EP1614854A1 - Procédé et dispositif pour déformer une pièce en métal lors d'une application simultanée d'oscillations ultrasoniques - Google Patents

Procédé et dispositif pour déformer une pièce en métal lors d'une application simultanée d'oscillations ultrasoniques Download PDF

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Publication number
EP1614854A1
EP1614854A1 EP04076930A EP04076930A EP1614854A1 EP 1614854 A1 EP1614854 A1 EP 1614854A1 EP 04076930 A EP04076930 A EP 04076930A EP 04076930 A EP04076930 A EP 04076930A EP 1614854 A1 EP1614854 A1 EP 1614854A1
Authority
EP
European Patent Office
Prior art keywords
casing
exerting
ultrasonic oscillations
workpiece
mechanical force
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP04076930A
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German (de)
English (en)
Inventor
Louis Lopez Martinez
Pieter Cornelis Buitendijk
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Beheersmaatschappij P Buitendijk BV
Original Assignee
Beheersmaatschappij P Buitendijk BV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by Beheersmaatschappij P Buitendijk BV filed Critical Beheersmaatschappij P Buitendijk BV
Priority to EP04076930A priority Critical patent/EP1614854A1/fr
Publication of EP1614854A1 publication Critical patent/EP1614854A1/fr
Withdrawn legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E21B43/105—Expanding tools specially adapted therefor
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B4/00—Drives for drilling, used in the borehole
    • E21B4/06—Down-hole impacting means, e.g. hammers
    • E21B4/12—Electrically operated hammers

Definitions

  • the present invention is generally directed to deforming a metal workpiece and more particularly to a method and apparatus for deforming a metal workpiece by application of a mechanical force and ultrasonic oscillations, as well as a method for extracting subterranean hydrocarbons.
  • US 2003/ 0051885 teaches a method including stretching a metal casing member of a borehole, wherein an expansion tool is lowered into the casing member having a first diameter.
  • the expansion tool disclosed in US 2003/ 0051885 expands the casing member to a larger, second diameter using pulsed mechanical forces at a frequency between 10 and 50 Hz.
  • casings are constructed quite heavily to sustain hydraulic pressures without causing leakages. Therefore a large mass is required to provide a downward oriented force that has a sufficiently large amplitude. In practice, the mass is always limited. Further, much driving energy is required for exerting the mechanical force. Especially when expanding long casings, e.g. several kilometers, this will be a time consuming operation.
  • the present invention is directed toward overcoming one or more of the problems discussed above.
  • a first aspect of the invention is a method of deforming a metal workpiece, wherein the mechanical force is more effective. To that end, ultrasonic oscillations are transferred to the metal workpiece.
  • the invention is particularly useful in expanding the inner diameter of a casing.
  • By transferring ultrasonic oscillations to the casing less mechanical energy is required to obtain a predetermined expansion rate of the casing member using an expansion tool such as an expansion cone.
  • an expansion tool such as an expansion cone.
  • this is believed to be due to the fact that the deformation energy needed for the plastic irreversible deformation is provided not only by means of mechanical energy, but also by means of the ultrasonic oscillations.
  • the ultrasonic oscillations render the atomic structure of the casing member more apt for deformation, so that the mechanical force can deform it more easily and more effectively after the material of the workpiece has reached some saturation level.
  • a substantially equal expanded borehole length per time unit can be obtained by applying less mechanical energy, thus saving costs in energy and equipment.
  • Exerting less mechanical force on a casing advantageously results in less damage on the surface of the casing, e.g. sandscreens.
  • a larger deformation of the workpiece e.g., casing
  • a larger cross sectional area of a borehole can be obtained, leading to a larger throughput.
  • the material properties of the workpiece return to the normal values of the material before the application of ultrasonic oscillations.
  • the material properties are substantially the same or better than compared to the situation in which the workpiece has been deformed using mechanical forces only.
  • ultrasonic oscillation signals have a non-zero frequency spectrum which lies above the audio range, i.e. above 15-20 kHz, preferably in the range of 15 kHz to 100 kHz and higher.
  • metal workpieces also include workpieces made of alloys comprising a metal, such as steel.
  • the exertion of the mechanical force and the transfer of the ultrasonic oscillations occur substantially simultaneously, so that the oscillations and the mechanical energy cooperate in deforming the workpiece.
  • substantially simultaneously means that the mechanical force is applied within a certain time frame after transferring the ultrasonic oscillations to the workpiece, in which time frame the material properties still deviate from the normal values, so that both kinds of energy cooperate.
  • the ultrasonic oscillations and the mechanical energy can be applied to the working piece at the same instant, but it is also possible that the method comprises a sequence of transferring the ultrasonic oscillations to the workpiece and subsequently exerting the mechanical force to it within the time frame.
  • the casing area to which the ultrasonic oscillations are transferred is annular, so that the ultrasonic oscillations are equally distributed over the part of the casing member which is to be expanded. This is the situation in particular if the expansion tool is provided with an expansion cone at the lower part, so that the ultrasonic oscillations and the mechanical energy are transferred to substantially the same casing area for optimal performance of the expansion tool.
  • the ultrasonic oscillations can also be generated by means of a magnetostrictive transducer.
  • the ultrasonic oscillations are transferred to the metal piece work via an intermediate medium, so that a more efficient coupling of the ultrasonic oscillations is obtained from an energetic point of view.
  • the ultrasonic oscillations are applied to an operative portion of the casing.
  • the ultrasonic oscillations preferably vibrate the operative portion of the casing with an amplitude of at least 40 micrometers.
  • the ultrasonic oscillations may be of a radial mode, a longitudinal mode or a combination of radial and longitudinal modes.
  • a second aspect of the present invention is a tool for deforming a metal workpiece.
  • the tool includes a deformer exerting a mechanical force on the workpiece sufficient to deform the shape of the workpiece and an ultrasonic means for exerting ultrasonic oscillations on the workpiece.
  • the deformer may include an expansion cone and driving means operatively associated with the expansion cone for driving the expansion cone.
  • the workpiece is cylindrical, such as a casing.
  • the driving means drives the expansion cone axially of the casing.
  • the ultrasonic means may be a piezoelectric transducer or a magnetostrictive transducer. In those embodiments where the ultrasonic means is a piezoelectric transducer, the piezoelectric transducer may include a high strength, high ware plate.
  • a third aspect of the present invention is a casing member of a borehole made by a process including exerting ultrasonic oscillations on the casing member having a first diameter and exerting a mechanical force on the casing member, the mechanical force producing a deformation between the first and a second diameter increasing the inner diameter at least about 25%.
  • a fourth aspect of the present invention is a method for extracting hydrocarbon for a subterranean hydrocarbon deposit.
  • the method includes drilling a borehole in communication with the subterranean hydrocarbon deposit and installing a casing having a first diameter in the borehole.
  • a mechanical force is exerted on an operative portion of the casing having a first diameter to expand the operative portion of the casing to a larger, second diameter, the mechanical force being radially outwardly oriented with respect to a geometrically axis of the borehole.
  • Ultrasonic oscillations are exerted on the operative portion of the casing member substantially simultaneously to exerting the mechanical force.
  • the radially outwardly oriented mechanical force is exerted using an expansion tool having an expansion zone, the expansion tool being located above or inside the borehole near the operative portion of the casing member having the first diameter, the expansion cone of the expansion tool being subjected to a downwardly oriented mechanical force.
  • the ultrasonic oscillations on the operative portion of the casing vibrate the operative portion of the casing with an amplitude of at least 40 micrometers.
  • the ultrasonic oscillations are preferably of a longitudinal mode, a radial mode or a combination thereof.
  • the ultrasonic oscillations are preferably exerted on the workpiece by converting electrical energy to the ultrasonic oscillations using at least one of the piezoelectric transducer and a magnetostrictive transducer.
  • the ultrasonic oscillations may be exerted on the metal workpiece via an intermediate medium.
  • Fig. 1 shows a schematic view of an expansion tool according to the invention
  • Fig. 2 shows a graph of a plot of deformation curves
  • Figs. 3A and 3B are schematic views of an alternate embodiment of an expansion tool according to the present invention.
  • Figure 1 shows a schematic view of a tool 1 for deforming a workpiece according to the invention.
  • the tool 1 is an expansion tool 1 comprising a deformer.
  • the deformer may be a stamp which, in the preferred embodiment disclosed herein for use in deforming casings, is in the form of a cylindrical body 1a with an expansion cone 3.
  • the expansion tool 1 comprises ultrasonic means for transferring or exerting ultrasonic oscillations.
  • the ultrasonic means comprise an ultrasonic transducer or transducers 4, such as a piezoelectric transducer or transducers and/or a magnetostrictive transducer or transducers or a combination of both types of transducers.
  • the expansion tool 1 is placed above or within the casing 5 of a borehole, also called a tubing downhole, such as a steel pipe, which is a first embodiment of a workpiece to be deformed.
  • a borehole also called a tubing downhole, such as a steel pipe, which is a first embodiment of a workpiece to be deformed.
  • Typical boreholes have a diameter ranging from approximately 0.1 m to approximately 1 m, but smaller or larger dimensions are also possible.
  • the expansion tool 1 comprises receiving means 6 for cooperating with driving means 7 which exerts mechanical forces.
  • the driving means 7 may comprise any number of devices (either alone or in combination) for applying a mechanical force to a deformer such as a stamp or the expansion cone 3.
  • the driving means 7 may be a mechanical construction such as a vibration hammer, mechanical and/or electrical cylinder, rams, jacks, jack screws, tooth rack mechanisms, winches and/or linear motors.
  • the driving means 7 may also be a structure for applying hydraulic pressure difference on the respective sides of the deformer by pressurizable fluids; for example, hydraulic cylinders.
  • the expansion tool 1 is driven through a section 8 of the borehole with a first inner diameter (ahead of the expansion tool 1), so that a section 9 with a second, larger diameter is obtained (behind the expansion tool 1).
  • an "operative portion of a casing" is the part of the casing experiencing the diameter change.
  • the mechanical force may be exerted by the driving means on the deformer in a downward, upward or any other direction such as horizontally, so that an operative portion of a workpiece can be deformed as desired.
  • the critical aspect of application of the force is that the operative portion of the casing is enlarged during continuous movement of the expansion tool in an axial direction of the borehole.
  • the mechanical force will be exerted in a downward direction.
  • the expansion tool 1' may comprise a deformer in the form of a cylinder 20 with a substantially constant first diameter D1 which is inserted into a casing segment 22 and which is subsequently expanded to a second larger diameter by mechanical force from some form of a driving means 24 of the type described above operatively associated with the cylinder 20, thereby forcing the casing to a larger diameter D2. See Fig. 3B.
  • the cylinder is then returned to its first diameter and moved axially to an adjacent casing segment and the process is repeated.
  • This embodiment is also intended for use with the ultrasonic means as described below.
  • electrical power In situ in the borehole, electrical power, e.g. in the range of 3-30 kW, is available.
  • the electrical power can be generated locally by means of a generator, such as a hydro turbine, or can be made available via electrical energy transport means, such as copper cables 10.
  • the ultrasonic transducer 4 or transducers convert energy from the electric domain to the acoustic domain by converting electrical signals, such as alternating signals, to acoustic signals, such as ultrasonic oscillations.
  • Ultrasonic oscillations could be produced by means of either the magnetostrictive effect or by the piezoelectric effect.
  • ultrasonic oscillations generally comprise longitudinal modes and/or radial modes.
  • Longitudinal modes comprise waves oscillating lengthwise along the tube
  • radial modes comprise waves oscillating in a radial direction, which can be more difficult to generate.
  • radial modes can be applied.
  • ultrasonic oscillations of a longitudinal mode or a radial mode are transferred to the material of the borehole casing 5 via the transferring means comprising, in addition to the ultrasonic transducer(s), a transformer.
  • a combination of longitudinal mode or radial mode ultrasonic oscillations can be introduced into to the casing 5, whereby the material of the casing 5 is forced to vibrate. Vibrations of the operative portion of the casing having an amplitude of greater than 40 micrometers are preferred, although vibrations of an amplitude less than 40 micrometers may also be effective.
  • the ultrasonic means further comprises a body 2 which is tuned to resonate near the frequency of the ultrasonic oscillations.
  • the body can be integrated with the expansion cone 3, so that the mechanical force and the ultrasonic oscillations are applied to the workpiece via the same contact area.
  • the body of the ultrasonic means can be implemented differently, at different location, so that the mechanical force and the ultrasonic oscillations are separately exerted on the workpiece.
  • the tuned body can further be optimized to vibrate at desired frequencies. In this way, desired modes can be amplified while other modes that could be harmful to the structure can be suppressed.
  • Fig. 2 shows hypothetical deformation curves of materials on which mechanical forces are exerted.
  • the symbol F represents a force which is a measure for applied pressure on the workpiece.
  • the symbol D represents a deformation rate.
  • Curve B is an exemplary deformation curve of a specific material. In the area near the origin the curve is substantially linear, as the material behaves according to Hook's law. The deformation is reversible. If the deformation level increases, the curve passes a twist, after which the deformation is irreversible.
  • curve B changes to curve C.
  • a similar deformation rate D 1 requires a deformation force F2 which is much smaller than in the previous non-ultrasonic case where the deforming force F1 is applied.
  • the area under the curve is much smaller, indicating that much less strain energy is required for obtaining a predetermined deformation rate.
  • a significant increase in deformation is obtained, see e.g. D2 in the ultrasonic case versus D 1 in the non-ultrasonic case.
  • the physical effect can be explained using different theories, such as acoustic plasticity, strain energy or stress superposition approaches. Further, the amount of acoustic energy in relation to the total deformation energy can vary from application to application, e.g. ranging from approximately 1% or 2% to 10% or almost 100%.
  • the application of ultrasonic oscillations decreases the process time, reduces the deformation energy consumption, increases the degree of deformation while applying a particular mechanical deforming force or pressure, and enables workpiece deformation processes that would otherwise be difficult to perform in practice by using mechanical forces only, e.g. due to the use of a relatively thick metal layer in the workpiece or relatively rigid materials requiring too much energy, or because of the risk that cracks or other damages of the workpiece may be caused.
  • increase of the inner diameter of a casing of about 25% or more can be achieved without damaging the casing.
  • an intermediate medium is applied between the transducer or transformer, such as the expansion cone 3, and the workpiece, such as the casing of the borehole 5.
  • the intermediate medium may comprise a fluid, such as oil or other liquid.
  • the inner side of the borehole 5 can be subjected to a pretreatment for cleaning purposes, e.g. by means of a mechanical wiping arrangement, such as a wiper, by means of a heating element, such as heated oil, or by driving electrical currents into the metal borehole, thereby heating the casing.
  • a heating element such as heated oil
  • dirty particles can lose contact with the inner part of the casing, so that the borehole is cleaned. After cleaning, the surface is less rough, yielding improved direct contact with the expansion cone 3.
  • the method of deforming a metal workpiece is not limited to deforming workpieces made of casing members of a borehole, but is also applicable to workpieces made of other metal tubular pipes, such as steel tubular pipes.
  • the method of deforming a workpiece is applied for bending and forming other types of workpieces, such as metal plates, e.g. for nautical, aeronautical or other applications, or other workpieces, such as profile elements in which a local radius is to be changed.
  • a substantially flat plate is bent by exerting a mechanical force on a section of the metal plate using a stamp or die.
  • ultrasonic energy is transferred to the section of the metal plate to facilitate the bending process.
  • the ultrasonic energy is introduced into the metal plate on the outer side of the bending curve in order to avoid cracks being generated by concentrated local strain forces in this area.
  • piezoelectric transducers or magnetostrictive transducers instead of piezoelectric transducers or magnetostrictive transducers also electromagnetic means can be used, such as a laser apparatus or means by which Lorenz forces are applied.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Mining & Mineral Resources (AREA)
  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Mechanical Engineering (AREA)
  • Apparatuses For Generation Of Mechanical Vibrations (AREA)
EP04076930A 2004-07-05 2004-07-05 Procédé et dispositif pour déformer une pièce en métal lors d'une application simultanée d'oscillations ultrasoniques Withdrawn EP1614854A1 (fr)

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Application Number Priority Date Filing Date Title
EP04076930A EP1614854A1 (fr) 2004-07-05 2004-07-05 Procédé et dispositif pour déformer une pièce en métal lors d'une application simultanée d'oscillations ultrasoniques

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EP04076930A EP1614854A1 (fr) 2004-07-05 2004-07-05 Procédé et dispositif pour déformer une pièce en métal lors d'une application simultanée d'oscillations ultrasoniques

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4131775A1 (de) * 1991-09-24 1993-03-25 Bernd Oertel Verfahren zur herstellung von kontaktkoerpern und/oder kontaktbauelementen
US20020014100A1 (en) 2000-05-30 2002-02-07 Prokopenko George I. Device for ultrasonic peening of metals
US20030051885A1 (en) 2001-06-19 2003-03-20 Simpson Neil Andrew Abercrombie Tubing expansion
WO2003064813A1 (fr) * 2002-01-29 2003-08-07 E2Tech Limited Appareil et procede d'elargissement d'elements tubulaires
WO2003080994A1 (fr) * 2002-03-22 2003-10-02 Andergauge Limited Procede de deformation d'un element tubulaire
WO2004026017A2 (fr) * 2002-09-20 2004-04-01 Enventure Global Technology Contraintes residuelles dans une gaine tubulaire extensible

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4131775A1 (de) * 1991-09-24 1993-03-25 Bernd Oertel Verfahren zur herstellung von kontaktkoerpern und/oder kontaktbauelementen
US20020014100A1 (en) 2000-05-30 2002-02-07 Prokopenko George I. Device for ultrasonic peening of metals
US20030051885A1 (en) 2001-06-19 2003-03-20 Simpson Neil Andrew Abercrombie Tubing expansion
WO2003064813A1 (fr) * 2002-01-29 2003-08-07 E2Tech Limited Appareil et procede d'elargissement d'elements tubulaires
WO2003080994A1 (fr) * 2002-03-22 2003-10-02 Andergauge Limited Procede de deformation d'un element tubulaire
WO2004026017A2 (fr) * 2002-09-20 2004-04-01 Enventure Global Technology Contraintes residuelles dans une gaine tubulaire extensible

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