines a centrally positioned valveable passage 206a adapted to receive, for example, a ball, plug or other similar device for closing the passage. An end of the shoe 206b is coupled to a lower tubular end 208a of a tubular launcher assembly 208 that includes the lower tubular end, an upper tubular end 208b, and a tapered tubular transition member 208c. The lower tubular end 208a of the tubular launcher assembly 208 has a greater inside diameter than the inside diameter of the upper tubular end 208b. The tapered tubular transition member 208c connects the lower tubular end 208a and the upper tubular end 208b. The upper tubular end 208b of the tubular launcher assembly 208 is coupled to an end of the expandable tubular member 202. One or more seals 210 are coupled to the outside surface of the other end of the expandable tubular member 202.
100301 An expansion device 212 is centrally positioned within and mates with the tubular launcher assembly 208. The expansion device 212 defines a centrally positioned fluid pathway 212a, and includes a lower section 212b, a middle section 212c, and an upper section 212d. The lower section 212b of the expansion device 212 defines an inclined expansion surface 212ba that supports the tubular launcher assembly 208 by mating with the tapered tubular transition member 208c of the tubular launcher assembly. The upper section 212d of the expansion device 212 is coupled to an end of a tubular member 218 that defines a fluid pathway 218a. The fluid pathway 218a of the tubular member 218 is fluidicly coupled to the fluid pathway 212a defined by the expansion device 212.
One or more spaced apart cup seals 220 and 222 are coupled to the outside surface of the tubular member 218 for sealing against the interior surface of the expandable tubular member 202. In an exemplary embodiment, cup seal 222 is positioned near a top end of the expandable tubular member 202. A top fluid valve 224 is coupled to the tubular member 218 above the cup seal 222 and defines a fluid pathway 226 that is fluidicly coupled to the fluid pathway 218a.
[00311 During operation of the device 200, as illustrated in Figure 2, the device 200 is initially lowered into the borehole 102. In an exemplary embodiment, during the lowering of the device 200 into the borehole 102, a fluid 228 within the borehole 102 passes upwardly through the device 200 through the valveable passage 206a into the fluid pathway 212a and 218a and out of the device 200 through the fluid pathway 226 defined by the top fluid valve 224.
[00321 Referring now to Figure 3, in an exemplary embodiment, a hardenable fluidic sealing material 300, such as, for example, cement, is then pumped down the fluid pathway 218a and 212a and out through the valveable passage 206a into the borehole 102 with the top fluid valve 224 in a 224623.01/2725.24202 closed position. The hardenable fluidic sealing material 300 thereby fills an annular space 302 between the borehole 102 and the outside diameter of the expandable tubular member 202.
100331 Refemng now to Figure 4, a plug 402 is then injected with a fluidic material 404. The plug thereby fits into and closes the valveable passage 206a to further fluidic flow. Continued injection of the fluidic material 404 then pressurizes a chamber 406 defined by the shoe 206, the bottom of the expansion device 212, and the walls of the launcher assembly 208 and the expandable tubular member 202. Continued pressurization of the chamber 406 then displaces the expansion device 212 in an upward direction 408 relative to the expandable tubular member 202 thereby causing radial expansion and plastic deformation of the launcher assembly 208 and the expandable tubular member.
[0034] Referring now to Figure 5, the radial expansion and plastic deformation of the expandable tubular member 202 is then completed and the expandable tubular member is coupled to the existing casing 106. The hardenable fluidic sealing material 300, such as, for example, cement fills the annulus 302 between the expandable tubular member 202 and the borehole 102.
The device 200 has been withdrawn from the borehole and a conventional device 100 for drilling the borehole 102 may then be utilized to drill out the shoe 206 and continue drilling the borehole 102, if desired.
[0035] Referring now to Figure 6, the use of a fixed diameter expansion cone with device 200 may not accommodate surface anomalies 600 on a casing 602 or wellbore and may leave one or more gaps 604 between the outside diameter 606 of an expandable tubular member 608 and the inside diameter 610 of the casing 602 or wel]bore.
[0036] Referring now to Figures 7 and 8, in an exemplary embodiment, a conventional expansion device 700 includes roller expansion elements 702 that radially expand and plastically deform an expandable tubular member 704 upon the rotation in a direction 706 of the expansion device within the expandable tubular member. The expansion device 700 may be rotated in the direction 706 with the use of a mud motor 708 or by rotation of the drill string 710, or rotated in another conventional manner. The roller expansion elements 702 may be displaced in a radial direction using hydraulic pressure in an conventional manner, such as, for example, in the commercially available products of Weatherford. In another exemplary embodiment, the roller expansion elements 702 may be tapered.
[0037] Referring now to Figure 9, the radial expansion and plastic deformation of expandable tubular member 704 at a connection joint 712 by the roller expansion elements 702 of the expansion device 700 can cause the connection joint to lose connection strength and sealing ability. As a result, the connection joint 712 may not provide a metal to metal seal and/or a fluid tight seal.
[0038] Referring now to Figure 10, in an exemplary embodiment, an expansion device 1000 includes an expansion cone 1002, a central roller section 1004, circumferentially spaced apart roller 224623.0 l /2725.24202 expansion elements 1006, and a]ower tubular end 1008. The expansion cone 1002 has a leading surface 1010 and an outer inclined surface 1012 that defines an angle al. The outer inclined surface 1012 and roller expansion elements 1006 together form the expansion surfaces 1014 that upon displacement of the expansion device 1000 relative to an expandable tubular member radially expand and plastically deform the expandable tubular member. The central roller section 1004 may be rotated in a direction 1016 by use of a mud motor 1018, rotation of the drill string 1020, or by rotation in another conventional manner. The roller expansion elements 1006 are displaced in a radial direction using hydraulic pressure in an conventional manner, such as, for example, in the commercially available products of Weatherford.
[0039] The expansion device 1000 includes a sensor 1022 that detects connection joints of an expandable tubular member and sends a signal to a controller 1024. In an exemplary embodiment, the sensor 1022 may, for example, be a conventional acoustic and/or magnetic sensor. The controller 1024 receives the signal from the sensor 1022 and retracts the roller expansion elements 1006 when the roller expansion elements are near the connection joints of an expandable tubular member. In this manner, an expandable tubular member is radially expanded and plastically deformed by the expansion cone 1002 and not by the roller expansion elements 1006 near the vicinity of the connection joints. Furthermore, the expandable tubular member between the connection joints and outside the vicinity of the connection joints is radially expanded and plastically deforrned by both the expansion cone 1002 and the roller expansion elements 1006. In another exemplary embodiment, the expansion cone 1002 has an adjustable diameter.
[0040] In an exemplary embodiment, the expansion device 212 consists of one or more of the expansion devices 700 and 1000.
[0041] Referring now to Figure 11, in an exemplary embodiment, the expansion device 1000 displaces the roller expansion elements 1006 in an outer radial direction from the central roller section 1004 using hydraulic pressure.
[0042] In an exemplary embodiment, a strain controlled expansion device may be substituted for the expansion cone 1002. A strain controlled expansion device is an expansion device in which the shape of the expansion device controls the amount of strain in the material that is expanded. In an exemplary embodiment, a stress controlled expansion device may be substituted for the roller expansion elements 1006. A stress controlled expansion device is an expansion device in which the contact pressure applied to the inside surface of the material to be expanded is controlled, thereby controlling the stress in the material to be expanded.
224623.01 /272 5.24202 (0043] Referring now to Figures 12, 13, and 14, in an exemplary embodiment, during the operation of the system 1000, the system implements a method 1200 in which in 1202 expansion of the expandable tubular member 1304 by the system is initiated by the expansion device 1000 being displaced in an upward direction 1300, by the injection of a fluidic material 1302, relative to the expandable tubular member 1304 thereby causing radial expansion and plastic deformation of the expandable tubular member into intimate contact with an outer casing member 1306. In an exemplary embodiment, in the initial expansion 1202, the expansion device 1000 is rotated in a direction 1016 by the use of a mud motor 1018, rotation of the drill string 1020, or other conventional manner of providing rotation, thereby causing radial expansion and plastic deformation of the expandable tubular member 1304 by the expansion cone 1002 and the roller expansion elements 1006. In an exemplary embodiment, the expandable tubular member 1304 may be comprised of individual sections coupled together with one or more connection joints 1308. In an exemplary embodiment, the connection joints 1308 include threaded connections.
[0044] In an exemplary embodiment, operation of the expansion device 1000 with roller expansion elements 1006 radially expands and plastically deforms the expandable tubing member 1304 into intimate contact with the outer casing member 1306 or wellbore and thereby may accommodate surface anomalies 1402 on the casing or wellbore and may also fill in any gaps between the outside diameter 1404 of the expandable tubing member and the inside diameter 1406 of the casing or wellbore.
[0045] Referring now to Figures 12, 15, and 16, in an exemplary embodiment, during continued operation of the system 1000, the sensor 1022 of the system continually determines if the roller expansion elements 1006 are within the vicinity of the connection joints 1308 in 1204. If the sensor 1022 of the system 1000 determines that the roller expansion elements 1006 are within the vicinity of the connection joints 1308 in 1204, then the system retracts the roller expansion elements 1006 within the central roller section 1004 in 1206. As a result, the continued operation of the system 1000 to radially expand and plastically deform the expandable tubular member 1304 is provided solely by the engagement of the expansion cone 1002 with the expandable tubular member during the relative displacement of the expansion cone with the expandable tubular member. No rotation of the drill string 1020 or operation of the mud motor 1018 is required when the roller expansion elements 1006 are allowed to fully retract within the central roller section 1004.
[0046] Referring now to Figures 12, 17 and 18, in an exemplary embodiment, during continued operation of the system 1000, the sensor 1022 of the system continually determines if the roller expansion elements 1006 are outside the vicinity of the connection joints 1308 in 1208. If the sensor 224623.01 /272 5.24202 1022 of the system 1000 determines that the roller expansion elements 1006 are outside the vicinity of the connection joints 1308 in 1208, then the system extends the roller expansion elements in a radially outward direction in 1210. As a result, the continued radial expansion and plastic deformation of the expandable tubular member 1304 is provided by the combination of the expansion cone 1002 and the roller expansion elements 1006 engaging the expandable tubular member 1304 during the relative displacement of the expansion cone and the roller expansion elements with the expandable tubular member.
[0047] In an exemplary embodiment, during operation of the system 1000 in accordance with the method 1200, as illustrated in Figure 18, the integrity of the connection joints 1308 may be maintained due to the expansion of the connection joints 1308 solely by the expansion cone 1002 in 1206. As a result, in an exemplary embodiment, the connection joint 1308, following the radial expansion and plastic deformation of the expandable tubular member 1304, provides a metal to metal and/or fluid tight seal.
[0048] Referring now to Figures 12, 19, 20, and 21, in an exemplary embodiment, during continued operation of the system 1000, the sensor 1022 of the system 1000 continually determines if the roller expansion elements 1006 are within the vicinity of the connection joints 1308 in 1204. If the sensor 1022 of the system 1000 determines that the roller expansion elements 1006 are within the vicinity of the connection joints 1308 in 1204, then the system retracts the roller expansion elements 1006 partially within the central roller section 1004 in 1206. As a result, the continued operation of the system 1000 to radially expand and plastically deform the expandable tubular member 1304 is provided by the combination of the expansion cone 1002 and the partially retracted roller expansion elements 1006 engaging the expandable tubular member 1304 during the relative displacement of the expansion cone and the roller expansion elements with the expandable tubular member. In an exemplary embodiment, the extent to which the roller expansion elements 1006 may be retracted in 1206 in order to maintain the integrity of the connection joints 1308 during and following the radial expansion and plastic deformation of the connection joints, may be determined using experimental empirical methods.
[0049] In an exemplary embodiment, the determination that the roller expansion elements 1006 are within the vicinity of the connection joints 1308, may be determined using empirical methods. The determination that the roller expansion elements 1006 are within the vicinity of the connection joints 1308 may be a function of, among other things, the type of connection joint, the metallurgy of the expandable tubular member, the geometry of the expansion device, the wall thickness of the 224623.01 /272 5.24202 expandable tubular member, and the amount the expandable tubular member is to be radially expanded and plastically deformed.
[0050] Referring now to Figure 22 and 23, in an exemplary embodiment, an expansion device 2200 is substantially identical to expansion device 1000, however a flexible shell 2202 is positioned around the outer circumference formed by the exterior surfaces of the roller expansion elements 1006 and the central roller section 1004. The flexible shell 2202 is attached at opposite ends of the upper and lower portions of the central roller section 1004.
[0051] Referring now to Figures 24 and 25, in an exemplary embodiment, during operation of the expansion device 2200, the roller expansion elements 1006 are displaced in an outward direction and the expansion device is rotated in a direction 1016, thereby causing radial expansion and plastic deformation of the expandable tubular member 1304 by the expansion cone 1002 and the flexible shell 2202. During operation, in an exemplary embodiment, the flexible shell 2202 positioned around the exterior circumference of the roller expansion elements 1006 and the central roller section 1004 distributes the stress applied by the roller expansion elements to the interior surface of expandable tubular member 1304. As a result, the use of the flexible shell 2202 decreases the stress concentrations in the connection joints 1308 of the expandable tubular member 1304 caused by the roller expansion elements and allows radial expansion and plastic deformation of the connection joints without loss of connection strength or sealing ability. As a result, the connection joint 1308 provides a metal to metal seal andlor a fluid tight seal during and after radial expansion and plastic deformation of the connection joint. In an exemplary embodiment, during operation of the expansion device 2200, the flexible shell 2202 is not plastically deformed by the roller expansion elements 1006 and conforms around the exterior of the central roller section 1004 when the roller expansion elements 1006 are fully retracted.
[0052] In an exemplary embodiment, the roller expansion elements 1006 may be displaced in a radially outwardly direction with the use of a variable compressibility fluid.
Variable compressibility can be achieved, for example, by the insertion into the fluid of frangible ceramic spheres that collapse above a certain pressure. The compressibility of the fluid may also be varied by the use of gaseous bubbles in the fluid. In an exemplary embodiment, the variable compressibility of the fluid used to displace the roller expansion elements 1006 into engagement with the expandable tubular member 1304 mitigates damage to the connection joint 1308. For example, the compressibility of the variable compressibility fluid may be controlled such that as the rate of strain of the tubular member increases, due to operation of the rollers, the contact stresses may not increase as fast, may be stable, or may decrease. Furthermore, for example, since the yield point of the connection joint 224623.01/2725.24202 1308 is typically different from the yield point of the remaining portions of the expandable tubular member 1304, the variable compressibility of the fluid may be designed using empirically experimental methods to provide a relationship as shown in Figure 26.
Referring to Figure 26, the graph 2600 indicates that as the rate of strain increases, the rate of increase in stress is designed to go down. The variable compressibility fluid is designed to account for this and permits the roller expansion elements 1006 to adjust to the connections joints 1308 and radially expand and plastically deform the connection joints and provide a metal to metal seal and/or a fluid tight seal during and after radial expansion and plastic deformation of the connection joint.
[0053] In an exemplary embodiment, during operation of the system 1000, the radial expansion and plastic deformation of the expandable tubular member 1304 may be provided by displacing the system 1000 in a top down or bottoms up configuration, pushing down or pulling up on a drillstring, or a combination of these methods.
[0054] In an exemplary embodiment, the expandable tubular member 202 consists of one or more of the expandable tubular members 704 and 1304.
[0055] An expansion device for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the mechanical joints of the tubular member assembly; and a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the non-mechanical joint portion of the tubular member assembly.
[0056] An expansion device for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes a first expansion device comprising a substantially continuous outer tapered surface for engaging an interior surface of the tubular member; and a second expansion device operably coupled to the first expansion device comprising one or more roller expansion elements for engaging the interior surface of the tubular member.
[0057] An expansion device for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes a first expansion device comprising a substantially continuous outer tapered surface for engaging an interior surface of the tubular member assembly; a second expansion device operably coupled to the first expansion device comprising one or more roller expansion elements for engaging the interior surface of the tubular member assembly; one or more sensors to sense 224623.01 /272 5.24202 connection joints of the tubular member assembly; and a controller operably coupled to the sensor and the second expansion device; wherein the controller retracts the roller expansion elements based on the vicinity of the expansion device to a connection joint of the tubular member assembly; and wherein the mechanical joints are threaded connections.
[0058] A method of radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes controllably straining the mechanical joint of the tubular member assembly; and controllably stressing and straining the non-mechanical joint portion of the tubular member assembly.
[0059] A method of radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the mechanical joints of the tubular member assembly; and operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the non-mechanical joint portion of the tubular member assembly.
[0060] A method of radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; and operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions.
[0061] A method of radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes: operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; operating one or more sensors to sense connection joints of the tubular member assembly; and operating a controller coupled to the sensor and the second expansion device. The controller retracts the roller expansion elements based on the vicinity of the 224623.01 /2725.24202 expansion device to a connection joint of the tubular member assembly; and the mechanical joints are threaded connections.
100621 A method of radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes: operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; operating one or more sensors to sense connection joints of the tubular member assembly; and operating a controller coupled to the sensor and the second expansion device. The controller retracts the roller expansion elements based on the vicinity of the expansion device to a connection joint of the tubular member assembly; wherein the mechanical joints are threaded connections; and determining the amount the roller expansion elements are retracted by empirical methods.
[00631 An expansion system for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes means for controllably straining the mechanical joint of the tubular member assembly; and means for controllably stressing and straining the non-mechanical joint portion of the tubular member assembly.
100641 An expansion system for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes means for operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the mechanical joints of the tubular member assembly; and means for operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the non-mechanical joint portion of the tubular member assembly.
[00651 An expansion system for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes: means for operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; and means for operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions.
224623.01/2725.24202 [0066] An expansion system for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes: means for operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; means for operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions;
means for operating one or more sensors to sense connection joints of the tubular member assembly;
means for operating a controller coupled to the sensor and the second expansion device; wherein the controller retracts the roller expansion elements based on the vicinity of the expansion device to a connection joint of the tubular member assembly; and wherein the mechanical joints are threaded connections.
[0067] An expansion system for radially expanding and plastically deforming a tubular member assembly comprising tubular members connected end to end with a mechanical joint has been described that includes: means for operating a first expansion device comprising a substantially continuous outer tapered surface to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions; means for operating a second expansion device comprising one or more roller expansion elements to radially expand and plastically deform the tubular member assembly as a function of sensed operating conditions;
means for operating one or more sensors to sense connection joints of the tubular member assembly;
means for operating a controller coupled to the sensor and the second expansion device; wherein the controller retracts the roller expansion elements based on the vicinity of the expansion device to a connection joint of the tubular member assembly; wherein the mechanical joints are threaded connections; and determining the amount the roller expansion elements are retracted by empirical methods.
[0068] In an exemplary embodiment, other forms of strain controlled expansion devices may be used instead of or in addition to the expansion cone. In an exemplary embodiment, other forms of stress controlled expansion processes may be used instead of or in addition to the roller cones.
[0069] Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features, and some steps of the present invention may be executed without a corresponding execution of other steps. In some instances, some features of the present invention may be employed with a corresponding use of other features, and some steps of the present invention may be executed with a corresponding execution of other steps. Accordingly, all such modifications, changes and 224623.01/2725.24202 substitutions are intended to be included within the scope of this invention as defined in the following claims, and it is appropriate that the claims be construed broadly and in a manner consistent with the scope of the invention. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.
224623.01/2725.24202
Claims (33)
1. A device for radially expanding and plastically deforming a tubular member assembly, comprising:
a first expansion device comprising one or more roller expansion elements adapted to radially expand and plastically deform the tubular member assembly; and one or more of the following:
a second expansion device having a substantially continuous outer tapered surface adapted to radially expand and plastically deform the tubular member assembly;
a flexible tubular shell surrounding an outer circumference of the one or more roller expansion elements of the first expansion device; and a fluidic material by which at least one of the one or more roller expansion elements of the first expansion device are radially displaced, the fluidic material comprising a variable compressibility.
a first expansion device comprising one or more roller expansion elements adapted to radially expand and plastically deform the tubular member assembly; and one or more of the following:
a second expansion device having a substantially continuous outer tapered surface adapted to radially expand and plastically deform the tubular member assembly;
a flexible tubular shell surrounding an outer circumference of the one or more roller expansion elements of the first expansion device; and a fluidic material by which at least one of the one or more roller expansion elements of the first expansion device are radially displaced, the fluidic material comprising a variable compressibility.
2. The device of claim 1, wherein the tubular member assembly comprises a plurality of tubular members coupled end to end by corresponding mechanical joints.
3. The device of claim 2, wherein the mechanical joints comprise threaded connections.
4. The device of claim 2, further comprising:
one or more sensors adapted to sense the mechanical joints of the tubular member assembly; and a controller operably coupled to the sensors and the first expansion device.
one or more sensors adapted to sense the mechanical joints of the tubular member assembly; and a controller operably coupled to the sensors and the first expansion device.
5. The device of claim 4, wherein the controller is adapted to retract at least one of the one or more roller expansion elements based upon the vicinity of the first expansion device to the mechanical joint of the tubular member assembly.
6. The device of claim 5, wherein the mechanical joints comprise threaded connections.
7. The device of claim 5, wherein the controller is adapted to partially retract at least one of the one or more roller expansion elements based upon the vicinity of the first expansion device to the mechanical joint of the tubular member assembly.
8. The device of claim 7, wherein the controller is adapted to fully retract at least one of the one or more roller expansion elements out of engagement with the tubular member assembly based upon the vicinity of the first expansion device to the mechanical joint of the tubular member assembly.
9. The device of claim 1, comprising the second expansion device having the substantially continuous outer tapered surface adapted to radially expand and plastically deform the tubular member assembly.
10. The device of claim 9, comprising the flexible tubular shell surrounding the outer circumference of the one or more roller expansion elements of the first expansion device.
11. The device of claim 9, comprising the fluidic material by which the one or more roller expansion elements of the first expansion device are radially displaced, the fluidic material comprising the variable compressibility.
12. The device of claim 1, comprising the flexible tubular shell surrounding the outer circumference of the one or more roller expansion elements of the first expansion device.
13. The device of claim 12, comprising the fluidic material by which the one or more roller expansion elements of the first expansion device are radially displaced, the fluidic material comprising the variable compressibility.
14. The device of claim 1, comprising the fluidic material by which the one or more roller expansion elements of the first expansion device are radially displaced, the fluidic material comprising the variable compressibility.
15. The device of claim 14, comprising the flexible tubular shell surrounding the outer circumference of the one or more roller expansion elements of the first expansion device.
16. A device for radially expanding and plastically deforming a tubular member assembly, comprising:
a first expansion device adapted to exert a contact pressure on the tubular member assembly; and one or more of the following:
a second expansion device adapted to distribute the contact pressure, wherein the second expansion device is placed between the first expansion device and the tubular member assembly; and a fluidic material by which the first expansion device exerts the contact pressure on the tubular member assembly, the fluidic material comprising a variable compressibility.
a first expansion device adapted to exert a contact pressure on the tubular member assembly; and one or more of the following:
a second expansion device adapted to distribute the contact pressure, wherein the second expansion device is placed between the first expansion device and the tubular member assembly; and a fluidic material by which the first expansion device exerts the contact pressure on the tubular member assembly, the fluidic material comprising a variable compressibility.
17. The device of 16, comprising the second expansion device adapted to distribute the contact pressure, wherein the second expansion device is placed between the first expansion device and the tubular member.
18. The device of 16, comprising the fluidic material by which the first expansion device exerts the contact pressure on the tubular member, the fluidic material comprising the variable compressibility.
19. The device of claim 16, comprising:
the second expansion device adapted to distribute the contact pressure, wherein the second expansion device is placed between the first expansion device and the tubular member; and the fluidic material by which the first expansion device exerts the contact pressure on the tubular member, the fluidic material comprising the variable compressibility.
the second expansion device adapted to distribute the contact pressure, wherein the second expansion device is placed between the first expansion device and the tubular member; and the fluidic material by which the first expansion device exerts the contact pressure on the tubular member, the fluidic material comprising the variable compressibility.
20. A method of radially expanding a tubular member assembly, comprising:
operating a first expansion device comprising one or more roller expansion elements to radially expand the tubular member assembly; and one or more of the following:
operating a second expansion device having a substantially continuous outer tapered surface to radially expand the tubular member assembly;
surrounding the outer circumference of the one or more roller expansion elements of the second expansion device with a flexible tubular shell; and radially displacing at least one of the one or more roller expansion elements using a fluidic material comprising a variable compressibility.
operating a first expansion device comprising one or more roller expansion elements to radially expand the tubular member assembly; and one or more of the following:
operating a second expansion device having a substantially continuous outer tapered surface to radially expand the tubular member assembly;
surrounding the outer circumference of the one or more roller expansion elements of the second expansion device with a flexible tubular shell; and radially displacing at least one of the one or more roller expansion elements using a fluidic material comprising a variable compressibility.
21. The method of claim 20, wherein the tubular member assembly comprises a plurality of tubular members coupled end to end by corresponding mechanical joints.
22. The method of claim 21, wherein the mechanical joints comprise threaded connections.
23. The method of claim 21, further comprising:
sensing one or more of the mechanical joints of the tubular member assembly.
sensing one or more of the mechanical joints of the tubular member assembly.
24. The method of claim 23, further comprising:
retracting at least one of the one or more roller expansion elements based upon the vicinity of the first expansion device to the mechanical joint of the tubular member assembly.
retracting at least one of the one or more roller expansion elements based upon the vicinity of the first expansion device to the mechanical joint of the tubular member assembly.
25. The method of claim 24, wherein the mechanical joints comprise threaded connections.
26. The method of claim 24, wherein retracting further comprises:
partially retracting at least one of the one or more roller expansion elements.
partially retracting at least one of the one or more roller expansion elements.
27. The method of claim 24, wherein retracting further comprises:
fully retracting at least one of the one or more roller expansion elements out of engagement with the tubular member assembly.
fully retracting at least one of the one or more roller expansion elements out of engagement with the tubular member assembly.
28. The method of claim 20, comprising operating the second expansion device having the substantially continuous outer tapered surface to radially expand the tubular member assembly.
29. The method of claim 28, comprising surrounding the outer circumference of the one or more roller expansion elements of the second expansion device with the flexible tubular shell.
30. The method of claim 28, comprising radially displacing at least one of the one or more roller expansion elements using the fluidic material comprising the variable compressibility.
31. The method of claim 20, comprising surrounding the outer circumference of the one or more roller expansion elements of the second expansion device with the flexible tubular shell.
32. The method of claim 31, comprising radially displacing at least one of the one or more roller expansion elements using the fluidic material comprising the variable compressibility.
33. The method of claim 20, comprising radially displacing at least one of the one or more roller expansion elements using the fluidic material comprising the variable compressibility.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US89367107P | 2007-03-08 | 2007-03-08 | |
| US60/893,671 | 2007-03-08 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2624405A1 true CA2624405A1 (en) | 2008-09-08 |
Family
ID=39747254
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002624405A Abandoned CA2624405A1 (en) | 2007-03-08 | 2008-03-06 | Expansion system |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2624405A1 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104190826A (en) * | 2014-09-01 | 2014-12-10 | 杭州蓝达工艺制品有限公司 | Metal paper basket side wall forming machine |
| CN108372251A (en) * | 2018-04-24 | 2018-08-07 | 三河科达实业有限公司 | Spinning electric tube expander |
-
2008
- 2008-03-06 CA CA002624405A patent/CA2624405A1/en not_active Abandoned
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104190826A (en) * | 2014-09-01 | 2014-12-10 | 杭州蓝达工艺制品有限公司 | Metal paper basket side wall forming machine |
| CN104190826B (en) * | 2014-09-01 | 2016-04-06 | 杭州蓝达工艺制品有限公司 | A kind of metal foiled paper square-bottomed bamboo basket side wall surface forming machine |
| CN108372251A (en) * | 2018-04-24 | 2018-08-07 | 三河科达实业有限公司 | Spinning electric tube expander |
| CN108372251B (en) * | 2018-04-24 | 2024-04-23 | 三河科达实业有限公司 | Spinning tube expander |
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| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Dead |