US20060266527A1 - Apparatus for radially expanding and plastically deforming a tubular member - Google Patents
Apparatus for radially expanding and plastically deforming a tubular member Download PDFInfo
- Publication number
- US20060266527A1 US20060266527A1 US10/552,253 US55225305A US2006266527A1 US 20060266527 A1 US20060266527 A1 US 20060266527A1 US 55225305 A US55225305 A US 55225305A US 2006266527 A1 US2006266527 A1 US 2006266527A1
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- US
- United States
- Prior art keywords
- tubular member
- expansion device
- filed
- expandable
- adjustable expansion
- 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.)
- Abandoned
Links
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Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B21/00—Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor
- E21B21/10—Valve arrangements in drilling-fluid circulation systems
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B23/00—Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells
- E21B23/06—Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells for setting packers
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B29/00—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
- E21B29/002—Cutting, e.g. milling, a pipe with a cutter rotating along the circumference of the pipe
- E21B29/005—Cutting, e.g. milling, a pipe with a cutter rotating along the circumference of the pipe with a radially-expansible cutter rotating inside the pipe, e.g. for cutting an annular window
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/12—Packers; Plugs
- E21B33/128—Packers; Plugs with a member expanded radially by axial pressure
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/12—Packers; Plugs
- E21B33/128—Packers; Plugs with a member expanded radially by axial pressure
- E21B33/1285—Packers; Plugs with a member expanded radially by axial pressure by fluid pressure
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/12—Packers; Plugs
- E21B33/129—Packers; Plugs with mechanical slips for hooking into the casing
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/12—Packers; Plugs
- E21B33/129—Packers; Plugs with mechanical slips for hooking into the casing
- E21B33/1291—Packers; Plugs with mechanical slips for hooking into the casing anchor set by wedge or cam in combination with frictional effect, using so-called drag-blocks
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/12—Packers; Plugs
- E21B33/129—Packers; Plugs with mechanical slips for hooking into the casing
- E21B33/1295—Packers; Plugs with mechanical slips for hooking into the casing actuated by fluid pressure
- E21B33/12955—Packers; Plugs with mechanical slips for hooking into the casing actuated by fluid pressure using drag blocks frictionally engaging the inner wall of the well
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/13—Methods or devices for cementing, for plugging holes, crevices, or the like
- E21B33/14—Methods or devices for cementing, for plugging holes, crevices, or the like for cementing casings into boreholes
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B34/00—Valve arrangements for boreholes or wells
- E21B34/06—Valve arrangements for boreholes or wells in wells
- E21B34/14—Valve arrangements for boreholes or wells in wells operated by movement of tools, e.g. sleeve valves operated by pistons or wire line tools
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP 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
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP 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
Definitions
- This invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration.
- an apparatus for radially expanding and plastically deforming an expandable tubular member includes a support member, a cutting device for cutting the tubular member coupled to the support member, and an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member.
- an apparatus for radially expanding and plastically deforming an expandable tubular member includes a support member, an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member, and an actuator coupled to the support member for displacing the expansion device relative to the support member.
- an apparatus for radially expanding and plastically deforming an expandable tubular member includes a support member; an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a sealing assembly for sealing an annulus defined between the support member and the tubular member.
- an apparatus for radially expanding and plastically deforming an expandable tubular member includes a support member; a first expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a second expansion device for radially expanding and plastically deforming the tubular member coupled to the support member.
- an apparatus for radially expanding and plastically deforming an expandable tubular member includes a support member; an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a packer coupled to the support member.
- an apparatus for radially expanding and plastically deforming an expandable tubular member includes a support member; a cutting device for cutting the tubular member coupled to the support member; a gripping device for gripping the tubular member coupled to the support member; a sealing device for sealing an interface with the tubular member coupled to the support member; a locking device for locking the position of the tubular member relative to the support member; a first adjustable expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; a second adjustable expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; a packer coupled to the support member; and an actuator for displacing one or more of the sealing assembly, first and second adjustable expansion devices, and packer relative to the support member.
- an apparatus for cutting a tubular member includes a support member; and a plurality of movable cutting elements coupled to the support member.
- an apparatus for engaging a tubular member includes a support member; and a plurality of movable elements coupled to the support member.
- an apparatus for gripping a tubular member that includes a plurality of movable gripping elements.
- an actuator includes a tubular housing; a tubular piston rod movably coupled to and at least partially positioned within the housing; a plurality of annular piston chambers defined by the tubular housing and the tubular piston rod; and a plurality of tubular pistons coupled to the tubular piston rod, each tubular piston movably positioned within a corresponding annular piston chamber.
- an apparatus for controlling a packer includes a tubular support member; one or more drag blocks releasably coupled to the tubular support member; and a tubular stinger coupled to the tubular support member for engaging the packer.
- a packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve movably positioned within the passage of the support member.
- a method of radially expanding and plastically deforming an expandable tubular member within a borehole having a preexisting wellbore casing includes positioning the tubular member within the borehole in overlapping relation to the wellbore casing; radially expanding and plastically deforming a portion of the tubular member to form a bell section; and radially expanding and plastically deforming a portion of the tubular member above the bell section comprising a portion of the tubular member that overlaps with the wellbore casing; wherein the inside diameter of the bell section is greater than the inside diameter of the radially expanded and plastically deformed portion of the tubular member above the bell section.
- a method for forming a mono diameter wellbore casing includes positioning an adjustable expansion device within a first expandable tubular member; supporting the first expandable tubular member and the adjustable expansion device within a borehole; lowering the adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; positioning the adjustable expansion device within a second expandable tubular member; supporting the second expandable tubular member and the adjustable expansion device within the borehole in overlapping relation to the first expandable tubular member; lowering the adjustable expansion device out of the second expandable tubular member; increasing the outside dimension of the adjustable expansion device; and displacing the adjustable expansion device upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole
- a method for radially expanding and plastically deforming an expandable tubular member within a borehole includes positioning an adjustable expansion device within the expandable tubular member; supporting the expandable tubular member and the adjustable expansion device within the borehole; lowering the adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the adjustable expansion device; displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the borehole; and pressurizing an interior region of the expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the expandable tubular member within the borehole.
- a method for forming a mono diameter wellbore casing includes positioning an adjustable expansion device within a first expandable tubular member; supporting the first expandable tubular member and the adjustable expansion device within a borehole; lowering the adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; pressurizing an interior region of the first expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the first expandable tubular member within the borehole; positioning the adjustable expansion mandrel within a second expandable tubular member; supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member; lowering the adjustable expansion mandrel out of the second expandable tubular member; increasing the outside dimension of the adjustable
- a method for radially expanding and plastically deforming an expandable tubular member within a borehole includes positioning first and second adjustable expansion devices within the expandable tubular member; supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; lowering the first adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of
- a method for forming a mono diameter wellbore casing includes positioning first and second adjustable expansion devices within a first expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; lowering the first adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; positioning first and second adjustable expansion devices within a second expandable tubular member;
- a method for radially expanding and plastically deforming an expandable tubular member within a borehole includes positioning first and second adjustable expansion devices within the expandable tubular member; supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; lowering the first adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; pressurizing an interior region of the expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the expandable tubular member by the first adjustable expansion device; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand
- a method for forming a mono diameter wellbore casing includes positioning first and second adjustable expansion devices within a first expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; lowering the first adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; pressurizing an interior region of the first expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the first expandable tubular member by the first adjustable expansion device; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radi
- a method for radially expanding and plastically deforming an expandable tubular member within a borehole includes supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; increasing the size of the adjustable expansion device; and displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member.
- a method for forming a mono diameter wellbore casing within a borehole that includes a preexisting wellbore casing includes supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; increasing the size of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting wellbore casing that overlaps with an end of the remaining portion of the expandable tubular member.
- a method of radially expanding and plastically deforming a tubular member includes positioning the tubular member within a preexisting structure; radially expanding and plastically deforming a lower portion of the tubular member to form a bell section; and radially expanding and plastically deforming a portion of the tubular member above the bell section.
- a method of radially expanding and plastically deforming a tubular member includes applying internal pressure to the inside surface of the tubular member at a plurality of discrete location separated from one another.
- a system for radially expanding and plastically deforming an expandable tubular member within a borehole having a preexisting wellbore casing includes means for positioning the tubular member within the borehole in overlapping relation to the wellbore casing; means for radially expanding and plastically deforming a portion of the tubular member to form a bell section; and means for radially expanding and plastically deforming a portion of the tubular member above the bell section comprising a portion of the tubular member that overlaps with the wellbore casing; wherein the inside diameter of the bell section is greater than the inside diameter of the radially expanded and plastically deformed portion of the tubular member above the bell section.
- a system for forming a mono diameter wellbore casing includes means for positioning an adjustable expansion device within a first expandable tubular member; means for supporting the first expandable tubular member and the adjustable expansion device within a borehole; means for lowering the adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; means for positioning the adjustable expansion device within a second expandable tubular member; means for supporting the second expandable tubular member and the adjustable expansion device within the borehole in overlapping relation to the first expandable tubular member; means for lowering the adjustable expansion device out of the second expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; and means for displacing the adjustable expansion device upwardly relative to the second expandable tubular member n times to radially expand
- a system for radially expanding and plastically deforming an expandable tubular member within a borehole includes means for positioning an adjustable expansion device within the expandable tubular member; means for supporting the expandable tubular member and the adjustable expansion device within the borehole; means for lowering the adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; means for displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the borehole; and means for pressurizing an interior region of the expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the expandable tubular member within the borehole.
- a system for forming a mono diameter wellbore casing includes means for positioning an adjustable expansion device within a first expandable tubular member; means for supporting the first expandable tubular member and the adjustable expansion device within a borehole; means for lowering the adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; means for pressurizing an interior region of the first expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the first expandable tubular member within the borehole; means for positioning the adjustable expansion mandrel within a second expandable tubular member; means for supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member; means for lowering the adjustable expansion mandre
- a system for radially expanding and plastically deforming an expandable tubular member within a borehole includes means for positioning first and second adjustable expansion devices within the expandable tubular member; means for supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; means for lowering the first adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; wherein
- a system for forming a mono diameter wellbore casing includes means for positioning first and second adjustable expansion devices within a first expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; means for lowering the first adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; means for positioning
- a system for radially expanding and plastically deforming an expandable tubular member within a borehole includes means for positioning first and second adjustable expansion devices within the expandable tubular member; means for supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; means for lowering the first adjustable expansion device out of the expandable tubular member, means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; means for pressurizing an interior region of the expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the expandable tubular member by the first adjustable expansion device; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second
- a system for forming a mono diameter wellbore casing includes means for positioning first and second adjustable expansion devices within a first expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; means for lowering the first adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; means for pressurizing an interior region of the first expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the first expandable tubular member by the first adjustable expansion device; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the
- a system for radially expanding and plastically deforming an expandable tubular member within a borehole includes means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; means for increasing the size of the adjustable expansion device; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member.
- a system for forming a mono diameter wellbore casing within a borehole that includes a preexisting wellbore casing includes means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; means for increasing the size of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting wellbore casing that overlaps with an end of the remaining portion of the expandable tubular member.
- a system for radially expanding and plastically deforming a tubular member includes means for positioning the tubular member within a preexisting structure; means for radially expanding and plastically deforming a lower portion of the tubular member to form a bell section; and means for radially expanding and plastically deforming a portion of the tubular member above the bell section.
- a system of radially expanding and plastically deforming a tubular member that includes a support member; and means for applying internal pressure to the inside surface of the tubular member at a plurality of discrete location separated from one another coupled to the support member.
- a method of cutting a tubular member includes positioning a plurality of cutting elements within the tubular member; and bringing the cutting elements into engagement with the tubular member.
- a method of gripping a tubular member includes positioning a plurality of gripping elements within the tubular member; bringing the gripping elements into engagement with the tubular member.
- bringing the gripping elements into engagement with the tubular member includes displacing the gripping elements in an axial direction; and displacing the gripping elements in a radial direction.
- a method of operating an actuator includes pressurizing a plurality of pressure chamber.
- a method of injecting a hardenable fluidic sealing material into an annulus between a tubular member and a preexisting structure includes positioning the tubular member into the preexisting structure; sealing off an end of the tubular member; operating a valve within the end of the tubular member; and injecting a hardenable fluidic sealing material through the valve into the annulus between the tubular member and the preexisting structure.
- a system for cutting a tubular member includes means for positioning a plurality of cutting elements within the tubular member; and means for bringing the cutting elements into engagement with the tubular member.
- a system for gripping a tubular member includes means for positioning a plurality of gripping elements within the tubular member;, and means for bringing the gripping elements into engagement with the tubular member.
- an actuator system that includes a support member; and means for pressurizing a plurality of pressure chambers coupled to the support member.
- the system further includes means for transmitting torsional loads.
- a system for injecting a hardenable fluidic sealing material into an annulus between a tubular member and a preexisting structure includes means for positioning the tubular member into the preexisting structure; means for sealing off an end of the tubular member; means for operating a valve within the end of the tubular member; and means for injecting a hardenable fluidic sealing material through the valve into the annulus between the tubular member and the preexisting structure.
- a method of engaging a tubular member includes positioning a plurality of elements within the tubular member; and bringing the elements into engagement with the tubular member.
- a system for engaging a tubular member includes means for positioning a plurality of elements within the tubular member; and means for bringing the elements into engagement with the tubular member.
- the elements include a first group of elements; and a second group of elements; wherein the first group of elements are interleaved with the second group of elements.
- FIG. 1 is a fragmentary cross-sectional illustration of an embodiment of a system for radially expanding and plastically deforming wellbore casing, including a tubular support member, a casing cutter, a ball gripper for gripping a wellbore casing, a force multiplier tension actuator, a safety sub, a cup sub, a casing lock, an extension actuator, a bell section adjustable expansion cone assembly, a casing section adjustable expansion cone assembly, a packer setting tool, a packer, a stinger, and an expandable wellbore casing, during the placement of the system within a wellbore.
- FIG. 2 is a fragmentary cross-sectional illustration of the system of FIG. 1 during the subsequent displacement of the bell section adjustable expansion cone assembly, the casing section adjustable expansion cone assembly, the packer setting tool, the packer, and the stinger downwardly out of the end of the expandable wellbore casing and the expansion of the size of the bell section adjustable expansion cone assembly and the casing section adjustable expansion cone assembly.
- FIG. 3 is a fragmentary cross-sectional illustration of the system of FIG. 2 during the subsequent operation of the tension actuator to displace the bell section adjustable expansion cone assembly upwardly into the end of the expandable wellbore casing to form a bell section in the end of the expandable wellbore casing.
- FIG. 4 is a fragmentary cross-sectional illustration of the system of FIG. 3 during the subsequent reduction of the bell section adjustable expansion cone assembly.
- FIG. 5 is a fragmentary cross-sectional illustration of the system of FIG. 4 during the subsequent upward displacement of the expanded casing section adjustable expansion cone assembly to radially expand the expandable wellbore casing.
- FIG. 6 is a fragmentary cross-sectional illustration of the system of FIG. 5 during the subsequent lowering of the tubular support member, casing cutter, ball gripper, a force multiplier tension actuator, safety sub, cup sub, casing lock, extension actuator, bell section adjustable expansion cone assembly, casing section adjustable expansion cone assembly, packer setting tool, packer, and stinger and subsequent setting of the packer within the expandable wellbore casing above the bell section.
- FIG. 7 is a fragmentary cross-sectional illustration of the system of FIG. 6 during the subsequent injection of fluidic materials into the system to displace the expanded casing section adjustable expansion cone assembly upwardly through the expandable wellbore casing to radially expand and plastically deform the expandable wellbore casing.
- FIG. 8 is a fragmentary cross-sectional illustration of the system of FIG. 7 during the subsequent injection of fluidic materials into the system to displace the expanded casing section adjustable expansion cone assembly upwardly through the expandable wellbore casing and a surrounding preexisting wellbore casing to radially expand and plastically deform the overlapping expandable wellbore casing and the surrounding preexisting wellbore casing.
- FIG. 9 is a fragmentary cross-sectional illustration of the system of FIG. 8 during the subsequent operation of the casing cutter to cut off an end of the expandable wellbore casing.
- FIG. 10 is a fragmentary cross-sectional illustration of the system of FIG. 9 during the subsequent removal of the cut off end of the expandable wellbore casing.
- FIGS. 11-1 and 11 - 2 are fragmentary cross-sectional and perspective illustrations of an exemplary embodiment of a casing cutter assembly.
- FIGS. 12 A 1 to 12 A 4 and 12 C 1 to 12 C 4 are fragmentary cross-sectional illustrations of an exemplary embodiment of a ball gripper assembly.
- FIG. 12B is a top view of a portion of the ball gripper assembly of FIGS. 12 A 1 to 12 A 4 and 12 C 1 to 12 C 4 .
- FIGS. 13 A 1 to 13 A 8 and 13 B 1 to 13 B 7 are fragmentary cross-sectional illustrations of an exemplary embodiment of a tension actuator assembly.
- FIG. 14A is a fragmentary cross-sectional illustrations of an exemplary embodiment of a safety sub assembly.
- FIGS. 14A, 14B and 14 C are fragmentary cross-sectional and perspective illustrations of an exemplary embodiment of a cup seal assembly.
- FIGS. 15-1 and 15 - 2 are fragmentary cross-sectional and perspective illustrations of an exemplary embodiment of an adjustable bell section expansion cone assembly.
- FIGS. 16-1 and 16 - 2 , 16 A 1 to 16 A 2 , 16 B 1 to 16 B 2 , 16 C, 16 D, 16 E, 16 F, 16 G, 16 H, 161 , 16 j , 16 K, 16 L, 16 M, 16 N, 160 , 16 P, 16 R, 16 S, 16 T, 16 U, 16 V, 16 W, 16 ⁇ , 16 Y, 16 Z 1 - 16 Z 4 , 16 AA 1 to 16 AA 4 , 16 AB 1 to 16 AB 4 , 16 AC 1 to 16 AC 4 , 16 AD, and 16 AE are fragmentary cross-sectional and perspective illustrations of an exemplary embodiment of an adjustable casing expansion cone assembly.
- FIGS. 17A to 17 C is a fragmentary cross-sectional illustration of an exemplary embodiment of a packer setting tool assembly.
- FIGS. 18-1 to 18 - 5 is a fragmentary cross-sectional illustration of an exemplary embodiment of a packer assembly.
- FIGS. 19 A 1 to 19 A 5 , 19 B 1 to 19 B 5 , 19 C 1 to 19 C 5 , 19 D 1 to 19 D 5 , 19 E 1 to 19 E 6 , 19 F 1 to 19 F 6 , 19 G 1 to 19 G 6 , and 19 H 1 to 19 H 5 are fragmentary cross-sectional illustrations of an exemplary embodiment of the operation of the packer setting tool and the packer assembly of FIGS. 17A to 17 C and 18 - 1 to 18 - 5 .
- FIGS. 20 and 20 A to 20 AX are fragmentary perspective and cross-sectional illustrations of an alternative embodiment of the packer assembly.
- an exemplary embodiment of a system 10 for radially expanding and plastically deforming a wellbore casing includes a conventional tubular support 12 having an end that is coupled to an end of a casing cutter assembly 14 .
- the casing cutter assembly 14 may be, or may include elements, of one or more conventional commercially available casing cutters for cutting wellbore casing, or equivalents thereof.
- ball gripper assembly 16 is coupled to another end of the casing cutter assembly 14 .
- the ball gripper assembly 14 may be, or may include elements, of one or more conventional commercially available ball grippers, or other types of gripping devices, for gripping wellbore casing, or equivalents thereof.
- tension actuator assembly 18 is coupled to another end of the ball gripper assembly 16 .
- the tension actuator assembly 18 may be, or may include elements, of one or more conventional commercially actuators, or equivalents thereof.
- a safety sub assembly 20 is coupled to another end of the tension actuator assembly 18 .
- the safety sub assembly 20 may be, or may include elements, of one or more conventional apparatus that provide quick connection and/or disconnection of tubular members, or equivalents thereof.
- sealing cup assembly 22 An end of a sealing cup assembly 22 is coupled to another end of the safety sub assembly 20 .
- the sealing cup assembly 22 may be, or may include elements, of one or more conventional sealing cup assemblies, or other types of sealing assemblies, that sealingly engage the interior surfaces of surrounding tubular members, or equivalents thereof.
- casing lock assembly 24 An end of a casing lock assembly 24 is coupled to another end of the sealing cup assembly 22 .
- the casing lock assembly 24 may be, or may include elements, of one or more conventional casing lock assemblies that lock the position of wellbore casing, or equivalents thereof.
- an end of an extension actuator assembly 26 is coupled to another end of the casing lock assembly 24 .
- the extension actuator assembly 26 may be, or may include elements, of one or more conventional actuators, or equivalents thereof.
- an end of an adjustable bell section expansion cone assembly 28 is coupled to another end of the extension actuator assembly 26 .
- the adjustable bell section expansion cone assembly 28 may be, or may include elements, of one or more conventional adjustable expansion devices for radially expanding and plastically deforming wellbore casing, or equivalents thereof.
- an end of an adjustable casing expansion cone assembly 30 is coupled to another end of the adjustable bell section expansion cone assembly 28 .
- the adjustable casing expansion cone assembly 30 may be, or may include elements, of one or more conventional adjustable expansion devices for radially expanding and plastically deforming wellbore casing, or equivalents thereof.
- a packer setting tool assembly 32 is coupled to another end of the adjustable casing expansion cone assembly 30 .
- the packer setting tool assembly 32 may be, or may include elements, of one or more conventional adjustable expansion devices for controlling the operation of a conventional packer, or equivalents thereof.
- a stinger assembly 34 is coupled to another end of the packer setting tool assembly 32 .
- the stinger assembly 34 may be, or may include elements, of one or more conventional devices for engaging a conventional packer, or equivalents thereof.
- An end of a packer assembly 36 is coupled to another end of the stinger assembly 34 .
- the packer assembly 36 may be, or may include elements, of one or more conventional packers.
- one or more of the elements of the system 10 may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements of the system.
- an expandable wellbore casing 100 is coupled to and supported by the casing lock assembly 24 of the system.
- the system 10 is then positioned within a wellbore 102 that traverses a subterranean formation 104 and includes a preexisting wellbore casing 106 .
- the extension actuator assembly 26 is then operated to move the adjustable bell section expansion cone assembly 28 , adjustable casing expansion cone assembly 30 , packer setting tool assembly 32 , stinger assembly 34 , packer assembly 36 downwardly in a direction 108 and out of an end of the expandable wellbore casing 100 .
- the adjustable bell section expansion cone assembly 28 and adjustable casing expansion cone assembly 30 have been moved to a position out of the end of the expandable wellbore casing 100
- the adjustable bell section expansion cone assembly and adjustable casing expansion cone assembly are then operated to increase the outside diameters of the expansion cone assemblies.
- the increased outside diameter of the adjustable bell section expansion cone assembly 28 is greater than the increased outside diameter of the adjustable casing expansion cone assembly 30 .
- the ball gripper assembly 16 is then operated to engage and hold the position of the expandable tubular member 100 stationary relative to the tubular support member 12 .
- the tension actuator assembly 18 is then operated to move the adjustable bell section expansion cone assembly 28 , adjustable casing expansion cone assembly 30 , packer setting tool assembly 32 , stinger assembly 34 , packer assembly 36 upwardly in a direction 110 into and through the end of the expandable wellbore casing 100 .
- the end of the expandable wellbore casing 100 is radially expanded and plastically deformed by the adjustable bell section expansion cone assembly 28 to form a bell section 112 .
- the casing lock assembly 24 may or may not be coupled to the expandable wellbore casing 100 .
- the length of the end of the expandable wellbore casing 100 that is radially expanded and plastically deformed by the adjustable bell section expansion cone assembly 28 is limited by the stroke length of the tension actuator assembly 18 .
- the ball gripper assembly 16 is operated to release the expandable tubular member 100 , and the tubular support 12 is moved upwardly to permit the tension actuator assembly to be re-set. In this manner, the length of the bell section 112 can be further extended by continuing to stroke and then re-set the position of the tension actuator assembly 18 . Note, that, during the upward movement of the tubular support 12 to re-set the position of the tension actuator assembly 18 , the expandable tubular wellbore casing 100 is supported by the expansion surfaces of the adjustable bell section expansion cone assembly 28 .
- the casing lock assembly 24 is then operated to engage and maintain the position of the expandable wellbore casing 100 stationary relative to the tubular support 12 .
- the adjustable bell section expansion cone assembly 28 , adjustable casing expansion cone assembly 30 , packer setting tool assembly 32 , stinger assembly 34 , and packer assembly 36 are displaced downwardly into the bell section 112 in a direction 114 relative to the expandable wellbore casing 100 by operating the extension actuator 26 and/or by displacing the system 10 downwardly in the direction 114 relative to the expandable wellbore casing.
- the adjustable bell section expansion cone assembly 28 and adjustable casing expansion cone assembly 30 have been moved downwardly in the direction 114 into the bell section 112 of the expandable wellbore casing 100 , the adjustable bell section expansion cone assembly is then operated to decrease the outside diameter of the adjustable bell section expansion cone assembly.
- the decreased outside diameter of the adjustable bell section expansion cone assembly 28 is less than the increased outside diameter of the adjustable casing expansion cone assembly 30 .
- the ball gripper 16 may or may not be operated to engage the expandable wellbore casing 100 .
- the casing lock assembly 24 is then disengaged from the expandable wellbore casing 100 and fluidic material 116 is then injected into the system 10 through the tubular support 12 to thereby pressurize an annulus 118 defined within the expandable wellbore casing below the cup sub assembly 22 .
- a pressure differential is created across the cup seal assembly 22 that causes the cup seal assembly to apply a tensile force in the direction 120 to the system 10 .
- the system 10 is displaced upwardly in the direction 120 relative to the expandable wellbore casing 100 thereby pulling the adjustable casing expansion cone assembly 30 upwardly in the direction 120 through the expandable wellbore casing thereby radially expanding and plastically deforming the expandable wellbore casing.
- the tension actuator assembly 16 may also be operated during the injection of the fluidic material 116 to displace the adjustable casing expansion cone assembly 30 upwardly relative to the tubular support 12 . As a result, additional expansion forces may be applied to the expandable wellbore casing 100 .
- the radial expansion and plastic deformation of the expandable wellbore casing using the adjustable casing expansion cone assembly 30 continues until the packer assembly 36 is positioned within a portion of the expandable tubular member above the bell section 112 .
- the packer assembly 36 may then be operated to engage the interior surface of the expandable wellbore casing 100 above the bell section 112 .
- a hardenable fluidic sealing material 122 may then be injected into the system 10 through the tubular support 12 and then out of the system through the packer assembly to thereby permit the annulus between the expandable wellbore casing and the wellbore 102 to be filled with the hardenable fluidic sealing material.
- the hardenable fluidic sealing material 122 may then be allowed to cure to form a fluid tight annulus between the expandable wellbore casing 100 and the wellbore 102 , before, during, or after the completion of the radial expansion and plastic deformation of the expandable wellbore casing.
- the fluidic material 116 is then re-injected into the system 10 through the tubular support 12 to thereby re-pressurize the annulus 118 defined within the expandable wellbore casing below the cup sub assembly 22 .
- a pressure differential is once again created across the cup seal assembly 22 that causes the cup seal assembly to once again apply a tensile force in the direction 120 to the system 10 .
- the system 10 is displaced upwardly in the direction 120 relative to the expandable wellbore casing 100 thereby pulling the adjustable casing expansion cone assembly 30 upwardly in the direction 120 through the expandable wellbore casing thereby radially expanding and plastically deforming the expandable wellbore casing and disengaging the stinger assembly 34 from the packer assembly 36 .
- the packer assembly 36 prevents the flow of fluidic materials out of the expandable wellbore casing 100 .
- the pressurization of the annulus 118 is rapid and efficient thereby enhancing the operational efficiency of the subsequent radial expansion and plastic deformation of the expandable wellbore casing 100 .
- the tension actuator assembly 16 may also be operated during the re-injection of the fluidic material 116 to displace the adjustable casing expansion cone assembly 30 upwardly relative to the tubular support 12 . As a result, additional expansion forces may be applied to the expandable wellbore casing 100 .
- the radial expansion and plastic deformation of the expandable wellbore casing using the adjustable casing expansion cone assembly 30 continues until the adjustable casing expansion c/one assembly 30 reaches the portion 124 of the expandable wellbore casing 100 that overlaps with the preexisting wellbore casing 106 .
- the system 10 may radially expand the portion 124 of the expandable wellbore casing 100 that overlaps with the preexisting wellbore casing 106 and the surrounding portion of the preexisting wellbore casing.
- the tension actuator assembly 16 is also operated to displace the adjustable casing expansion cone assembly 30 upwardly relative to the tubular support 12 .
- additional expansion forces may be applied to the expandable wellbore casing 100 and the preexisting wellbore casing 106 during the radial expansion of the portion 124 of the expandable wellbore casing that overlaps with the preexisting wellbore casing.
- the entire length of the portion 124 of the expandable wellbore casing 100 that overlaps with the preexisting wellbore casing 106 is not radially expanded and plastically deformed. Rather, only part of the portion 124 of the expandable wellbore casing 100 that overlaps with the preexisting wellbore casing 106 is radially expanded and plastically deformed. The remaining part of the portion 124 of the expandable wellbore casing 100 that overlaps with the preexisting wellbore casing 106 is then cut away by operating the casing cutter assembly 14 .
- the remaining part of the portion 124 of the expandable wellbore casing 100 that overlaps with the preexisting wellbore casing 106 that is cut away by operating the casing cutter assembly 14 is then also carried out of the wellbore 102 using the casing cutter assembly.
- the inside diameter of the expandable wellbore casing 100 above the bell section 112 is equal to the inside diameter of the portion of the preexisting wellbore casing 106 that does not overlap with the expandable wellbore casing 100 .
- a wellbore casing is constructed that includes overlapping wellbore casings that together define an internal passage having a constant cross-sectional area.
- one or more of the operational elements of the system 10 may be omitted, at least in part, and/or combined, at least in part, with one or more of the other operational elements of the system.
- the system 10 includes one or more of the methods and apparatus disclosed in one or more of the following: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claims priority from provisional application 60/121,702, filed on Feb. 25, 1999, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb.
- the casing cutter assembly 14 is provided and operates substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, filed on Sep. 22, 2003, and/or (2) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (3) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (4) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference.
- the casing cutter assembly 14 includes an upper tubular tool joint 14002 that defines a longitudinal passage 14002 a and mounting holes, 14002 b and 14002 c , and includes an internal threaded connection 14002 d , an inner annular recess 14002 e , an inner annular recess 14002 f , and an internal threaded connection 14002 g .
- a tubular torque plate 14004 that defines a longitudinal passage 14004 a and includes circumferentially spaced apart teeth 14004 b is received within, mates with, and is coupled to the internal annular recess 14002 e of the upper tubular tool joint 14002 .
- a sealing element 14010 is received within the external annular recess 14008 y of the tubular toggle bushing 14008 for sealing the interface between the tubular toggle bushing and the upper tubular tool joint 14002 .
- a sealing element 14012 is received within the internal annular recess 14008 z of the tubular toggle bushing 14008 for sealing the interface between the tubular toggle bushing and the tubular lower mandrel 14006 .
- Mounting screws, 14014 a and 14014 b , mounted within and coupled to the mounting holes, 14008 w and 14008 x , respectively, of the tubular toggle bushing 14008 are also received within the mounting holes, 14002 b and 14002 c , of the upper tubular tool joint 14002 .
- Mounting pins, 14016 a , 14016 b , 14016 c , 14016 d , and 14016 e are mounted within the mounting holes, 14008 e , 14008 f , 14008 g , 14008 h , and 14008 i , respectively.
- Mounting pins, 14018 a , 14018 b , 14018 c , 14018 d , and 14018 e are mounted within the mounting holes, 14008 t , 14008 s , 14008 r , 14008 q , and 14008 p , respectively.
- Mounting screws, 14020 a and 14020 b are mounted within the mounting holes, 14008 u and 14008 v , respectively.
- a first upper toggle link 14022 defines mounting holes, 14022 a and 14022 b , for receiving the mounting pins, 14016 a and 14016 b , and includes a mounting pin 14022 c at one end.
- a first lower toggle link 14024 defines mounting holes, 14024 a , 14024 b , and 14024 c , for receiving the mounting pins, 14022 c , 14016 c , and 14016 d , respectively and includes an engagement arm 14024 d .
- a first trigger 14026 defines a mounting hole 14026 a for receiving the mounting pin 14016 e and includes an engagement arm 14026 b at one end, an engagement member 14026 c , and an engagement arm 14026 d at another end.
- a second upper toggle link 14028 defines mounting holes, 14028 a and 14028 b , for receiving the mounting pins, 14018 a and 14018 b , and includes a mounting pin 14028 c at one end.
- a second lower toggle link 14030 defines mounting holes, 14030 a , 14030 b , and 14030 c , for receiving the mounting pins, 14028 c , 14018 c , and 14018 d , respectively and includes an engagement arm 14030 d .
- a second trigger 14032 defines a mounting hole 14032 a for receiving the mounting pin 14018 e and includes an engagement arm 14032 b at one end, an engagement member 14032 c , and an engagement arm 14032 d at another end.
- An end of a tubular spring housing 14034 that defines a longitudinal passage 14034 a , mounting holes, 14034 b and 14034 c , and mounting holes, 14034 ba and 14034 ca , and includes an internal flange 14034 d and an internal annular recess 14034 e at one end, and an internal flange 14034 f , an internal annular recess 14034 g , an internal annular recess 14034 h , and an external threaded connection 14034 i at another end receives and mates with the end of the tubular toggle bushing 14008 .
- Mounting screws, 14035 a and 14035 b are mounted within and coupled to the mounting holes, 14008 xb and 14008 xa , respectively, of the tubular toggle bushing 14008 and are received within the mounting holes, 14034 ba and 14034 ca , respectively, of the tubular spring housing 14034 .
- a tubular retracting spring ring 14036 that defines mounting holes, 14036 a and 14036 b , receives and mates with a portion of the tubular lower mandrel 14006 and is received within and mates with a portion of the tubular spring housing 14034 .
- Mounting screws, 14038 a and 14038 b are mounted within and coupled to the mounting holes, 14036 a and 14036 b , respectively, of the tubular retracting spring ring 14036 and extend into the mounting holes, 14034 b and 14034 c , respectively, of the tubular spring housing 14034 .
- Casing diameter sensor springs, 14040 a and 14040 b are positioned within the longitudinal slots, 14008 c and 1408 d , respectively, of the tubular toggle bushing 14008 that engage the engagement members, 14026 c and 14032 c , and engagement arms, 14026 d and 14032 d , of the first and second triggers, 14026 and 14032 , respectively.
- An inner flange 14042 a of an end of a tubular spring washer 14042 mates with and receives a portion of the tubular lower mandrel 14006 and an end face of the inner flange of the tubular spring washer is positioned proximate and end face of the external flange 14006 d of the tubular lower mandrel.
- the tubular spring washer 14042 is further received within the longitudinal passage 14034 a of the tubular spring housing 14034 .
- An end of a retracting spring 14044 that receives the tubular lower mandrel 14006 is positioned within the tubular spring washer 14042 in contact with the internal flange 14042 a of the tubular spring washer and the other end of the retracting spring is positioned in contact with an end face of the tubular retracting spring ring 14036 .
- a sealing element 14046 is received within the external annular recess 14006 j of the tubular lower mandrel 14006 for sealing the interface between the tubular lower mandrel and the tubular spring housing 14034 .
- a sealing element 14048 is received within the internal annular recess 14034 h of the tubular spring housing 14034 for sealing the interface between the tubular spring housing and the tubular lower mandrel 14006 .
- An internal threaded connection 14050 a of an end of a tubular upper hinge sleeve 14050 that includes an internal flange 14050 b and an internal pivot 14050 c receives and is coupled to the external threaded connection 14034 i of the end of the tubular spring housing 14034 .
- An external flange 14052 a of a base member 14052 b of an upper cam assembly 14052 that is mounted upon and receives the lower tubular mandrel 14006 , that includes an internal flange 14052 c that is received within the external annular recess 14006 e of the lower tubular mandrel 14006 and a plurality of circumferentially spaced apart cam arms 14052 d extending from the base member mates with and is received within the tubular upper hinge sleeve 14050 .
- the base member 14052 b of the upper cam assembly 14052 further includes a plurality of circumferentially spaced apart teeth 14052 f that mate with and are received within a plurality of circumferentially spaced apart teeth 14034 j provided on the end face of the tubular spring housing 14034 and an end face of the external flange 14052 a of the base member of the upper cam assembly is positioned in opposing relation to an end face of the internal flange 14050 b of the tubular upper hinge sleeve 14050 .
- Each of the cam arms 14052 d of the upper cam assembly 14052 include external cam surfaces 14052 e .
- the teeth 14052 f of the base member 14052 b of the upper cam assembly 14052 and the teeth 14034 j provided on the end face of the tubular spring housing 14034 permit torsional loads to be transmitted between the tubular spring housing and the upper cam assembly.
- a plurality of circumferentially spaced apart upper casing cutter segments 14054 are mounted upon and receive the lower tubular mandrel 14006 and each include an external pivot recess 14054 a for mating with and receiving the internal pivot 14050 c of the tubular upper hinge sleeve 14050 and an external flange 14054 b and are pivotally mounted within the tubular upper hinge sleeve and are interleaved with the circumferentially spaced apart cam arms 14052 d of the upper cam assembly 14052 .
- a casing cutter element 14056 is coupled to and supported by the upper surface of each upper casing cutter segments 14054 proximate the external flange 14054 b.
- a plurality of circumferentially spaced apart lower casing cutter segments 14058 are mounted upon and receive the lower tubular mandrel 14006 , are interleaved among the upper casing cutter segments 14054 , are oriented in the opposite direction to the upper casing cutter segments 14054 , each include an external pivot recess 14058 a , and are positioned in opposing relation to corresponding circumferentially spaced apart cam arms 14052 d of the upper cam assembly 14052 .
- a lower cam assembly 14060 is mounted upon and receives the lower tubular mandrel 14006 that includes a base member 14060 a having an external flange 14060 b , a plurality of circumferentially spaced apart cam arms 14060 d that extend from the base member that each include external cam surfaces 14060 e and define mounting holes 14060 f and 14060 g .
- the base member 14060 a of the lower cam assembly 14060 further includes a plurality of circumferentially spaced apart teeth 14060 h .
- the circumferentially spaced apart cam arms 14060 d of the lower cam assembly 14060 are interleaved among the lower casing cutter segments 14058 and the circumferentially spaced apart cam arms 14052 d of the upper cam assembly 14052 and positioned in opposing relation to corresponding upper casing cutter segments 14054 .
- Mounting screws, 14062 a , 14062 b , 14062 c , and 14062 e are mounted within the corresponding mounting holes, 14060 f and 14060 g , of the lower cam assembly 14060 and are received within the external annular recess 14006 g of the lower cam assembly 14060 .
- a tubular lower hinge sleeve 14064 that receives the lower casing cutter segments 14058 and the lower cam assembly 14060 includes an internal flange 14064 a for engaging the external flange 14060 b of the base member of the lower cam assembly 14060 , an internal pivot 14064 b for engaging and receiving the external pivot recess 14058 a of the lower casing cutter segments 14058 thereby pivotally mounting the lower casing cutter segments within the tubular lower hinge sleeve, and an internal threaded connection 14064 c.
- Mounting screws, 14070 a and 14070 b are mounted in and coupled to the mounting holes, 14068 c and 14068 d , respectively, of the tubular member 14068 that also extend into the mounting holes, 14066 b and 14066 c , respectively, of the tubular sleeve 14066 .
- a sealing element 14072 is received within the external annular recess 14068 e of the tubular member 14068 for sealing the interface between the tubular member and the tubular sleeve 14066 .
- a sealing element 14076 is received within the external annular recess 14074 d of the tubular retracting piston 14074 for sealing the interface between the tubular retracting piston and the tubular sleeve 14066 .
- a sealing element 14078 is received within the internal annular recess 14074 c of the tubular retracting piston 14074 for sealing the interface between the tubular retracting piston and the tubular lower mandrel 14006 .
- Locking dogs 14080 mate with and receive the external teeth 14006 h of the tubular lower mandrel 14006 .
- a spacer ring 14082 is positioned between an end face of the locking dogs 14080 and an end face of the lower cam assembly 14060 .
- a release piston 14084 mounted upon the tubular lower mandrel 14006 defines a radial passage 14084 a for mounting a burst disk 14086 includes sealing elements, 14084 b , 14084 c , and 14084 d .
- the sealing elements, 14084 b and 14084 d sealing the interface between the release piston 14084 and the tubular lower mandrel 14006 .
- An end face of the release piston 14084 is positioned in opposing relation to an end face of the locking dogs 14080 .
- the retracting spring 14044 is compressed and thereby applies a biasing spring force in a direction 14092 from the lower tubular mandrel 14006 to the tubular spring housing 14034 that, in the absence of other forces, moves and/or maintains the upper cam assembly 14052 and the upper casing cutter segments 14054 out of engagement with the lower casing cutter segments 14058 and the lower cam assembly 14060 .
- an external threaded connection 12 a of an end of the tubular support member 12 is coupled to the internal threaded connection 14002 d of the upper tubular tool joint 14002 and an internal threaded connection 16 a of an end of the ball gripper assembly 16 is coupled to the external threaded connection 14068 f of the tubular member 14068 .
- the upper cam assembly 14052 and the upper casing cutter segments 14054 may be brought into engagement with the lower casing cutter segments 14058 and the lower cam assembly 14060 by pressurizing an annulus 14094 defined between the lower tubular mandrel 14006 and the tubular spring housing 14034 .
- injection of fluidic materials into the cam cutter assembly 14 through the longitudinal passage 14006 b of the lower tubular mandrel 14006 and into the radial passage 14006 ba may pressurize the annulus 14094 thereby creating sufficient operating pressure to generate a force in a direction 14096 sufficient to overcome the biasing force of the retracting spring 14044 .
- the spring housing 14034 may be displaced in the direction 14096 relative to the lower tubular mandrel 14006 thereby displacing the tubular upper hinge sleeve 14050 , upper cam assembly 14052 , and upper casing cutter segments 14054 in the direction 14096 .
- the displacement of the upper cam assembly 14052 and upper casing cutter segments 14054 in the direction 14096 will cause the lower casing cutter segments 14058 to ride up the cam surfaces of the cam arms of the upper cam assembly 14052 while also pivoting about the lower tubular hinge segment 14064 , and will also cause the upper casing cutter segments 14054 to ride up the cam surfaces of the cam arms of the lower cam assembly 14060 while also pivoting about the upper tubular hinge segment 14050 .
- the casing cutter elements of the casing cutter segments are brought into intimate contact with the interior surface of a pre-selected portion of the expandable wellbore casing 100 .
- the casing cutter assembly 14 may then be rotated to thereby cause the casing cutter elements to cut through the expandable wellbore casing.
- the portion of the expandable wellbore casing 100 cut away from the remaining portion on the expandable wellbore casing may then be carried out of the wellbore 102 with the cut away portion of the expandable wellbore casing supported by the casing cutter elements.
- the upper cam assembly 14052 and the upper casing cutter segments 14054 may be moved out of engagement with the lower casing cutter segments 14058 and the lower cam assembly 14060 by reducing the operating pressure within the annulus 14094 .
- the upper cam assembly 14052 and the upper casing cutter segments 14054 may also be moved out of engagement with the lower casing cutter segments 14058 and the lower cam assembly 14060 by sensing the operating pressure within the longitudinal passage 14006 b of the lower tubular mandrel 14006 .
- the upper cam assembly 14052 and the upper casing cutter segments 14054 may also be moved out of engagement with the lower casing cutter segments 14058 and the lower cam assembly 14060 by sensing the operating pressure within the longitudinal passage 14006 b of the lower tubular mandrel 14006 .
- the burst disc 14086 will open the passage 14084 a thereby pressurizing the interior of the tubular release sleeve 14088 thereby displacing the tubular release sleeve 14088 downwardly in a direction 14092 away from engagement with the locking dogs 14080 .
- the locking dogs 14080 are displaced outwardly in the radial directed and thereby released from engagement with the lower tubular mandrel 14006 thereby permitting the lower casing cutter segments 14058 and the lower cam assembly 14060 to be displaced downwardly relative to the lower tubular mandrel.
- the operating pressure within the lower tubular mandrel 14066 may then cause the lower tubular mandrel to be displaced downwardly in the direction 14094 relative to the tubular lower mandrel 14006 and the retracting piston 14074 .
- the lower tubular mandrel 14066 , the lower casing cutter segments 14058 , the lower cam assembly 14060 , and tubular lower hinge sleeve 14064 are displaced downwardly in the direction 14094 relative to the tubular spring housing 14034 thereby moving the lower casing cutter segments 14058 and the lower cam assembly 14060 out of engagement with the upper cam assembly 14052 and the upper casing cutter segments 14054 .
- the casing cutter assembly 14 senses the diameter of the expandable wellbore casing 100 using the upper toggle links, 14022 and 14028 , lower toggle links, 14024 and 14030 , and triggers, 14026 and 14032 , and then prevents the engagement of the upper cam assembly 14052 and the upper casing cutter segments 14054 with the lower casing cutter segments 14058 and the lower cam assembly 14060 .
- the triggers, 14026 and 14032 will be pivoted by the engagement arms, 14024 d and 14030 d , of the lower toggle links, 14024 and 14030 , to a position in which the triggers will no longer engage the internal flange 14034 d of the end of the tubular spring housing 14034 thereby permitting the displacement of the tubular spring housing in the direction 14096 .
- the upper cam assembly 14052 and the upper casing cutter segments 14054 can be brought into engagement with the lower casing cutter segments 14058 and the lower cam assembly 14060 .
- the upper toggle links, 14022 and 14028 , and the lower toggle links, 14024 and 14030 are spring biased towards the position illustrated in FIG. 11W .
- the triggers, 14026 and 14032 will be maintained in a position in which the triggers will engage the internal flange 14034 d of the end of the tubular spring housing 14034 thereby preventing the displacement of the tubular spring housing in the direction 14096 .
- the upper cam assembly 14052 and the upper casing cutter segments 14054 cannot be brought into engagement with the lower casing cutter segments 14058 and the lower cam assembly 14060 .
- the triggers, 14026 and 14032 are spring biased towards the position illustrated in FIG. 11X .
- the tubular spring housing 14034 may be displaced upwardly in the direction 14098 even if the upper toggle links, 14022 and 14028 , and lower toggle links, 14024 and 14030 , are positioned within a portion of the expandable wellbore casing 100 that has not been radially expanded and plastically deformed by the system 10 .
- the tubular spring housing 14034 of the casing cutter assembly 14 defines internal annular recesses 14034 k and 14034 l , spaced apart by an internal flange 14034 m
- the tubular toggle bushing 14008 defines an external annular recess 14008 ac
- the casing cutter assembly further includes pins, 14100 a and 14100 b and 14102 a and 14102 b , mounted in holes 14008 j and 14008 o and 14008 k and 14008 n , respectively, of the tubular toggle bushing, and a one-shot deactivation device 14104 mounted on the tubular toggle bushing between the pins, 14100 a and 14100 b and 14102 a and 14102 b.
- the one-shot deactivation device 14104 includes a tubular body 14104 a that defines radial holes, 14104 b and 14014 c , and includes an external annular recess 14104 d at one end, a centrally positioned external flange 14104 e , a centrally positioned internal annular recess 14104 f , and an external annular recess 14104 g at another end.
- An engagement member 14106 that includes a base member 14106 a having a tapered end 14106 b and a key member 14106 c having a tapered end 14106 d is received within a portion of the internal annular recess 14104 f of the tubular body 14104 a and an engagement member 14108 that includes a base member 14108 a having a tapered end 14108 b and a key member 14108 c having a tapered end 14108 d is received within an opposite portion of the internal annular recess 14104 f of the tubular body 14104 a .
- Spring members, 14110 and 14112 are received within the annular recess 14104 f of the tubular body 14104 a for biasing the base members, base member 14106 a and 14108 a , of the engagement members, 14106 and 14108 , respectively, radially inwardly relative to the tubular body 14104 a.
- the one-shot deactivation device 14104 are positioned proximate and in intimate contact with the pins, 14102 a and 14102 b , with the tapered ends, 14106 b and 14108 b , of the base members, 14106 a and 14108 a , of the engagement members, 14106 and 14108 , received within the external annular recess 14008 ac of the tubular toggle bushing 14008 .
- the one-shot deactivation device 14104 is positioned as illustrated in FIG.
- the external annular recess 14104 d of the tubular body 14104 a of the one-shot deactivation device is moved out of engagement with the engagement arms, 14026 d and 14032 d , of the triggers, 14026 and 14032 , respectively.
- the triggers, 14026 and 14032 may operate normally as described above with reference to FIGS. 11W, 11X , and 11 Y.
- the one-shot deactivation device 14104 are positioned proximate and in intimate contact with the pins, 14100 a and 14100 b , with the tapered ends, 14106 b and 14108 b , of the base members, 14106 a and 14108 a , of the engagement members, 14106 and 14108 , not received within the external annular recess 14008 ac of the tubular toggle bushing 14008 .
- the one-shot deactivation device 14104 is positioned as illustrated in FIGS.
- the external annular recess 14104 d of the tubular body 14104 a of the one-shot deactivation device is moved into engagement with the engagement arms, 14026 d and 14032 d , of the triggers, 14026 and 14032 , respectively.
- the triggers, 14026 and 14032 are deactivated and may not operate normally as described above with reference to FIGS. 11W, 11X , and 11 Y.
- the elements of the casing cutter assembly 14 that sense the diameter of the expandable wellbore casing 100 may be disabled or omitted or adjusted to sense any pre-selected internal diameter of the expandable wellbore casing.
- the ball gripper assembly 16 is provided and operates substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22, 2003, (2) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, and/or (3) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (4) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (5) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference.
- the ball gripper assembly 16 includes an upper mandrel 1602 that defines a longitudinal passage 1602 a and a radial passage 1602 b and includes an internal threaded connection 1602 c at one end, an external flange 1602 d at an intermediate portion that includes an external annular recess 1602 e having a shoulder 1602 f and an external radial hole 1602 g , an external annular recess 1602 h , an external annular recess 1602 i , an external annular recess 1602 j having a tapered end 1602 k including an external annular recess 1602 ka , an external annular recess 16021 , and an external annular recess 1602 m , and an external annular recess 1602 n , an external radial hole 1602 o , an external annular recess 1602 p
- An upper tubular bushing 1604 defines an internally threaded radial opening 1604 a and includes an external flange 1604 b having an external annular recess 1604 c and an internal annular recess 1604 d mates with and receives the external flange 1602 d of the upper mandrel 1602 .
- the internal annular recess 1604 d of the upper tubular bushing 1604 mates with the shoulder 1602 f of the external annular recess 1602 e of the upper mandrel 1602 .
- a screw 1606 that is threadably coupled to the internally threaded radial opening 1604 a of the upper tubular bushing 1604 extends into the external radial hole 1602 g of the external flange 1602 d of the upper mandrel 1602 .
- a deactivation tubular sleeve 1608 defines a radial passage 1608 a and includes an internal annular recess 1608 b that mates with and receives an end of the external annular recess 1604 c of the external flange 1604 b of the upper tubular bushing 1604 , an internal annular recess 1608 c that mates with and receives the external flange 1602 d of the upper mandrel 1602 , an internal annular recess 1608 d , an internal annular recess 1608 e , and an internal annular recess 1608 f .
- a deactivation spring 1610 is received within an annulus 1612 defined between the internal annular recess 1608 b of the deactivation tubular sleeve 1608 , an end face of the external annular recess 1604 c of the external flange 1604 b of the upper tubular bushing 1604 , and the external annular recess 1602 h of the external flange 1602 d of the upper mandrel 1602 .
- a sealing member 1614 is received with the external annular recess 1602 i of the external flange 1602 d of the upper mandrel 1602 for sealing the interface between the upper mandrel and the deactivation tubular sleeve 1608 .
- An annular spacer element 1616 is received within the external annular recess 1602 ka of the tapered end 1602 k of the external annular recess 1602 j of the upper mandrel 1602 .
- One or more inner engagement elements 1618 a of a tubular coglet 1618 engage and are received within the external annular recess 1602 ka of the tapered end 1602 k of the external annular recess 1602 j of the upper mandrel 1602 and one or more outer engagement elements 1618 b of the coglet engage and are received within the internal annular recess 1608 d of the deactivation tubular sleeve 1608 .
- An external annular recess 1620 a of an end of a tubular coglet prop 1620 that includes an inner flange 1620 b receives and mates with the inner surfaces of the outer engagement elements 1618 b of the coglet 1618 .
- the end of the tubular coglet prop 1620 further receives and mates with the external annular recess 1602 j of the external flange 1602 d of the upper mandrel 1602 .
- a sealing element 1622 is received within the external annular recess 1602 l of the upper mandrel 1602 for sealing the interface between the upper mandrel and the tubular coglet prop 1620 .
- An end of a tubular bumper sleeve 1624 that includes internal and external flanges, 1624 a and 1624 b , and a hole 1624 c at another end mates with and receives the external annular recess 1602 m of the external flange 1602 d of the upper mandrel 1602 .
- a coglet spring 1626 is received within an annulus 1628 defined between the external annular recess 1602 m of the external flange 1602 d of the upper mandrel 1602 , the tubular coglet prop 1620 , the inner flange 1620 b of the tubular coglet prop, an end face of the tubular bumper sleeve 1624 , and the internal annular recess 1608 c of the deactivation tubular sleeve 1608 .
- a tubular ball race 1628 that defines a plurality of tapered annular recesses 1628 a and an internally threaded radial opening 1628 b and includes one or more axial engagement elements 1628 c at one end and one or more axial engagement elements 1628 d at another end receives and mates with the other end of the upper mandrel 1602 .
- the axial engagement elements 1628 c of the tubular ball race 1628 are received within and are coupled to the hole 1624 c of the tubular bumper sleeve 1624 .
- An end of a tubular activation sleeve 1630 that defines a plurality of radial openings 1630 a , a radial opening 1630 b , a radial opening 1630 c , and includes an internal annular recess 1630 d receives and mates with the tubular ball race 1628 .
- an end face of an end of the tubular activation sleeve 1630 is positioned proximate and in opposing relation to an end face of an end of the deactivation sleeve 1608 .
- the radial openings 1630 a are aligned with and positioned in opposing relation to corresponding of tapered annular recesses 1628 a of the tubular ball race 1628 , and the radial openings are also narrowed in cross section in the radial direction for reasons to be described.
- Balls 1632 are received within each of the of tapered annular recesses 1628 a and corresponding radial openings 1630 a of the tubular ball race 1628 and tubular activation sleeve 1630 , respectively.
- the narrowed cross sections of the radial openings 1630 a of the tubular activation sleeve 1630 will permit the balls 1632 to be displaced outwardly in the radial direction until at least a portion of the balls extends beyond the outer perimeter of the tubular activation sleeve to thereby permit engagement of the balls with an outer structure such as, for example, a wellbore casing.
- a lower mandrel 1634 that defines a longitudinal passage 1634 a and an internally threaded radial passage 1634 b at one end and includes internal annular recesses, 1634 c and 1634 d , for receiving and mating with the external annular recesses, 1602 p and 1602 q , of the upper mandrel 1602 , an internal annular recess 1634 e , an external flange 1634 f , and an externally threaded connection 1634 g at another end.
- the end of the lower mandrel 1634 further includes longitudinal recesses 1634 h for receiving and mating with corresponding axial engagement elements 1628 d of the tubular ball race 1628 .
- a sealing element 1635 is received within the internal annular recess 1634 d of the lower mandrel 1634 for sealing an interface between the lower mandrel and the external annular recess 1602 p of the upper mandrel 1602 .
- a tubular spring retainer 1636 that defines a radial passage 1636 a and includes an external annular recess 1636 b at one end mates with and receives the end of the lower mandrel 1634 and is positioned proximate an end face of the external flange 1634 f of the lower mandrel.
- a tubular spring retainer 1638 receives and mates with the end of the lower mandrel 1634 and is received and mates with the internal annular recess 1630 d of the tubular activation sleeve 1630 .
- An activation spring 1640 is received within an annulus 1642 defined an end face of the tubular spring retainer 1638 , an end face of the spring retainer 1636 , the internal annular recess 1630 d of the tubular activation sleeve 1630 , and the end of the lower mandrel 1634 .
- a retainer screw 1642 is received within and is threadably coupled to the internally threaded radial opening 1634 b of the lower mandrel 1634 that also extends into the external radial hole 1602 o of the upper mandrel 1602 .
- the ball gripper assembly 16 may be positioned within the expandable wellbore casing 100 and the internally threaded connection 1602 c of the upper mandrel 1602 may be coupled to an externally threaded connection 14 a of an end of the casing cutter assembly 14 and the externally threaded connection 1634 g of the lower mandrel 1634 may be coupled to an internally threaded connection 18 a of an end of the tension actuator assembly 18 .
- the internally threaded connection 1602 c of the upper mandrel 1602 may be coupled to an externally threaded connection of an end of the tension actuator assembly 18 and the externally threaded connection 1634 g of the lower mandrel 1634 may be coupled to an internally threaded connection of an end of casing cutter assembly 14 .
- the deactivation spring 1610 has a greater spring rate than the activation spring 1640 .
- a biasing spring force is applied to the deactivation sleeve 1608 and activation sleeve 1630 in a direction 1644 that maintains the activation sleeve in a position relative to the tubular ball race 1628 that maintains the balls 1632 within the radially inward portions of the corresponding tapered annular recesses 1628 a of the tubular ball race such that the balls do not extend beyond the perimeter of the activation sleeve to engage the expandable wellbore casing 100 .
- the ball gripper 16 may be operated to engage the interior surface of the expandable wellbore casing 100 by injecting a fluidic material 1650 into the ball gripper assembly through the longitudinal passages 1602 a and 1634 aa , of the upper and lower mandrels, 1602 and 1634 , respectively.
- the internal annular recess 1608 c of the deactivation tubular sleeve 1608 is pressurized.
- the operating pressure of the fluidic material 1650 within the internal annular recess 1608 c of the deactivation tubular sleeve 1608 is sufficient to overcome the biasing spring force of the deactivation spring 1610 , the deactivation tubular sleeve is displaced in a direction 1652 .
- the spring force provided by the activation spring 1640 then may displace the activation tubular sleeve 1630 in the direction 1652 thereby moving the balls 1632 on the corresponding tapered annular recesses 1628 a of the tubular ball race 1628 outwardly in a radial direction into engagement with the interior surface of the expandable wellbore casing 100 .
- the operating pressure of the fluidic material 1650 sufficient to overcome the biasing spring force of the deactivation spring 1610 was about 100 psi.
- the operating pressure of the fluidic material 1650 when the operating pressure of the fluidic material 1650 is reduced, the operating pressure of the fluidic material 1650 within the internal annular recess 1608 c of the deactivation tubular sleeve 1608 is no longer sufficient to overcome the biasing spring force of the deactivation spring 1610 , and the deactivation tubular sleeve and the activation tubular sleeve 1630 are displaced in a direction opposite to the direction 1652 thereby moving the balls 1632 radially inwardly and out of engagement with the interior surface of the expandable wellbore casing 100 .
- the ball gripper assembly 16 is operated to engage the interior surface of the expandable wellbore casing 100 in combination with the operation of the tension actuator assembly 18 to apply an upward tensile force to one or more elements of the system 10 coupled to and positioned below the tension actuator assembly.
- a reaction force comprising a downward tensile force is applied to the lower mandrel 1634 of the ball gripper assembly 16 in a direction opposite to the direction 1652 during the operation of the tension actuator assembly 18 .
- the balls 1632 are driven up the tapered annular recesses 1628 a of the tubular ball race 1628 with increased force and the contact force between the balls 1632 and the interior surface of the expandable wellbore casing 100 is significantly increased thereby correspondingly increasing the gripping force and effect of the ball gripper assembly.
- the ball gripper assembly 16 may be operated to radially expand and plastically deform discrete portions of the expandable wellbore casing 100 by controlling the amount of contact force applied to the interior surface of the expandable wellbore casing by the balls 1632 of the ball gripper assembly.
- an expandable wellbore casing was radially expanded and plastically deformed. This was an unexpected result.
- the tension actuator assembly 18 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, and/or (2) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22, 2003, and/or (3) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, and/or (4) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on Sep.
- PCT patent application serial number PCT/US04/_______ attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (6)
- PCT patent application serial number PCT/US04/______ attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (7)
- PCT patent application serial number PCT/US04/______ attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference.
- the tension actuator assembly 18 includes an upper tubular support member 18002 that defines a longitudinal passage 18002 a , and external internally threaded radial openings, 18002 b and 18002 c , and an external annular recess 18002 d and includes an internally threaded connection 18002 e at one end and an external flange 18002 f , an external annular recess 18002 g having an externally threaded connection, and an internal annular recess 18002 h having an internally threaded connection at another end.
- Torsional locking pins, 18006 a and 18006 b are coupled to and mounted within the external radial mounting holes, 18002 b and 18002 c , respectively, of the upper tubular support member and received within the radial passages, 18004 a and 18004 b , of the end of the tubular actuator barrel 18004 .
- the other end of the tubular actuator barrel 18004 receives and is threadably coupled to an end of a tubular barrel connector 18008 that defines an internal annular recess 18008 a , external radial mounting holes, 18008 b and 18008 c , radial passages, 18008 d and 18008 e , and external radial mounting holes, 18008 f and 18008 g and includes circumferentially spaced apart teeth 18008 h at one end.
- a sealing cartridge 18010 is received within and coupled to the internal annular recess 18008 a of the tubular barrel connector 18008 for fluidicly sealing the interface between the tubular barrel connector and the sealing cartridge.
- Torsional locking pins, 18012 a and 18012 b are coupled to and mounted within the external radial mounting holes, 18008 b and 18008 c , respectively, of the tubular barrel connector 18008 and received within the radial passages, 18004 c and 18004 d , of the tubular actuator barrel 18004 .
- a tubular member 18014 that defines a longitudinal passage 18014 a having one or more internal splines 18014 b at one end and circumferentially spaced apart teeth 18014 c at another end for engaging the circumferentially spaced apart teeth 18008 h of the tubular barrel connector 18008 mates with and is received within the actuator barrel 18004 and the one end of the tubular member abuts an end face of the other end of the upper tubular support member 18002 and at another end abuts and end face of the tubular barrel connector 18008 .
- a tubular guide member 18016 that defines a longitudinal passage 18016 a having a tapered opening 18016 aa , and radial passages, 18016 b and 18016 c , includes an external flange 18016 d having an externally threaded connection at one end that is received within and coupled to the internal annular recess 18002 h of the upper tubular support member 18002 .
- the other end of the tubular barrel connector 18008 is threadably coupled to and is received within an end of a tubular actuator barrel 18018 that defines a longitudinal passage 18018 a , radial passages, 18018 b and 18018 c , and radial passages, 18018 d and 18018 e .
- Torsional locking pins, 18020 a and 18020 b are coupled to and mounted within the external radial mounting holes, 18008 f and 18008 g , respectively, of the tubular barrel connector 18008 and received within the radial passages, 18018 b and 18018 c , of the tubular actuator barrel 18018 .
- the other end of the tubular actuator barrel 18018 receives and is threadably coupled to an end of a tubular barrel connector 18022 that defines an internal annular recess 18022 a , external radial mounting holes, 18022 b and 18022 c , radial passages, 18022 d and 18022 e , and external radial mounting holes, 18022 f and 18022 g .
- a sealing cartridge 18024 is received within and coupled to the internal annular recess 18022 a of the tubular barrel connector 18022 for fluidicly sealing the interface between the tubular barrel connector and the sealing cartridge.
- Torsional locking pins, 18024 a and 18024 b are coupled to and mounted within the external radial mounting holes, 18022 b and 18022 c , respectively, of the barrel connector 18022 and received within the radial passages, 18018 d and 18018 e , of the tubular actuator barrel 18018 .
- the other end of the tubular barrel connector 18022 is threadably coupled to and is received within an end of a tubular actuator barrel 18026 that defines a longitudinal passage 18026 a , radial passages, 18026 b and 18026 c , and radial passages, 18026 d and 18026 e .
- Torsional locking pins, 18028 a and 18028 b are coupled to and mounted within the external radial mounting holes, 18022 f and 18022 g , respectively, of the tubular barrel connector 18022 and received within the radial passages, 18026 b and 18026 c , of the tubular actuator barrel 18026 .
- the other end of the tubular actuator barrel 18026 receives and is threadably coupled to an end of a tubular barrel connector 18030 that defines an internal annular recess 18030 a , external radial mounting holes, 18030 b and 18030 c , radial passages, 18030 d and 18030 e , and external radial mounting holes, 18030 f and 18030 g .
- a sealing cartridge 18032 is received within and coupled to the internal annular recess 18030 a of the tubular barrel connector 18030 for fluidicly sealing the interface between the tubular barrel connector and the sealing cartridge.
- Torsional locking pins, 18034 a and 18034 b are coupled to and mounted within the external radial mounting holes, 18030 b and 18030 c , respectively, of the tubular barrel connector 18030 and received within the radial passages, 18026 d and 18026 e , of the tubular actuator barrel 18026 .
- the other end of the tubular barrel connector 18030 is threadably coupled to and is received within an end of a tubular actuator barrel 18036 that defines a longitudinal passage 18036 a , radial passages, 18036 b and 18036 c , and radial passages, 18036 d and 18036 e .
- Torsional locking pins, 18038 a and 18038 b are coupled to and mounted within the external radial mounting holes, 18030 f and 18030 g , respectively, of the tubular barrel connector 18030 and received within the radial passages, 18036 b and 18036 c , of the tubular actuator barrel 18036 .
- the other end of the tubular actuator barrel 18036 receives and is threadably coupled to an end of a tubular barrel connector 18040 that defines an internal annular recess 18040 a , external radial mounting holes, 18040 b and 18040 c , radial passages, 18040 d and 18040 e , and external radial mounting holes, 18040 f and 18040 g .
- a sealing cartridge 18042 is received within and coupled to the internal annular recess 18040 a of the tubular barrel connector 18040 for fluidicly sealing the interface between the tubular barrel connector and the sealing cartridge.
- Torsional locking pins, 18044 a and 18044 b are coupled to and mounted within the external radial mounting holes, 18040 b and 18040 c , respectively, of the tubular barrel connector 18040 and received within the radial passages, 18036 d and 18036 e , of the tubular actuator barrel 18036 .
- the other end of the tubular barrel connector 18040 is threadably coupled to and is received within an end of a tubular actuator barrel 18046 that defines a longitudinal passage 18046 a , radial passages, 18046 b and 18046 c , and radial passages, 18046 d and 18046 e .
- Torsional locking pins, 18048 a and 18048 b are coupled to and mounted within the external radial mounting holes, 18040 f and 18040 g , respectively, of the tubular barrel connector 18040 and received within the radial passages, 18046 b and 18046 c , of the tubular actuator barrel 18046 .
- the other end of the tubular actuator barrel 18046 receives and is threadably coupled to an end of a tubular barrel connector 18050 that defines an internal annular recess 18050 a , external radial mounting holes, 18050 b and 18050 c , radial passages, 18050 d and 18050 e , and external radial mounting holes, 18050 f and 18050 g .
- a sealing cartridge 18052 is received within and coupled to the internal annular recess 18050 a of the tubular barrel connector 18050 for fluidicly sealing the interface between the tubular barrel connector and the sealing cartridge.
- Torsional locking pins, 18054 a and 18054 b are coupled to and mounted within the external radial mounting holes, 18050 b and 18050 c , respectively, of the tubular barrel connector 18050 and received within the radial passages, 18046 d and 18046 e , of the tubular actuator barrel 18046 .
- the other end of the tubular barrel connector 18050 is threadably coupled to and is received within an end of a tubular actuator barrel 18056 that defines a longitudinal passage 18056 a , radial passages, 18056 b and 18056 c , and radial passages, 18056 d and 18056 e .
- Torsional locking pins, 18058 a and 18058 b are coupled to and mounted within the external radial mounting holes, 18050 f and 18050 g , respectively, of the tubular barrel connector 18050 and received within the radial passages, 18056 b and 18056 c , of the tubular actuator barrel 18056 .
- the other end of the tubular actuator barrel 18056 receives and is threadably coupled to an end of a tubular lower stop 18060 that defines an internal annular recess 18060 a , external radial mounting holes, 18060 b and 18060 c , and an internal annular recess 18060 d that includes one or more circumferentially spaced apart locking teeth 18060 e at one end and one or more circumferentially spaced apart locking teeth 18060 f at the other end.
- a sealing cartridge 18062 is received within and coupled to the internal annular recess 18060 a of the tubular lower stop 18060 for fluidicly sealing the interface between the tubular lower stop and the sealing cartridge.
- Torsional locking pins, 18064 a and 18064 b are coupled to and mounted within the external radial mounting holes, 18060 b and 18060 c , respectively, of the tubular lower stop 18060 and received within the radial passages, 18056 d and 18056 e , of the tubular actuator barrel 18056 .
- a connector tube 18066 that defines a longitudinal passage 18066 a and radial mounting holes, 18066 b and 18066 c , and includes external splines 18066 d at one end for engaging the internal splines 18014 b of the tubular member 18014 and radial mounting holes, 18066 e and 18066 f , at another end is received within and sealingly and movably engages the interior surface of the sealing cartridge 18010 mounted within the annular recess 18008 a of the tubular barrel connector 18008 . In this manner, during longitudinal displacement of the connector tube 18066 relative to the tubular barrel connector 18008 , a fluidic seal is maintained between the exterior surface of the connector tube and the interior surface of the tubular barrel connector.
- An end of the connector tube 18066 also receives and mates with the other end of the tubular guide member 18016 .
- Mounting screws, 18068 a and 18068 b are coupled to and received within the radial mounting holes, 18066 b and 18066 c , respectively of the connector tube 18066 .
- the other end of the connector tube 18066 is received within and threadably coupled to an end of a tubular piston 18070 that defines a longitudinal passage 18070 a , radial mounting holes, 18070 b and 18070 c , radial passages, 18070 d and 18070 e , and radial mounting holes, 18070 f and 18070 g , that includes a flange 18070 h at one end.
- a sealing cartridge 18072 is mounted onto and sealingly coupled to the exterior of the tubular piston 18070 proximate the flange 18070 h .
- the sealing cartridge 18072 also mates with and sealingly engages the interior surface of the tubular actuator barrel 18018 .
- Mounting screws, 18074 a and 18074 b are coupled to and mounted within the external radial mounting holes, 18070 b and 18070 c , respectively, of the tubular piston 18070 and received within the radial passages, 18066 e and 18066 f , of the connector tube 18066 .
- the other end of the tubular piston 18070 receives and is threadably coupled to an end of a connector tube 18076 that defines a longitudinal passage 18076 a , radial mounting holes, 18076 b and 18076 c , at one end and radial mounting holes, 18076 d and 18076 e , at another end.
- the connector tube 18076 is received within and sealingly and movably engages the interior surface of the sealing cartridge 18024 mounted within the annular recess 18022 a of the tubular barrel connector 18022 . In this manner, during longitudinal displacement of the connector tube 18076 relative to the tubular barrel connector 18022 , a fluidic seal is maintained between the exterior surface of the connector tube and the interior surface of the barrel connector.
- Mounting screws, 18078 a and 18078 b are coupled to and mounted within the external radial mounting holes, 18070 f and 18070 g , respectively, of the tubular piston 18070 and received within the radial passages, 18076 b and 18076 c , of the connector tube 18076 .
- the other end of the connector tube 18076 is received within and threadably coupled to an end of a tubular piston 18080 that defines a longitudinal passage 18080 a , radial mounting holes, 18080 b and 18080 c , radial passages, 18080 d and 18080 e , and radial mounting holes, 18080 f and 18080 g , that includes a flange 18080 h at one end.
- a sealing cartridge 18082 is mounted onto and sealingly coupled to the exterior of the tubular piston 18080 proximate the flange 18080 h .
- the sealing cartridge 18082 also mates with and sealingly engages the interior surface of the tubular actuator barrel 18026 .
- Mounting screws, 18084 a and 18084 b are coupled to and mounted within the external radial mounting holes, 18080 b and 18080 c , respectively, of the tubular piston 18080 and received within the radial passages, 18076 e and 18076 f , of the connector tube 18076 .
- the other end of the tubular piston 18080 receives and is threadably coupled to an end of a connector tube 18086 that defines a longitudinal passage 18086 a , radial mounting holes, 18086 b and 18086 c , at one end and radial mounting holes, 18086 d and 18086 e , at another end.
- the connector tube 18086 is received within and sealingly and movably engages the interior surface of the sealing cartridge 18032 mounted within the annular recess 18030 a of the tubular barrel connector 18030 . In this manner, during longitudinal displacement of the connector tube 18086 relative to the tubular barrel connector 18030 , a fluidic seal is maintained between the exterior surface of the connector tube and the interior surface of the barrel connector.
- Mounting screws, 18088 a and 18088 b are coupled to and mounted within the external radial mounting holes, 18080 f and 18080 g , respectively, of the tubular piston 18080 and received within the radial passages, 18086 b and 18086 c , of the connector tube 18086 .
- the other end of the connector tube 18086 is received within and threadably coupled to an end of a tubular piston 18090 that defines a longitudinal passage 18090 a , radial mounting holes, 18090 b and 18090 c , radial passages, 18090 d and 18090 e , and radial mounting holes, 18090 f and 18090 g , that includes a flange 18090 h at one end.
- a sealing cartridge 18092 is mounted onto and sealingly coupled to the exterior of the tubular piston 18090 proximate the flange 18090 h .
- the sealing cartridge 18092 also mates with and sealingly engages the interior surface of the tubular actuator barrel 18036 .
- Mounting screws, 18094 a and 18094 b are coupled to and mounted within the external radial mounting holes, 18090 b and 18090 c , respectively, of the tubular piston 18090 and received within the radial passages, 18086 e and 18086 f , of the connector tube 18086 .
- the other end of the tubular piston 18090 receives and is threadably coupled to an end of a connector tube 18096 that defines a longitudinal passage 18096 a , radial mounting holes, 18096 b and 18096 c , at one end and radial mounting holes, 18096 d and 18096 e , at another end.
- the connector tube 18096 is received within and sealingly and movably engages the interior surface of the sealing cartridge 18042 mounted within the annular recess 18040 a of the tubular barrel connector 18040 . In this manner, during longitudinal displacement of the connector tube 18096 relative to the tubular barrel connector 18040 , a fluidic seal is maintained between the exterior surface of the connector tube and the interior surface of the barrel connector.
- Mounting screws, 18098 a and 18098 b are coupled to and mounted within the external radial mounting holes, 18090 f and 18090 g , respectively, of the tubular piston 18090 and received within the radial passages, 18096 b and 18096 c , of the connector tube 18096 .
- the other end of the connector tube 18096 is received within and threadably coupled to an end of a tubular piston 18100 that defines a longitudinal passage 18100 a , radial mounting holes, 18100 b and 18100 c , radial passages, 18100 d and 18100 e , and radial mounting holes, 18100 f and 18100 g , that includes a flange 18100 h at one end.
- a sealing cartridge 18102 is mounted onto and sealingly coupled to the exterior of the tubular piston 18100 proximate the flange 18100 h .
- the sealing cartridge 18102 also mates with and sealingly engages the interior surface of the tubular actuator barrel 18046 .
- Mounting screws, 18104 a and 18104 b are coupled to and mounted within the external radial mounting holes, 18100 b and 18100 c , respectively, of the tubular piston 18100 and received within the radial passages, 18096 e and 18096 f , of the connector tube 18096 .
- the other end of the tubular piston 18100 receives and is threadably coupled to an end of a connector tube 18106 that defines a longitudinal passage 18106 a , radial mounting holes, 18106 b and 18106 c , at one end and radial mounting holes, 18106 d and 18106 e , at another end.
- the connector tube 18106 is received within and sealingly and movably engages the interior surface of the sealing cartridge 18052 mounted within the annular recess 18050 a of the tubular barrel connector 18050 . In this manner, during longitudinal displacement of the connector tube 18106 relative to the tubular barrel connector 18050 , a fluidic seal is maintained between the exterior surface of the connector tube and the interior surface of the barrel connector.
- Mounting screws, 18108 a and 18108 b are coupled to and mounted within the external radial mounting holes, 18100 f and 18100 g , respectively, of the tubular piston 18100 and received within the radial passages, 18106 b and 18106 c , of the connector tube 18106 .
- the other end of the connector tube 18106 is received within and threadably coupled to an end of a tubular piston 18110 that defines a longitudinal passage 18110 a , radial mounting holes, 18110 b and 18110 c , radial passages, 18110 d and 18110 e , radial mounting holes, 18110 f and 18110 g , that includes a flange 18110 h at one end and circumferentially spaced teeth 18110 i at another end for engaging the one or more circumferentially spaced apart locking teeth 18060 e of the tubular lower stop 18060 .
- a sealing cartridge 18112 is mounted onto and sealingly coupled to the exterior of the tubular piston 18110 proximate the flange 18110 h .
- the sealing cartridge 18112 also mates with and sealingly engages the interior surface of the actuator barrel 18056 . In this manner, during longitudinal displacement of the tubular piston 18110 relative to the actuator barrel 18056 , a fluidic seal is maintained between the exterior surface of the piston and the interior surface of the actuator barrel.
- Mounting screws, 18114 a and 18114 b are coupled to and mounted within the external radial mounting holes, 18110 b and 18110 c , respectively, of the tubular piston 18110 and received within the radial passages, 18106 d and 18106 e , of the connector tube 18106 .
- the other end of the tubular piston 18110 receives and is threadably coupled to an end of a connector tube 18116 that defines a longitudinal passage 18116 a , radial mounting holes, 18116 b and 18116 c , at one end and radial mounting holes, 18116 d and 18116 e , at another end that includes an external flange 18116 f that includes circumferentially spaced apart teeth 18116 g that extend from an end face of the external flange for engaging the teeth 18060 f of the tubular lower stop 18060 , and an externally threaded connection 18116 h at another end.
- the connector tube 18116 is received within and sealingly and movably engages the interior surface of the sealing cartridge 18062 mounted within the annular recess 18060 a of the lower tubular stop 18060 . In this manner, during longitudinal displacement of the connector tube 18116 relative to the lower tubular stop 18060 , a fluidic seal is maintained between the exterior surface of the connector tube and the interior surface of the lower tubular stop.
- Mounting screws, 18118 a and 18118 b are coupled to and mounted within the external radial mounting holes, 18110 f and 18110 g , respectively, of the tubular piston 18110 and received within the radial passages, 18116 b and 18116 c , of the connector tube 18116 .
- the internally threaded connection 18002 e of the upper tubular support member 18002 receives and is coupled to the externally threaded connection 1234 g of the lower mandrel 1234 of the ball grabber assembly 16 and the externally threaded connection 18116 h of the connector tube 18116 is received within and is coupled to an internally threaded connection 20 a of an end of the safety sub assembly 20 .
- the tension actuator assembly is positioned within the expandable wellbore casing 100 and fluidic material 18200 is injected into the tension actuator assembly through the passages 18002 a , 18016 a , 18066 a , 18070 a , 18076 a , 18080 a , 18086 a , 18090 a , 18096 a , 18100 a , 18106 a , 18110 a , and 18116 a .
- the injected fluidic material 18200 will also pass through the radial passages, 18070 d and 18070 e , 18080 d and 18080 e , 18090 d and 18090 e , 18100 d and 18100 e , 18110 d and 18110 e , of the tubular pistons, 18070 , 18080 , 18090 , 18100 , and 18110 , respectively, into annular piston chambers, 18202 , 18204 , 18206 , 18208 , 18208 , and 18210 .
- the operating pressure of the fluidic material 18200 may then be increased by, for example, controllably blocking or limiting the flow of the fluidic material through the passage 18116 a and/or increasing the operating pressure of the outlet of a pumping device for injecting the fluidic material 18200 into the tension actuator assembly 18 .
- the operating pressures of the annular piston chambers, 18202 , 18204 , 18206 , 18208 , 18208 , and 18210 will be increased sufficiently to displace the tubular pistons, 18070 , 18080 , 18090 , 18100 , and 18110 , upwardly in the direction 18212 thereby also displacing the connector tube 18116 .
- a upward tensile force is applied to all elements of the system 10 coupled to and positioned below the connector tube 18116 .
- fluidic materials displaced by the tubular pistons within discharge annular chambers, 18214 , 18216 , 18218 , 18220 , and 18222 are exhausted out of the tension actuator assembly 18 through the radial passages, 18008 d and 18008 e , 18022 d and 18022 e , 18030 d and 18030 e , 18040 d and 18040 e , 18050 d and 18050 e , respectively.
- the upward displacement of the tubular pistons, 18070 , 18080 , 18090 , 18100 , and 18110 further causes the external splines 18066 d of the connector tube 18066 to engage the internal splines 18014 b of the tubular member 18014 and the circumferentially spaced apart teeth 18116 g of the connector tube 18116 to engage the circumferentially spaced teeth 18060 f of the tubular lower stop 18060 .
- the safety sub assembly 20 includes a tubular body 200 a that defines a longitudinal passage 200 b and includes an external flange 200 c and an internal annular recess 200 d at one end, and external annular recesses, 200 e , 200 f , 200 g , and 200 h at another end.
- a sealing member 202 is positioned within the external annular recess 200 h at the other end of the tubular body 200 a.
- the sealing cup assembly 22 includes an upper tubular mandrel 2202 that defines a longitudinal passage 2202 a and internally threaded radial mounting holes, 2202 b and 2202 c , and includes an internal annular recess 2202 d at one end, an internal annular recess 2202 e , an internal annular recess 2202 f , an internal annular recess 2202 g , and an internally threaded internal annular recess 2202 h and an external flange 2202 i at another end.
- the internal annular recesses, 2202 d , 2202 e , and 2202 f , of the upper tubular mandrel 2202 of the sealing cup assembly 22 receive, mate with, and are coupled to the other end of the tubular body 200 a of the safety sub assembly 20 .
- Mounting screws, 2250 a and 2205 b are received within and coupled to the mounting holes, 2202 c and 2202 b , respectively, of the tubular mandrel 2202 that extend into and engage the external annular recess 2204 c of the lower tubular mandrel 2204 .
- a tubular cup seal spacer 2206 receives and is mounted upon the lower tubular mandrel 2204 proximate the external flange 2202 i of the upper tubular mandrel 2202 .
- a tubular cup seal retainer 2208 that includes an internal flange 2208 a at one end receives and is mounted upon the lower tubular mandrel 2204 proximate the tubular cup seal spacer 2206 .
- a tubular cup seal retainer 2210 that includes an internal flange 2210 a at one end receives and is mounted upon the lower tubular mandrel 2204 proximate the other end of the tubular cup seal retainer 2208 .
- tubular cup seal retainer 2210 is nested within the other end of the tubular cup seal retainer 2208 .
- a tubular cup seal 2212 that includes an internal flange 2212 a at one end receives and is mounted upon the lower tubular mandrel 2204 proximate the other end of the tubular cup seal retainer 2210 .
- the tubular cup seal 2212 is nested within the other end of the tubular cup seal retainer 2210 .
- a sealing member 2211 is received within the external annular recess 2204 b of the lower tubular mandrel 2204 for sealing the interface between the lower tubular mandrel and the upper tubular mandrel 2202 .
- a tubular spacer 2214 receives and is mounted upon the lower tubular mandrel 2204 proximate the other end of the tubular cup seal 2212 .
- a tubular cup seal spacer 2216 receives and is mounted upon the lower tubular mandrel 2204 proximate the other end of the tubular spacer 2214 .
- a tubular cup seal retainer 2218 that includes an internal flange 2218 a at one end receives and is mounted upon the lower tubular mandrel 2204 proximate the other end of the tubular cup seal spacer 2216 .
- a tubular cup seal retainer 2220 that includes an internal flange 2220 a at one end receives and is mounted upon the lower tubular mandrel 2204 proximate the other end of the tubular cup seal retainer 2218 .
- tubular cup seal retainer 2220 is nested within the other end of the tubular cup seal retainer 2218 .
- a tubular cup seal 2222 that includes an internal flange 2222 a at one end receives and is mounted upon the lower tubular mandrel 2204 proximate the other end of the tubular cup seal retainer 2220 .
- the tubular cup seal 2222 is nested within the other end of the tubular cup seal retainer 2220 .
- a tubular spacer 2224 receives and is mounted upon the lower tubular mandrel 2204 proximate the other end of the tubular cup seal 2222 at one end and proximate the external flange 2204 d of the lower tubular mandrel at another end.
- a retaining ring 2226 receives and is mounted upon the other end of the tubular spacer 2224 proximate the external flange 2204 d of the lower tubular mandrel 2204 .
- the end of the tubular body 200 a of the safety sub assembly 20 is coupled to and receives and is coupled to an end of the tension actuator assembly 18 and the other end of the lower tubular mandrel 2204 of the sealing cup assembly 22 is received within and is coupled to an end of the casing lock assembly 24 .
- the tubular cup seals, 2212 and/or 2222 sealingly engage the interior surface of the expandable tubular member 100 .
- an annulus defined between the system 10 and the expandable wellbore casing 10 , below the tubular cup seals, 2212 and/or 2222 is pressurized, the resulting pressure differential across the tubular cup seals applies an upward tensile force to the system thereby pulling the adjustable bell section expansion cone assembly 28 and/or the adjustable casing expansion cone assembly 30 through the expandable wellbore casing.
- the adjustable bell section expansion cone assembly 28 and/or the adjustable casing expansion cone assembly 30 may radially expand and plastically deform the expandable wellbore casing 100 .
- the sealing cup assembly 22 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on Nov. 12, 2002, and/or (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, and/or (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on Feb. 29, 2003, and/or (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep.
- PCT patent application serial number PCT/US03/14153 attorney docket number 25791.104.02, filed on Nov. 13, 2003
- PCT patent application serial number PCT/US03/18530 attorney docket number 25791.108.02, filed on Jun. 11, 2003
- PCT patent application serial number PCT/US04/______ attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (8)
- the casing lock assembly 24 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, and/or (2) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22, 2003, and/or (3) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, and/or (4) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar.
- PCT patent application serial number PCT/US04/______ attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (6) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference.
- the extension actuator assembly 26 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, and/or (2) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep.
- PCT patent application serial number PCT/US ______ attorney docket number 25791.107.02, filed on ______
- PCT patent application serial number PCT/US/______ attorney docket number 25791.114.02, filed on ______
- PCT patent application serial number PCT/US04/______ attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (6)
- PCT patent application serial number PCT/US04/_______ attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (7)
- PCT patent application serial number PCT/US04/_______ attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference.
- the adjustable bell section expansion cone assembly 28 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on Nov. 12, 2002, and/or (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, and/or (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on Feb. 29, 2003, and/or (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep.
- PCT patent application serial number PCT/US03/14153 attorney docket number 25791.104.02, filed on Nov. 13, 2003
- PCT patent application serial number PCT/US03/18530 attorney docket number 25791.108.02, filed on Jun. 11, 2003
- PCT patent application serial number PCT/US04/______ attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (8)
- the adjustable bell section expansion cone assembly 28 includes an upper tubular tool joint 28002 that defines a longitudinal passage 28002 a and mounting holes, 28002 b and 28002 c , and includes an internal threaded connection 28002 d , an inner annular recess 28002 e , an inner annular recess 28002 f , and an internal threaded connection 28002 g
- a tubular torque plate 28004 that defines a longitudinal passage 28004 a and includes circumferentially spaced apart teeth 28004 b is received within, mates with, and is coupled to the internal annular recess 28002 e of the upper tubular tool joint 28002 .
- a sealing element 28010 is received within the external annular recess 28008 y of the tubular toggle bushing 28008 for sealing the interface between the tubular toggle bushing and the upper tubular tool joint 28002 .
- a sealing element 28012 is received within the internal annular recess 28008 z of the tubular toggle bushing 28008 for sealing the interface between the tubular toggle bushing and the tubular lower mandrel 28006 .
- Mounting screws, 28014 a and 28014 b , mounted within and coupled to the mounting holes, 28008 w and 28008 x , respectively, of the tubular toggle bushing 28008 are also received within the mounting holes, 28002 b and 28002 c , of the upper tubular tool joint 28002 .
- Mounting pins, 28016 a , 28016 b , 28016 c , 28016 d , and 28016 e are mounted within the mounting holes, 28008 e , 28008 f , 28008 g , 28008 h , and 28008 i , respectively.
- Mounting pins, 28018 a , 28018 b , 28018 c , 28018 d , and 28018 e are mounted within the mounting holes, 28008 t , 28008 s , 28008 r , 28008 q , and 28008 p , respectively.
- Mounting screws, 28020 a and 28020 b are mounted within the mounting holes, 28008 u and 28008 v , respectively.
- a first upper toggle link 28022 defines mounting holes, 28022 a and 28022 b , for receiving the mounting pins, 28016 a and 28016 b , and includes a mounting pin 28022 c at one end.
- a first lower toggle link 28024 defines mounting holes, 28024 a , 28024 b , and 28024 c , for receiving the mounting pins, 28022 c , 28016 c , and 28016 d , respectively and includes an engagement arm 28024 d .
- a first trigger 28026 defines a mounting hole 28026 a for receiving the mounting pin 28016 e and includes an engagement arm 28026 b at one end, an engagement member 28026 c , and an engagement arm 28026 d at another end.
- a second upper toggle link 28028 defines mounting holes, 28028 a and 28028 b , for receiving the mounting pins, 28018 a and 28018 b , and includes a mounting pin 28028 c at one end.
- a second lower toggle link 28030 defines mounting holes, 28030 a , 28030 b , and 28030 c , for receiving the mounting pins, 28028 c , 28018 c , and 28018 d , respectively and includes an engagement arm 28030 d .
- a second trigger 28032 defines a mounting hole 28032 a for receiving the mounting pin 28018 e and includes an engagement arm 28032 b at one end, an engagement member 28032 c , and an engagement arm 28032 d at another end.
- An end of a tubular spring housing 28034 that defines a longitudinal passage 28034 a , mounting holes, 28034 b and 28034 c , and mounting holes, 28034 ba and 28034 ca , and includes an internal flange 28034 d and an internal annular recess 28034 e at one end, and an internal flange 28034 f , an internal annular recess 28034 g , an internal annular recess 28034 h , and an external threaded connection 28034 i at another end receives and mates with the end of the tubular toggle bushing 28008 .
- Mounting screws, 28035 a and 28035 b are mounted within and coupled to the mounting holes, 28008 xb and 28008 xa , respectively, of the tubular toggle bushing 28008 and are received within the mounting holes, 28034 ba and 28034 ca , respectively, of the tubular spring housing 28034 .
- a tubular retracting spring ring 28036 that defines mounting holes, 28036 a and 28036 b , receives and mates with a portion of the tubular lower mandrel 28006 and is received within and mates with a portion of the tubular spring housing 28034 .
- Mounting screws, 28038 a and 28038 b are mounted within and coupled to the mounting holes, 28036 a and 28036 b , respectively, of the tubular retracting spring ring 28036 and extend into the mounting holes, 28034 b and 28034 c , respectively, of the tubular spring housing 28034 .
- Casing diameter sensor springs, 28040 a and 28040 b are positioned within the longitudinal slots, 28008 c and 2808 d , respectively, of the tubular toggle bushing 28008 that engage the engagement members, 28026 c and 28032 c , and engagement arms, 28026 d and 28032 d , of the first and second triggers, 28026 and 28032 , respectively.
- An inner flange 28042 a of an end of a tubular spring washer 28042 mates with and receives a portion of the tubular lower mandrel 28006 and an end face of the inner flange of the tubular spring washer is positioned proximate and end face of the external flange 28006 d of the tubular lower mandrel.
- the tubular spring washer 28042 is further received within the longitudinal passage 28034 a of the tubular spring housing 28034 .
- An end of a retracting spring 28044 that receives the tubular lower mandrel 28006 is positioned within the tubular spring washer 28042 in contact with the internal flange 28042 a of the tubular spring washer and the other end of the retracting spring is positioned in contact with an end face of the tubular retracting spring ring 28036 .
- a sealing element 28046 is received within the external annular recess 28006 j of the tubular lower mandrel 28006 for sealing the interface between the tubular lower mandrel and the tubular spring housing 28034 .
- a sealing element 28048 is received within the internal annular recess 28034 h of the tubular spring housing 28034 for sealing the interface between the tubular spring housing and the tubular lower mandrel 28006 .
- An internal threaded connection 28050 a of an end of a tubular upper hinge sleeve 28050 that includes an internal flange 28050 b and an internal pivot 28050 c receives and is coupled to the external threaded connection 28034 i of the end of the tubular spring housing 28034 .
- An external flange 28052 a of a base member 28052 b of an upper cam assembly 28052 that is mounted upon and receives the lower tubular mandrel 28006 , that includes an internal flange 28052 c that is received within the external annular recess 28006 e of the lower tubular mandrel 28006 and a plurality of circumferentially spaced apart tapered cam arms 28052 d extending from the base member mates with and is received within the tubular upper hinge sleeve 28050 .
- the base member 28052 b of the upper cam assembly 28052 further includes a plurality of circumferentially spaced apart teeth 28052 f that mate with and are received within a plurality of circumferentially spaced apart teeth 28034 j provided on the end face of the tubular spring housing 28034 and an end face of the external flange 28052 a of the base member of the upper cam assembly is positioned in opposing relation to an end face of the internal flange 28050 b of the tubular upper hinge sleeve 28050 .
- Each of the cam arms 28052 d of the upper cam assembly 28052 include external cam surfaces 28052 e .
- the teeth 28052 f of the base member 28052 b of the upper cam assembly 28052 and the teeth 28034 j provided on the end face of the tubular spring housing 28034 permit torsional loads to be transmitted between the tubular spring housing and the upper cam assembly.
- a plurality of circumferentially spaced apart upper expansion segments 28054 are mounted upon and receive the lower tubular mandrel 28006 and each include an external pivot recess 28054 a at one end for mating with and receiving the internal pivot 28050 c of the tubular upper hinge sleeve 28050 and an external tapered expansion surface 28054 b at another end and are pivotally mounted within the tubular upper hinge sleeve and are interleaved with the circumferentially spaced apart cam arms 28052 d of the upper cam assembly 28052 .
- the upper expansion segments 28054 are interleaved among the cam arms 28052 d of the upper cam assembly 28052 .
- a plurality of circumferentially spaced apart lower expansion segments 28058 are mounted upon and receive the lower tubular mandrel 28006 , are interleaved among the upper expansion segments 28054 , are oriented in the opposite direction to the upper expansion segments 28054 , each include an external pivot recess 28058 a at one end and an external tapered expansion surface 28054 b at another end and are positioned in opposing relation to corresponding circumferentially spaced apart cam arms 28052 d of the upper cam assembly 28052 .
- a lower cam assembly 28060 is mounted upon and receives the lower tubular mandrel 28006 that includes a base member 28060 a having an external flange 28060 b , a plurality of circumferentially spaced apart cam arms 28060 d that extend from the base member that each include external cam surfaces 28060 e and define mounting holes 28060 f and 28060 g .
- the base member 28060 a of the lower cam assembly 28060 further includes a plurality of circumferentially spaced apart teeth 28060 h .
- the circumferentially spaced apart cam arms 28060 d of the lower cam assembly 28060 are interleaved among the lower expansion segments 28058 and the circumferentially spaced apart cam arms 28052 d of the upper cam assembly 28052 and positioned in opposing relation to corresponding upper expansion segments 28054 .
- Mounting screws, 28062 a , 28062 b , 28062 c , and 28062 e are mounted within the corresponding mounting holes, 28060 f and 28060 g , of the lower cam assembly 28060 and are received within the external annular recess 28006 g of the lower cam assembly 28060 .
- a tubular lower hinge sleeve 28064 that receives the lower expansion segments 28058 and the lower cam assembly 28060 includes an internal flange 28064 a for engaging the external flange 28060 b of the base member of the lower cam assembly 28060 , an internal pivot 28064 b for engaging and receiving the external pivot recess 28058 a of the lower expansion segments 28058 thereby pivotally mounting the lower expansion segments within the tubular lower hinge sleeve, and an internal threaded connection 28064 c.
- Mounting screws, 28070 a and 28070 b are mounted in and coupled to the mounting holes, 28068 c and 28068 d , respectively, of the tubular member 28068 that also extend into the mounting holes, 28066 b and 28066 c , respectively, of the tubular sleeve 28066 .
- a sealing element 28072 is received within the external annular recess 28068 e of the tubular member 28068 for sealing the interface between the tubular member and the tubular sleeve 28066 .
- a sealing element 28076 is received within the external annular recess 28074 d of the tubular retracting piston 28074 for sealing the interface between the tubular retracting piston and the tubular sleeve 28066 .
- a sealing element 28078 is received within the internal annular recess 28074 c of the tubular retracting piston 28074 for sealing the interface between the tubular retracting piston and the tubular lower mandrel 28006 .
- Locking dogs 28080 mate with and receive the external teeth 28006 h of the tubular lower mandrel 28006 .
- a spacer ring 28082 is positioned between an end face of the locking dogs 28080 and an end face of the lower cam assembly 28060 .
- a release piston 28084 mounted upon the tubular lower mandrel 28006 defines a radial passage 28084 a for mounting a burst disk 28086 includes sealing elements, 28084 b , 28084 c , and 28084 d .
- the sealing elements, 28084 b and 28084 d sealing the interface between the release piston 28084 and the tubular lower mandrel 28006 .
- An end face of the release piston 28084 is positioned in opposing relation to an end face of the locking dogs 28080 .
- a release sleeve 28088 that receives and is mounted upon the locking dogs 28080 and the release piston 28084 includes an internal flange 28088 a at one end that sealingly engages the tubular lower mandrel 28006 .
- a bypass sleeve 28090 that receives and is mounted upon the release sleeve 28088 includes an internal flange 28090 a at one end.
- the retracting spring 28044 is compressed and thereby applies a biasing spring force in a direction 28092 from the lower tubular mandrel 28006 to the tubular spring housing 28034 that, in the absence of other forces, moves and/or maintains the upper cam assembly 28052 and the upper expansion segments 28054 out of engagement with the lower expansion segments 28058 and the lower cam assembly 28060 .
- an external threaded connection 26 a of an end of the extension actuator assembly 26 is coupled to the internal threaded connection 28002 d of the upper tubular tool joint 28002 and an internal threaded connection 30 a of an end of the adjustable casing expansion cone assembly 30 is coupled to the external threaded connection 28068 f of the tubular member 28068 .
- the upper cam assembly 28052 and the upper expansion segments 28054 may be brought into engagement with the lower expansion segments 28058 and the lower cam assembly 28060 by pressurizing an annulus 28094 defined between the lower tubular mandrel 28006 and the tubular spring housing 28034 .
- injection of fluidic materials into the adjustable bell section expansion cone assembly 28 through the longitudinal passage 28006 b of the lower tubular mandrel 28006 and into the radial passage 28006 ba may pressurize the annulus 28094 thereby creating sufficient operating pressure to generate a force in a direction 28096 sufficient to overcome the biasing force of the retracting spring 28044 .
- the spring housing 28034 may be displaced in the direction 28096 relative to the lower tubular mandrel 28006 thereby displacing the tubular upper hinge sleeve 28050 , upper cam assembly 28052 , and upper expansion segments 28054 in the direction 28096 .
- the displacement of the upper cam assembly 28052 and upper expansion segments 28054 in the direction 28096 will cause the lower expansion segments 28058 to ride up the cam surfaces 28052 e of the cam arms 28052 d of the upper cam assembly 28052 while also pivoting about the lower tubular hinge segment 28064 , and will also cause the upper expansion segments 28054 to ride up the cam surfaces 28060 e of the cam arms 28060 d of the lower cam assembly 28060 while also pivoting about the upper tubular hinge segment 28050 .
- the upper and lower expansion segments, 28054 and 28058 when brought into axial alignment, they define an outer expansion surface that is approximately contiguous in a circumferential direction and which provides an outer expansion surface that at least approximates a conical surface.
- the adjustable bell section expansion cone assembly 28 when the upper and lower expansion segments, 28054 and 28058 , brought into axial alignment into a radially expanded position, the upper and lower expansion segments, 28054 and 28058 , are displaced relative to the expandable wellbore casing 100 to thereby radially expand and plastically deform at least a portion of the expandable wellbore casing.
- the adjustable bell section expansion cone assembly 28 may then be rotated relative to the expandable wellbore casing to enhance and/or modify the rate at which the expandable wellbore casing is radially expanded and plastically deformed.
- the upper cam assembly 28052 and the upper expansion segments 28054 may be moved out of engagement with the lower expansion segments 28058 and the lower cam assembly 28060 by reducing the operating pressure within the annulus 28094 .
- the upper cam assembly 28052 and the upper expansion segments 28054 may also be moved out of engagement with the lower expansion segments 28058 and the lower cam assembly 28060 by sensing the operating pressure within the longitudinal passage 28006 b of the lower tubular mandrel 28006 .
- the upper cam assembly 28052 and the upper expansion segments 28054 may also be moved out of engagement with the lower expansion segments 28058 and the lower cam assembly 28060 by sensing the operating pressure within the longitudinal passage 28006 b of the lower tubular mandrel 28006 .
- the burst disc 28086 will open the passage 28084 a thereby pressurizing the interior of the tubular release sleeve 28088 thereby displacing the tubular release sleeve 28088 downwardly in a direction 28092 away from engagement with the locking dogs 28080 .
- the locking dogs 28080 are displaced outwardly in the radial directed and thereby released from engagement with the lower tubular mandrel 28006 thereby permitting the lower expansion segments 28058 and the lower cam assembly 28060 to be displaced downwardly relative to the lower tubular mandrel.
- the operating pressure within the lower tubular mandrel 28066 may then cause the lower tubular mandrel to be displaced downwardly in the direction 28094 relative to the tubular lower mandrel 28006 and the retracting piston 28074 .
- the lower tubular mandrel 28066 , the lower expansion segments 28058 , the lower cam assembly 28060 , and tubular lower hinge sleeve 28064 are displaced downwardly in the direction 28094 relative to the tubular spring housing 28034 thereby moving the lower expansion segments 28058 and the lower cam assembly 28060 out of engagement with the upper cam assembly 28052 and the upper expansion segments 28054 .
- the adjustable bell section expansion cone assembly senses the diameter of the expandable wellbore casing 100 using the upper toggle links, 28022 and 28028 , lower toggle links, 28024 and 28030 , and triggers, 28026 and 28032 , and then prevents the engagement of the upper cam assembly 28052 and the upper expansion segments 28054 with the lower expansion segments 28058 and the lower cam assembly 28060 .
- the triggers, 28026 and 28032 will be pivoted by the engagement arms, 28024 d and 28030 d , of the lower toggle links, 28024 and 28030 , to a position in which the triggers will no longer engage the internal flange 28034 d of the end of the tubular spring housing 28034 thereby permitting the displacement of the tubular spring housing in the direction 28096 .
- the upper cam assembly 28052 and the upper expansion segments 28054 can be brought into engagement with the lower expansion segments 28058 and the lower cam assembly 28060 .
- the upper toggle links, 28022 and 28028 , and the lower toggle links, 28024 and 28030 are spring biased towards the position illustrated in FIG. 15W .
- the triggers, 28026 and 28032 will be maintained in a position in which the triggers will engage the internal flange 28034 d of the end of the tubular spring housing 28034 thereby preventing the displacement of the tubular spring housing in the direction 28096 .
- the upper cam assembly 28052 and the upper expansion segments 28054 cannot be brought into engagement with the lower expansion segments 28058 and the lower cam assembly 28060 .
- the triggers, 28026 and 28032 are spring biased towards the position illustrated in FIG. 15X .
- the tubular spring housing 28034 may be displaced upwardly in the direction 28098 even if the upper toggle links, 28022 and 28028 , and lower toggle links, 28024 and 28030 , are positioned within a portion of the expandable wellbore casing 100 that has not been radially expanded and plastically deformed by the system 10 .
- the tubular spring housing 28034 of the adjustable bell section expansion cone assembly 28 defines internal annular recesses 28034 k and 280341, spaced apart by an internal flange 28034 m
- the tubular toggle bushing 28008 defines an external annular recess 28008 ac
- the adjustable bell section expansion cone assembly further includes pins, 28100 a and 28100 b and 28102 a and 28102 b , mounted in holes 28008 j and 28008 o and 28008 k and 28008 n , respectively, of the tubular toggle bushing, and a one-shot deactivation device 28104 mounted on the tubular toggle bushing between the pins, 28100 a and 28100 b and 28102 a and 28102 b.
- the one-shot deactivation device 28104 includes a tubular body 28104 a that defines radial holes, 28104 b and 28014 c , and includes an external annular recess 28104 d at one end, a centrally positioned external flange 28104 e , a centrally positioned internal annular recess 28104 f , and an external annular recess 28104 g at another end.
- An engagement member 28106 that includes a base member 28106 a having a tapered end 28106 b and a key member 28106 c having a tapered end 28106 d is received within a portion of the internal annular recess 28104 f of the tubular body 28104 a and an engagement member 28108 that includes a base member 28108 a having a tapered end 28108 b and a key member 28108 c having a tapered end 28108 d is received within an opposite portion of the internal annular recess 28104 f of the tubular body 28104 a .
- Spring members, 28110 and 28112 are received within the annular recess 28104 f of the tubular body 28104 a for biasing the base members, base member 28106 a and 28108 a , of the engagement members, 28106 and 28108 , respectively, radially inwardly relative to the tubular body 28104 a.
- the one-shot deactivation device 28104 are positioned proximate and in intimate contact with the pins, 28102 a and 28102 b , with the tapered ends, 28106 b and 28108 b , of the base members, 28106 a and 28108 a , of the engagement members, 28106 and 28108 , received within the external annular recess 28008 ac of the tubular toggle bushing 28008 .
- the one-shot deactivation device 28104 is positioned as illustrated in FIGS.
- the external annular recess 28104 d of the tubular body 28104 a of the one-shot deactivation device is moved out of engagement with the engagement arms, 28026 d and 28032 d , of the triggers, 28026 and 28032 , respectively.
- the triggers, 28026 and 28032 may operate normally as described above with reference to FIGS. 15W, 15X , and 15 Y.
- the one-shot deactivation device 28104 are positioned proximate and in intimate contact with the pins, 28100 a and 28100 b , with the tapered ends, 28106 b and 28108 b , of the base members, 28106 a and 28108 a , of the engagement members, 28106 and 28108 , not received within the external annular recess 28008 ac of the tubular toggle bushing 28008 .
- the one-shot deactivation device 28104 is positioned as illustrated in FIG.
- the external annular recess 28104 d of the tubular body 28104 a of the one-shot deactivation device is moved into engagement with the engagement arms, 28026 d and 28032 d , of the triggers, 28026 and 28032 , respectively.
- the triggers, 28026 and 28032 are deactivated and may not operate normally as described above with reference to FIGS. 15W, 15X , and 15 Y.
- the elements of the adjustable bell section expansion cone assembly 28 that sense the diameter of the expandable wellbore casing 100 may be disabled or omitted or adjusted to sense any pre-selected internal diameter of the expandable wellbore casing.
- the adjustable casing expansion cone assembly 30 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on Nov. 12, 2002, and/or (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, and/or (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on Feb. 29, 2003, and/or (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep.
- PCT patent application serial number PCT/US03/14153 attorney docket number 25791.104.02, filed on Nov. 13, 2003
- PCT patent application serial number PCT/US03/18530 attorney docket number 25791.108.02, filed on Jun. 11, 2003
- PCT patent application serial number PCT/US04/______ attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (8)
- the adjustable casing expansion cone assembly 30 includes an upper tubular tool joint 30002 that defines a longitudinal passage 30002 a and mounting holes, 30002 b and 30002 c , and includes an internal threaded connection 30002 d , an inner annular recess 30002 e , an inner annular recess 30002 f , and an internal threaded connection 30002 g .
- a tubular torque plate 30004 that defines a longitudinal passage 30004 a and includes circumferentially spaced apart teeth 30004 b is received within, mates with, and is coupled to the internal annular recess 30002 e of the upper tubular tool joint 30002 .
- a sealing element 30010 is received within the external annular recess 30008 y of the tubular toggle bushing 30008 for sealing the interface between the tubular toggle bushing and the upper tubular tool joint 30002 .
- a sealing element 30012 is received within the internal annular recess 30008 z of the tubular toggle bushing 30008 for sealing the interface between the tubular toggle bushing and the tubular lower mandrel 30006 .
- Mounting screws, 30014 a and 30014 b , mounted within and coupled to the mounting holes, 30008 w and 30008 x , respectively, of the tubular toggle bushing 30008 are also received within the mounting holes, 30002 b and 30002 c , of the upper tubular tool joint 30002 .
- Mounting pins, 30016 a , 30016 b , 30016 c , 30016 d , and 30016 e are mounted within the mounting holes, 30008 e , 30008 f , 30008 g , 30008 h , and 30008 i , respectively.
- Mounting pins, 30018 a , 30018 b , 30018 c , 30018 d , and 30018 e are mounted within the mounting holes, 30008 t , 30008 s , 30008 r , 30008 q , and 30008 p , respectively.
- Mounting screws, 30020 a and 30020 b are mounted within the mounting holes, 30008 u and 30008 v , respectively.
- a first upper toggle link 30022 defines mounting holes, 30022 a and 30022 b , for receiving the mounting pins, 30016 a and 30016 b , and includes a mounting pin 30022 c at one end.
- a first lower toggle link 30024 defines mounting holes, 30024 a , 30024 b , and 30024 c , for receiving the mounting pins, 30022 c , 30016 c , and 30016 d , respectively and includes an engagement arm 30024 d .
- a first trigger 30026 defines a mounting hole 30026 a for receiving the mounting pin 30016 e and includes an engagement arm 30026 b at one end, an engagement member 30026 c , and an engagement arm 30026 d at another end.
- a second upper toggle link 30028 defines mounting holes, 30028 a and 30028 b , for receiving the mounting pins, 30018 a and 30018 b , and includes a mounting pin 30028 c at one end.
- a second lower toggle link 30030 defines mounting holes, 30030 a , 30030 b , and 30030 c , for receiving the mounting pins, 30028 c , 30018 c , and 30018 d , respectively and includes an engagement arm 30030 d .
- a second trigger 30032 defines a mounting hole 30032 a for receiving the mounting pin 30018 e and includes an engagement arm 30032 b at one end, an engagement member 30032 c , and an engagement arm 30032 d at another end.
- An end of a tubular spring housing 30034 that defines a longitudinal passage 30034 a , mounting holes, 30034 b and 30034 c , and mounting holes, 30034 ba and 30034 ca , and includes an internal flange 30034 d and an internal annular recess 30034 e at one end, and an internal flange 30034 f , an internal annular recess 30034 g , an internal annular recess 30034 h , and an external threaded connection 30034 i at another end receives and mates with the end of the tubular toggle bushing 30008 .
- Mounting screws, 30035 a and 30035 b are mounted within and coupled to the mounting holes, 30008 xb and 30008 xa , respectively, of the tubular toggle bushing 30008 and are received within the mounting holes, 30034 ba and 30034 ca , respectively, of the tubular spring housing 30034 .
- a tubular retracting spring ring 30036 that defines mounting holes, 30036 a and 30036 b , receives and mates with a portion of the tubular lower mandrel 30006 and is received within and mates with a portion of the tubular spring housing 30034 .
- Mounting screws, 30038 a and 30038 b are mounted within and coupled to the mounting holes, 30036 a and 30036 b , respectively, of the tubular retracting spring ring 30036 and extend into the mounting holes, 30034 b and 30034 c , respectively, of the tubular spring housing 30034 .
- Casing diameter sensor springs, 30040 a and 30040 b are positioned within the longitudinal slots, 30008 c and 3008 d , respectively, of the tubular toggle bushing 30008 that engage the engagement members, 30026 c and 30032 c , and engagement arms, 30026 d and 30032 d , of the first and second triggers, 30026 and 30032 , respectively.
- An inner flange 30042 a of an end of a tubular spring washer 30042 mates with and receives a portion of the tubular lower mandrel 30006 and an end face of the inner flange of the tubular spring washer is positioned proximate and end face of the external flange 30006 d of the tubular lower mandrel.
- the tubular spring washer 30042 is further received within the longitudinal passage 30034 a of the tubular spring housing 30034 .
- An end of a retracting spring 30044 that receives the tubular lower mandrel 30006 is positioned within the tubular spring washer 30042 in contact with the internal flange 30042 a of the tubular spring washer and the other end of the retracting spring is positioned in contact with an end face of the tubular retracting spring ring 30036 .
- a sealing element 30046 is received within the external annular recess 30006 j of the tubular lower mandrel 30006 for sealing the interface between the tubular lower mandrel and the tubular spring housing 30034 .
- a sealing element 30048 is received within the internal annular recess 30034 h of the tubular spring housing 30034 for sealing the interface between the tubular spring housing and the tubular lower mandrel 30006 .
- An internal threaded connection 30050 a of an end of a tubular upper hinge sleeve 30050 that includes an internal flange 30050 b and an internal pivot 30050 c receives and is coupled to the external threaded connection 30034 i of the end of the tubular spring housing 30034 .
- An external flange 30052 a of a base member 30052 b of an upper cam assembly 30052 that is mounted upon and receives the lower tubular mandrel 30006 , that includes an internal flange 30052 c that is received within the external annular recess 30006 e of the lower tubular mandrel 30006 and a plurality of circumferentially spaced apart tapered cam arms 30052 d extending from the base member mates with and is received within the tubular upper hinge sleeve 30050 .
- the base member 30052 b of the upper cam assembly 30052 further includes a plurality of circumferentially spaced apart teeth 30052 f that mate with and are received within a plurality of circumferentially spaced apart teeth 30034 j provided on the end face of the tubular spring housing 30034 and an end face of the external flange 30052 a of the base member of the upper cam assembly is positioned in opposing relation to an end face of the internal flange 30050 b of the tubular upper hinge sleeve 30050 .
- Each of the cam arms 30052 d of the upper cam assembly 30052 include external cam surfaces 30052 e .
- the teeth 30052 f of the base member 30052 b of the upper cam assembly 30052 and the teeth 30034 j provided on the end face of the tubular spring housing 30034 permit torsional loads to be transmitted between the tubular spring housing and the upper cam assembly.
- a plurality of circumferentially spaced apart upper expansion segments 30054 are mounted upon and receive the lower tubular mandrel 30006 and each include an external pivot recess 30054 a at one end for mating with and receiving the internal pivot 30050 c of the tubular upper hinge sleeve 30050 and an external tapered expansion surface 30054 b at another end and are pivotally mounted within the tubular upper hinge sleeve and are interleaved with the circumferentially spaced apart cam arms 30052 d of the upper cam assembly 30052 .
- the upper expansion segments 30054 are interleaved among the cam arms 30052 d of the upper cam assembly 30052 .
- a plurality of circumferentially spaced apart lower expansion segments 30058 are mounted upon and receive the lower tubular mandrel 30006 , are interleaved among the upper expansion segments 30054 , are oriented in the opposite direction to the upper expansion segments 30054 , each include an external pivot recess 30058 a at one end and an external tapered expansion surface 30054 b at another end and are positioned in opposing relation to corresponding circumferentially spaced apart cam arms 30052 d of the upper cam assembly 30052 .
- a lower cam assembly 30060 is mounted upon and receives the lower tubular mandrel 30006 that includes a base member 30060 a having an external flange 30060 b , a plurality of circumferentially spaced apart cam arms 30060 d that extend from the base member that each include external cam surfaces 30060 e and define mounting holes 30060 f and 30060 g .
- the base member 30060 a of the lower cam assembly 30060 further includes a plurality of circumferentially spaced apart teeth 30060 h .
- the circumferentially spaced apart cam arms 30060 d of the lower cam assembly 30060 are interleaved among the lower expansion segments 30058 and the circumferentially spaced apart cam arms 30052 d of the upper cam assembly 30052 and positioned in opposing relation to corresponding upper expansion segments 30054 .
- Mounting screws, 30062 a , 30062 b , 30062 c , and 30062 e are mounted within the corresponding mounting holes, 30060 f and 30060 g , of the lower cam assembly 30060 and are received within the external annular recess 30006 g of the lower cam assembly 30060 .
- a tubular lower hinge sleeve 30064 that receives the lower expansion segments 30058 and the lower cam assembly 30060 includes an internal flange 30064 a for engaging the external flange 30060 b of the base member of the lower cam assembly 30060 , an internal pivot 30064 b for engaging and receiving the external pivot recess 30058 a of the lower expansion segments 30058 thereby pivotally mounting the lower expansion segments within the tubular lower hinge sleeve, and an internal threaded connection 30064 c.
- Mounting screws, 30070 a and 30070 b are mounted in and coupled to the mounting holes, 30068 c and 30068 d , respectively, of the tubular member 30068 that also extend into the mounting holes, 30066 b and 30066 c , respectively, of the tubular sleeve 30066 .
- a sealing element 30072 is received within the external annular recess 30068 e of the tubular member 30068 for sealing the interface between the tubular member and the tubular sleeve 30066 .
- a sealing element 30076 is received within the external annular recess 30074 d of the tubular retracting piston 30074 for sealing the interface between the tubular retracting piston and the tubular sleeve 30066 .
- a sealing element 30078 is received within the internal annular recess 30074 c of the tubular retracting piston 30074 for sealing the interface between the tubular retracting piston and the tubular lower mandrel 30006 .
- Locking dogs 30080 mate with and receive the external teeth 30006 h of the tubular lower mandrel 30006 .
- a spacer ring 30082 is positioned between an end face of the locking dogs 30080 and an end face of the lower cam assembly 30060 .
- a release piston 30084 mounted upon the tubular lower mandrel 30006 defines a radial passage 30084 a for mounting a burst disk 30086 includes sealing elements, 30084 b , 30084 c , and 30084 d .
- the sealing elements, 30084 b and 30084 d sealing the interface between the release piston 30084 and the tubular lower mandrel 30006 .
- An end face of the release piston 30084 is positioned in opposing relation to an end face of the locking dogs 30080 .
- the retracting spring 30044 is compressed and thereby applies a biasing spring force in a direction 30092 from the lower tubular mandrel 30006 to the tubular spring housing 30034 that, in the absence of other forces, moves and/or maintains the upper cam assembly 30052 and the upper expansion segments 30054 out of engagement with the lower expansion segments 30058 and the lower cam assembly 30060 .
- an external threaded connection 20 a of an end of the sealing cup assembly 20 is coupled to the internal threaded connection 30002 d of the upper tubular tool joint 30002 and an internal threaded connection 30 a of an end of the adjustable casing expansion cone assembly 30 is coupled to the external threaded connection 30068 f of the tubular member 30068 .
- the upper cam assembly 30052 and the upper expansion segments 30054 may be brought into engagement with the lower expansion segments 30058 and the lower cam assembly 30060 by pressurizing an annulus 30094 defined between the lower tubular mandrel 30006 and the tubular spring housing 30034 .
- injection of fluidic materials into the adjustable casing expansion cone assembly 30 through the longitudinal passage 30006 b of the lower tubular mandrel 30006 and into the radial passage 30006 ba may pressurize the annulus 30094 thereby creating sufficient operating pressure to generate a force in a direction 30096 sufficient to overcome the biasing force of the retracting spring 30044 .
- the spring housing 30034 may be displaced in the direction 30096 relative to the lower tubular mandrel 30006 thereby displacing the tubular upper hinge sleeve 30050 , upper cam assembly 30052 , and upper expansion segments 30054 in the direction 30096 .
- the displacement of the upper cam assembly 30052 and upper expansion segments 30054 in the direction 30096 will cause the lower expansion segments 30058 to ride up the cam surfaces 30052 e of the cam arms 30052 d of the upper cam assembly 30052 while also pivoting about the lower tubular hinge segment 30064 , and will also cause the upper expansion segments 30054 to ride up the cam surfaces 30060 e of the cam arms 30060 d of the lower cam assembly 30060 while also pivoting about the upper tubular hinge segment 30050 .
- the upper and lower expansion segments, 30054 and 30058 when brought into axial alignment, they define an outer expansion surface that is approximately contiguous in a circumferential direction and which provides an outer expansion surface that at least approximates a conical surface.
- the adjustable casing expansion cone assembly 30 when the upper and lower expansion segments, 30054 and 30058 , brought into axial alignment into a radially expanded position, the upper and lower expansion segments, 30054 and 30058 , are displaced relative to the expandable wellbore casing 100 to thereby radially expand and plastically deform at least a portion of the expandable wellbore casing.
- the adjustable casing expansion cone assembly 30 may then be rotated relative to the expandable wellbore casing to enhance and/or modify the rate at which the expandable wellbore casing is radially expanded and plastically deformed.
- the upper cam assembly 30052 and the upper expansion segments 30054 may be moved out of engagement with the lower expansion segments 30058 and the lower cam assembly 30060 by reducing the operating pressure within the annulus 30094 .
- the upper cam assembly 30052 and the upper expansion segments 30054 may also be moved out of engagement with the lower expansion segments 30058 and the lower cam assembly 30060 by sensing the operating pressure within the longitudinal passage 30006 b of the lower tubular mandrel 30006 .
- the upper cam assembly 30052 and the upper expansion segments 30054 may also be moved out of engagement with the lower expansion segments 30058 and the lower cam assembly 30060 by sensing the operating pressure within the longitudinal passage 30006 b of the lower tubular mandrel 30006 .
- the burst disc 30086 will open the passage 30084 a thereby pressurizing the interior of the tubular release sleeve 30088 thereby displacing the tubular release sleeve 30088 downwardly in a direction 30092 away from engagement with the locking dogs 30080 .
- the locking dogs 30080 are displaced outwardly in the radial directed and thereby released from engagement with the lower tubular mandrel 30006 thereby permitting the lower expansion segments 30058 and the lower cam assembly 30060 to be displaced downwardly relative to the lower tubular mandrel.
- the operating pressure within the lower tubular mandrel 30066 may then cause the lower tubular mandrel to be displaced downwardly in the direction 30094 relative to the tubular lower mandrel 30006 and the retracting piston 30074 .
- the lower tubular mandrel 30066 , the lower expansion segments 30058 , the lower cam assembly 30060 , and tubular lower hinge sleeve 30064 are displaced downwardly in the direction 30094 relative to the tubular spring housing 30034 thereby moving the lower expansion segments 30058 and the lower cam assembly 30060 out of engagement with the upper cam assembly 30052 and the upper expansion segments 30054 .
- the adjustable casing expansion cone assembly senses the diameter of the expandable wellbore casing 100 using the upper toggle links, 30022 and 30028 , lower toggle links, 30024 and 30030 , and triggers, 30026 and 30032 , and then prevents the engagement of the upper cam assembly 30052 and the upper expansion segments 30054 with the lower expansion segments 30058 and the lower cam assembly 30060 .
- the triggers, 30026 and 30032 will be pivoted by the engagement arms, 30024 d and 30030 d , of the lower toggle links, 30024 and 30030 , to a position in which the triggers will no longer engage the internal flange 30034 d of the end of the tubular spring housing 30034 thereby permitting the displacement of the tubular spring housing in the direction 30096 .
- the upper cam assembly 30052 and the upper expansion segments 30054 can be brought into engagement with the lower expansion segments 30058 and the lower cam assembly 30060 .
- the upper toggle links, 30022 and 30028 , and the lower toggle links, 30024 and 30030 are spring biased towards the position illustrated in FIG. 16W .
- the triggers, 30026 and 30032 will be maintained in a position in which the triggers will engage the internal flange 30034 d of the end of the tubular spring housing 30034 thereby preventing the displacement of the tubular spring housing in the direction 30096 .
- the upper cam assembly 30052 and the upper expansion segments 30054 cannot be brought into engagement with the lower expansion segments 30058 and the lower cam assembly 30060 .
- the triggers, 30026 and 30032 are spring biased towards the position illustrated in FIG. 16X .
- the tubular spring housing 30034 may be displaced upwardly in the direction 30098 even if the upper toggle links, 30022 and 30028 , and lower toggle links, 30024 and 30030 , are positioned within a portion of the expandable wellbore casing 100 that has not been radially expanded and plastically deformed by the system 10 ,
- the tubular spring housing 30034 of the adjustable casing expansion cone assembly 30 defines internal annular recesses 30034 k and 30034 i , spaced apart by an internal flange 30034 m
- the tubular toggle bushing 30008 defines an external annular recess 30008 ac
- the adjustable casing expansion cone assembly further includes pins, 30100 a and 30100 b and 30102 a and 30102 b , mounted in holes 30008 j and 30008 o and 30008 k and 30008 n , respectively, of the tubular toggle bushing, and a one-shot deactivation device 30104 mounted on the tubular toggle bushing between the pins, 30100 a and 30100 b and 30102 a and 30102 b.
- the one-shot deactivation device 30104 includes a tubular body 30104 a that defines radial holes, 30104 b and 30014 c , and includes an external annular recess 30104 d at one end, a centrally positioned external flange 30104 e , a centrally positioned internal annular recess 30104 f , and an external annular recess 30104 g at another end.
- An engagement member 30106 that includes a base member 30106 a having a tapered end 30106 b and a key member 30106 c having a tapered end 30106 d is received within a portion of the internal annular recess 30104 f of the tubular body 30104 a and an engagement member 30108 that includes a base member 30108 a having a tapered end 30108 b and a key member 30108 c having a tapered end 30108 d is received within an opposite portion of the internal annular recess 30104 f of the tubular body 30104 a .
- Spring members, 30110 and 30112 are received within the annular recess 30104 f of the tubular body 30104 a for biasing the base members, base member 30106 a and 30108 a , of the engagement members, 30106 and 30108 , respectively, radially inwardly relative to the tubular body 30104 a.
- the one-shot deactivation device 30104 are positioned proximate and in intimate contact with the pins, 30102 a and 30102 b , with the tapered ends, 30106 b and 30108 b , of the base members, 30106 a and 30108 a , of the engagement members, 30106 and 30108 , received within the external annular recess 30008 ac of the tubular toggle bushing 30008 .
- the one-shot deactivation device 30104 is positioned as illustrated in FIG.
- the external annular recess 30104 d of the tubular body 30104 a of the one-shot deactivation device is moved out of engagement with the engagement arms, 30026 d and 30032 d , of the triggers, 30026 and 30032 , respectively.
- the triggers, 30026 and 30032 may operate normally as described above with reference to FIGS. 16W, 16X , and 16 Y.
- the one-shot deactivation device 30104 are positioned proximate and in intimate contact with the pins, 30100 a and 30100 b , with the tapered ends, 30106 b and 30108 b , of the base members, 30106 a and 30108 a , of the engagement members, 30106 and 30108 , not received within the external annular recess 30008 ac of the tubular toggle bushing 30008 .
- the one-shot deactivation device 30104 is positioned as illustrated in FIGS.
- the external annular recess 30104 d of the tubular body 30104 a of the one-shot deactivation device is moved into engagement with the engagement arms, 30026 d and 30032 d , of the triggers, 30026 and 30032 , respectively.
- the triggers, 30026 and 30032 are deactivated and may not operate normally as described above with reference to FIGS. 16W, 16X , and 16 Y.
- the elements of the adjustable casing expansion cone assembly 30 that sense the diameter of the expandable wellbore casing 100 may be disabled or omitted or adjusted to sense any pre-selected internal diameter of the expandable wellbore casing.
- the packer setting tool assembly 32 includes a tubular adaptor 3202 that defines a longitudinal passage 3202 a , radial external mounting holes, 3202 b and 3202 c , radial passages, 3202 d and 3202 e , and includes an external threaded connection 3202 f at one end and an internal annular recess 3202 g having an internal threaded connection at another end.
- Mounting screws, 3205 a and 3205 b are received within and coupled to the mounting holes, 3204 c and 3204 d , of the tubular upper mandrel 3204 that also extend into the radial passages, 3202 d and 3202 e , of the tubular adaptor 3202 .
- An external threaded connection 3206 a of an end of a mandrel 3206 that defines a longitudinal passage 3206 b and includes an external annular recess 3206 c and an external annular recess 3206 d having an external threaded connection is received within and is coupled to the internal threaded connection 3204 j of the tubular upper mandrel 3204 .
- a sealing member 3210 is mounted upon and coupled to the external annular recess 3206 d of the mandrel 3206 .
- An internal flange 3212 a of a tubular key 3212 that includes an external annular recess 3212 b at one end and an internal annular recess 3212 c at another end is movably received within and engages the external annular recess 3204 f of the tubular upper mandrel 3204 .
- a garter spring 3214 is received within and engages the external annular recess 3212 b of the tubular key 3212 .
- An end of a tubular bushing 3216 that defines a longitudinal passage 3216 a for receiving and mating with the upper mandrel 3204 , and radial passages, 3216 b and 3216 c , and includes an external threaded connection 3216 d at an intermediate portion, and an external flange 3216 e , an internal annular recess 3216 f , circumferentially spaced apart teeth 3216 g , and external flanges, 3216 h and 3216 i , at another end is received within and mates with the internal annular recess 3212 c of the tubular key 3212 .
- An internal threaded connection 3218 a of a tubular drag block body 3218 that defines a longitudinal passage 3218 b for receiving the tubular bushing 3216 , mounting holes, 3218 c and 3218 d , mounting holes, 3218 e and 3218 f , and includes an internal threaded connection 3218 g at one end, a centrally positioned external annular recess 3218 h , and an external threaded connection 3218 i at another end is received within and coupled to the external threaded connection 3216 d of the tubular bushing 3216 .
- Drag blocks, 3228 and 3230 that are received within the external annular recess 3218 h of the tubular drag block body 3218 , include ends that mate with and are received within the end of the first tubular keeper 3220 , and other ends that mate with and are received within the end of the second tubular keeper 3224 .
- the drag blocks, 3228 and 3230 further include internal annular recesses, 3228 a and 3230 a , respectively, that receive and mate with ends of springs, 3232 and 3234 , respectively.
- the springs, 3232 and 3234 also receive and mate with the external annular recess 3218 h of the tubular drag block body 3218 .
- An external threaded connection 3236 a of an end of a tubular releasing cap extension 3236 that defines a longitudinal passage 3236 b and includes an internal annular recess 3236 c and an internal threaded connection 3236 d at another end is received within and is coupled to the internal threaded connection 3218 g of the tubular drag block body 3218 .
- An external threaded connection 3238 a of an end of a tubular releasing cap 3238 that defines a longitudinal passage 3238 b and includes an internal annular recess 3238 c is received within and coupled to the internal threaded connection 3236 d of the tubular releasing cap extension 3236 .
- a sealing element 3240 is received within the internal annular recess 3238 c of the tubular releasing cap 3238 for fluidicly sealing the interface between the tubular releasing cap and the upper mandrel 3204 .
- An internal flange 3244 a of a tubular coupling ring 3244 that defines a longitudinal passage 3244 b and radial passages, 3244 c and 3244 d , receives and mates with the external flange 3216 h of the tubular bushing 3216 and an end face of the internal flange of the tubular coupling ring is positioned proximate and in opposing relation to an end face of the external flange 3216 i of the tubular bushing.
- An internal flange 3246 a of a tubular retaining collet 3246 that includes a plurality of axially extending collet fingers 3246 b , each having internal flanges 3246 c at an end of each collet finger, for engaging and receiving the tubular coupling ring 3244 receives and mates with external flange 3216 e of the tubular bushing 3216 and an end face of the internal flange of the tubular retaining collet is positioned proximate and in opposing relation to an end face of the external flange 3216 h of the tubular bushing.
- the packer assembly 36 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, and/or (2) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on Sep. 23, 2003, and/or (3) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (4) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (5) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference.
- the packer assembly 36 includes a tubular upper adaptor 3602 that defines a longitudinal passage 3602 a having a tapered opening 3602 b and mounting holes, 3602 c and 3602 d , that includes a plurality of circumferentially spaced apart teeth 3602 e at one end, an external flange 3602 f , and an internal threaded connection 3602 g at another end.
- the tubular upper adaptor 3602 is fabricated from aluminum.
- the tubular upper mandrel 3604 is fabricated from aluminum.
- An upper tubular spacer ring 3606 that defines mounting holes, 3606 a and 3606 b , receives and mates with the end of the tubular upper mandrel 3604 and includes an angled end face 3606 c and another end face that is positioned proximate to an end face of the tubular upper adaptor 3602 is coupled to the tubular upper mandrel by shear pins, 3608 a and 3608 b , that are mounted within and coupled to the mounting holes, 3604 c and 3606 a , and, 3604 d and 3606 b , respectively, of the tubular upper mandrel and upper tubular spacer ring, respectively.
- a lower tubular spacer ring 3610 that includes an angled end face 3610 a receives, mates, and is coupled to the other end of the tubular upper mandrel 3604 and includes another end face that is positioned proximate to an end face of the external flange 3604 i of the tubular upper mandrel 3604 .
- the upper and tubular spacer rings, 3606 and 3610 are fabricated from a composite material.
- An upper tubular slip 3612 that receives and is movably mounted upon the tubular upper mandrel 3604 defines a longitudinal passage 3612 a having a tapered opening 3612 b and includes external annular recesses, 3612 c , 3612 d , 3612 e , 3612 f , and 3612 g , and an angled end face 3612 h that mates with and is positioned proximate the angled end face 3606 c of the upper tubular spacer ring 3606 .
- Slip retaining bands 3614 a , 3614 b , 3614 c , 3614 d , and 3614 e , are received within and coupled to the external annular recesses, 3612 c , 3612 d , 3612 e , 3612 f , and 3612 g , of the upper tubular slip 3612 .
- a lower tubular slip 3616 that receives and is movably mounted upon the tubular upper mandrel 3604 defines a longitudinal passage 3616 a having a tapered opening 3616 b and includes external annular recesses, 3616 c , 3616 d , 3616 e , 3616 f , and 3616 g , and an angled end face 3616 h that mates with and is positioned proximate the angled end face 3610 a of the lower tubular spacer ring 3610 .
- Slip retaining bands, 3618 a , 3618 b , 3618 c , 3618 d , and 3618 e are received within and coupled to the external annular recesses, 3616 c , 3616 d , 3616 e , 3616 f , and 3616 g , of the lower tubular slip 3616 .
- the upper and lower tubular slips, 3612 and 3616 are fabricated from composite materials, and at least some of the slip retaining bands, 3614 a , 3614 b , 3614 c , 3614 d , 3614 e , 3618 a , 3618 b , 3618 c , 3618 d , and 3618 e are fabricated from carbide insert materials.
- An upper tubular wedge 3620 that defines an longitudinal passage 3620 a for receiving the tubular upper mandrel 3604 and mounting holes, 3620 b and 3620 c , and includes an angled end face 3620 d at one end that is received within and mates with the tapered opening 3612 b of the upper tubular slip 3612 , and an angled end face 3620 e at another end is coupled to the tubular upper mandrel by shear pins, 3622 a and 3622 b , mounted within and coupled to the mounting holes, 3604 e and 3620 b , and, 3604 f and 3620 c , respectively, of the tubular upper mandrel and upper tubular wedge, respectively.
- a lower tubular wedge 3624 that defines an longitudinal passage 3624 a for receiving the tubular upper mandrel 3604 and mounting holes, 3624 b and 3624 c , and includes an angled end face 3624 d at one end that is received within and mates with the tapered opening 3616 b of the lower tubular slip 3616 , and an angled end face 3624 e at another end is coupled to the tubular upper mandrel by shear pins, 3626 a and 3626 b , mounted within and coupled to the mounting holes, 3604 g and 3624 b , and, 3604 h and 3624 c , respectively, of the tubular upper mandrel and lower tubular wedge, respectively.
- the upper and lower tubular wedges, 3620 and 3624 are fabricated from composite materials.
- An upper tubular extrusion limiter 3628 that defines a longitudinal passage 3628 a for receiving the tubular upper mandrel 3604 includes an angled end face 3628 b at one end that mates with the angled end face 3620 e of the upper tubular wedge 3620 , an angled end face 3628 c at another end having recesses 3628 d , and external annular recesses, 3628 e , 3628 f and 3628 g .
- Retaining bands, 3630 a , 3630 b , and 3630 c are mounted within and coupled to the external annular recesses, 3628 e , 3628 f and 3628 g , respectively, of the upper tubular extrusion limiter 3628 .
- Circular disc-shaped extrusion preventers 3632 are coupled and mounted within the recesses 3628 d .
- a lower tubular extrusion limiter 3634 that defines a longitudinal passage 3634 a for receiving the tubular upper mandrel 3604 includes an angled end face 3634 b at one end that mates with the angled end face 3624 e of the lower tubular wedge 3624 , an angled end face 3634 c at another end having recesses 3634 d , and external annular recesses, 3634 e , 3634 f and 3634 g .
- Retaining bands 3636 a , 3636 b , and 3636 c , are mounted within and coupled to the external annular recesses, 3634 e , 3634 f and 3634 g , respectively, of the lower tubular extrusion limiter 3634 .
- Circular disc-shaped extrusion preventers 3638 are coupled and mounted within the recesses 3634 d .
- the upper and lower extrusion limiters, 3628 and 3634 are fabricated from composite materials.
- An upper tubular elastomeric packer element 3640 that defines a longitudinal passage 3640 a for receiving the tubular upper mandrel 3604 includes an angled end face 3640 b at one end that mates with and is positioned proximate the angled end face 3628 c of the upper tubular extrusion limiter 3628 and an curved end face 3640 c at another end.
- a lower tubular elastomeric packer element 3642 that defines a longitudinal passage 3642 a for receiving the tubular upper mandrel 3604 includes an angled end face 3642 b at one end that mates with and is positioned proximate the angled end face 3634 c of the lower tubular extrusion limiter 3634 and an curved end face 3642 c at another end.
- a central tubular elastomeric packer element 3644 that defines a longitudinal passage 3644 a for receiving the tubular upper mandrel 3604 includes a curved outer surface 3644 b for mating with and engaging the curved end faces, 3640 c and 3642 c , of the upper and lower tubular elastomeric packer elements, 3640 and 3642 , respectively.
- An external threaded connection 3646 a of a tubular lower mandrel 3646 that defines a longitudinal passage 3646 b having throat passages, 3646 c and 3646 d , and flow ports, 3646 e and 3646 f , and a mounting hole 3646 g , and includes an internal annular recess 3646 h at one end, and an external flange 3646 i , internal annular recess 3646 j , and internal threaded connection 3646 k at another end.
- the tubular lower mandrel 3646 is fabricated from aluminum.
- a sealing element 3648 is received within the inner annular recess 3604 j of the other end of the tubular upper mandrel 3604 for sealing an interface between the tubular upper mandrel and the tubular lower mandrel 3646 .
- a tubular sliding sleeve valve 3650 that defines a longitudinal passage 3650 a and radial flow ports, 3650 b and 3650 c , and includes collet fingers 3650 d at one end for engaging the internal annular recess 3646 h of the lower tubular mandrel 3646 , an external annular recess 3650 e , an external annular recess 3650 f , an external annular recess 3650 g , and circumferentially spaced apart teeth 3650 h at another end is received within and is slidably coupled to the longitudinal passage 3646 b of the tubular lower mandrel 3646 .
- the tubular sliding sleeve valve 3650 is fabricated from aluminum.
- a set screw 3652 is mounted within and coupled to the mounting hole 3646 g of the tubular lower mandrel 3646 that is received within the external annular recess 3650 e of the tubular sliding sleeve 3650 .
- Sealing elements, 3654 and 3656 are mounted within the external annular recesses, 3650 f and 3650 g , respectively, of the tubular sliding sleeve valve 3650 for sealing an interface between the tubular sliding sleeve valve and the tubular lower mandrel 3646 .
- An end of a tubular outer sleeve 3658 that defines a longitudinal passage 3658 a , radial passages, 3658 b and 3658 c , upper flow ports, 3658 d and 3658 e , lower flow ports, 3658 f and 3658 g , and radial passages, 3658 h and 3658 i , receives, mates with, and is coupled to the other end of the tubular upper mandrel 3604 and an end face of the end of the tubular outer sleeve is positioned proximate and end face of the lower tubular spacer ring 3610 .
- the other end of the tubular outer sleeve 3658 receives, mates with, and is coupled to the other end of the tubular lower mandrel 3646 .
- An external threaded connection 3660 a of an end of a tubular bypass mandrel 3660 that defines a longitudinal passage 3660 b , upper flow ports, 3660 c and 3660 d , lower flow ports, 3660 e and 3660 f , and a mounting hole 3660 g and includes an internal annular recess 3660 h and an external threaded connection 3660 i at another end is received within and coupled to the internal threaded connection 3646 k of the tubular lower mandrel 3646 .
- a sealing element 3662 is received within the internal annular recess 3646 j of the tubular lower mandrel 3646 for sealing an interface between the tubular lower mandrel and the tubular bypass mandrel 3660 .
- a tubular plug seat 3664 that defines a longitudinal passage 3664 a having a tapered opening 3664 b at one end, and flow ports, 3664 c and 3664 d , and includes an external annular recess 3664 e , an external annular recess 3664 f , an external annular recess 3664 g , an external annular recess 3664 h , and an external annular recess 3664 i having an external threaded connection at another end is received within and is movably coupled to the longitudinal passage 3660 b of the tubular bypass mandrel 3660 .
- a tubular nose 3666 is, threadably coupled to and mounted upon the external annular recess 3664 i of the tubular plug seat 3664 .
- the tubular plug seat 3664 is fabricated from aluminum. Sealing elements, 3668 , 3670 , and 3672 , are received within the external annular recesses, 3664 e , 3664 g , and 3664 h , respectively, of the tubular plug seat 3664 for sealing an interface between the tubular plug seat and the tubular bypass mandrel 3660 .
- a set screw 3674 is mounted within and coupled to the mounting hole 3660 g of the tubular bypass mandrel 3660 that is received within the external annular recess 3664 f of the tubular plug seat 3664 .
- tubular bypass sleeve 3676 that defines a longitudinal passage 3676 a and includes an internal annular recess 3676 b at one end and an internal threaded connection 3676 c at another end is coupled to the other end of the tubular outer sleeve 3658 and mates with and receives the tubular bypass mandrel 3660 .
- the tubular bypass sleeve 3676 is fabricated from aluminum.
- the tubular valve seat 3678 is fabricated from aluminum.
- a sealing element 3680 is received within the external annular recess 3678 g of the tubular valve seat 3678 for fluidicly sealing an interface between the tubular valve seat and the tubular bypass sleeve 3676 .
- a poppet valve 3682 mates with and is positioned within the valve seat 3678 c of the tubular valve seat 3678 .
- An end of the poppet valve 3682 is coupled to an end of a stem bolt 3684 that is slidingly supported for longitudinal displacement by the spring retainer 3678 f
- a valve spring 3686 that surrounds a portion of the stem bolt 3684 is positioned in opposing relation to the head of the stem bolt and a support 3678 fa of the spring retainer 3678 f for biasing the poppet valve 3682 into engagement with the valve seat 3678 c of the tubular valve seat 3678 .
- the packer setting tool and packer assembly are coupled to one another by inserting the end of the tubular upper adaptor 3602 into the other end of the tubular coupling ring 3244 , bringing the circumferentially spaced teeth 3216 g of the other end of the tubular bushing 3216 into engagement with the circumferentially spaced teeth 3602 e of the end of the tubular upper adaptor, and mounting shear pins, 36100 a and 36100 b , within the mounting holes, 3244 c and 3602 c , and, 3244 d and 3602 d , respectively, of the tubular coupling ring and tubular upper adaptor, respectively.
- tubular mandrel 3206 and tubular stinger 3208 of the packer setting tool assembly 32 are thereby positioned within the longitudinal passage 3604 a of the tubular upper mandrel 3604 with the 3208 e of the tubular stinger positioned within the longitudinal passage 3646 b of the tubular lower mandrel 3646 proximate the collet fingers 3650 d of the tubular sliding sleeve valve 3650 .
- the packer setting tool and packer assembly are positioned within the expandable wellbore casing 100 and an internal threaded connection 30 a of an end of the adjustable casing expansion cone assembly 30 receives and is coupled to the external threaded connection 3202 f of the end of the tubular adaptor 3202 of the packer setting tool assembly.
- shear pins, 36102 a and 36102 b mounted within the mounting holes, 3658 b and 3658 c , of the tubular outer sleeve 3658 couple the tubular outer sleeve to the expandable wellbore casing.
- torsion loads may transferred between the tubular outer sleeve 3658 and the expandable wellbore casing 100 .
- a conventional plug 36104 is then injected into the setting tool assembly 32 and packer assembly 36 by injecting a fluidic material 36106 into the setting tool assembly and packer assembly through the longitudinal passages, 3202 a , 3204 b , 3206 b , 3208 b , 3650 a , 3646 a , 3660 b , and 3664 a of the tubular adaptor 3202 , tubular upper mandrel 3204 , tubular mandrel 3206 , tubular stinger 3208 , tubular sliding sleeve valve 3650 , tubular lower mandrel 3646 , tubular bypass mandrel 3660 , and tubular plug seat 3664 , respectively.
- the plug 36104 is thereby positioned within the longitudinal passage 3664 a of the tubular plug seat 3664 .
- Continued injection of the fluidic material 36106 following the seating of the plug 1606 within the longitudinal passage 3664 a of the tubular plug seat 3664 causes the plug and the tubular plug seat to be displaced downwardly in a direction 36108 until further movement of the tubular plug seat is prevented by interaction of the set screw 3674 with the external annular recess 3664 f of the tubular plug seat.
- the flow ports, 3664 c and 3664 d , of the tubular plug seat 3664 are moved out of alignment with the upper flow ports, 3660 c and 3660 d , of the tubular bypass mandrel 3660 .
- the setting tool assembly 32 and packer assembly 36 are then moved upwardly to a position within the expandable wellbore casing 100 above the bell section.
- the tubular adaptor 3202 is then rotated, by rotating the tool string of the system 10 above the setting tool assembly 32 , to displace and position the drag blocks, 3228 and 3230 , into engagement with the interior surface of the expandable wellbore casing 100 .
- the setting sleeve 3242 engages and displaces the upper tubular spacer ring 3606 thereby shearing the shear pins, 3622 a and 3622 b , and driving the upper tubular slip 3612 onto and up the angled end face 3620 d of the upper tubular wedge 3620 and into engagement with the interior surface of the expandable wellbore casing 100 .
- longitudinal displacement of the upper tubular slip 3612 relative to the expandable wellbore casing 100 is prevented.
- the 3246 b collet fingers of the tubular retaining collet 3246 are disengaged from the tubular upper adaptor 3602 .
- an upward tensile force is applied to the tubular support member 12 , and the ball gripper assembly 16 is then operate to engage the interior surface of the expandable wellbore casing.
- the tension actuator assembly 18 is then operated to apply an upward tensile force to the tubular adaptor 3202 thereby pulling the upper tubular spacer ring 3606 , lower tubular spacer ring 3610 , upper tubular slip 3612 , lower tubular slip 3616 , upper tubular wedge 3620 , lower tubular wedge 3624 , upper tubular extrusion limiter 3628 , lower tubular extrusion limiter 3634 , and central tubular elastomeric element 3644 upwardly into contact with the 3242 thereby compressing the upper tubular spacer ring, lower tubular spacer ring, upper tubular slip, lower tubular slip, upper tubular wedge, lower tubular wedge, upper tubular extrusion limiter, lower tubular extrusion limiter, and central tubular elastomeric element.
- the upper tubular slip 3612 , lower tubular slip 3616 , and central tubular elastomeric element 3644 engage the interior surface of the expandable wellbore casing 100 .
- an upward tensile force is then applied to the tubular adaptor 3202 thereby compressing the lower tubular slip 3616 , lower tubular wedge 3624 , central elastomeric packer element 3644 , upper tubular extrusion limiter 3628 , and upper tubular wedge 3620 between the lower tubular spacer ring 3610 and the stationary upper tubular slip 3612 .
- the lower tubular slip 3616 is driven onto and up the angled end face 3624 d of the lower tubular wedge 3624 and into engagement with the interior surface of the expandable wellbore casing 100 , and the central elastomeric packer element 3644 is compressed radially outwardly into engagement with the interior surface of the expandable tubular member.
- further longitudinal displacement of the upper tubular slip 3612 , lower tubular slip 3616 , and central elastomeric packer element 3644 relative to the expandable wellbore casing 100 is prevented.
- the tubular adaptor 102 is further rotated thereby causing the tubular drag block body 3218 and setting sleeve 3242 to be displaced further downwardly in the direction 36113 until the tubular drag block body and setting sleeve are disengaged from the tubular stinger 3208 .
- the tubular stinger 3208 of the setting tool assembly 32 may then be displaced downwardly into complete engagement with the tubular sliding sleeve valve 3650 .
- a fluidic material 36114 is then injected into the setting tool assembly 32 and the packer assembly 36 through the longitudinal passages 3202 a , 3204 b , 3206 b , 3208 b , 3604 b , 3650 a , and 3646 b of the tubular adaptor 3202 , tubular upper mandrel 3204 , tubular mandrel 3206 , tubular stinger 3208 , tubular upper mandrel 3604 , tubular sliding sleeve valve 3650 , and tubular lower mandrel 3646 , respectively.
- the plug 36104 is seated within and blocks the longitudinal passage 3664 a of the tubular plug seat 3664 , the longitudinal passages 3604 b , 3650 a , and 3646 b of the tubular upper mandrel 3604 , tubular sliding sleeve valve 3650 , and tubular lower mandrel 3646 are pressurized thereby displacing the tubular upper adaptor 3602 and tubular upper mandrel 3604 downwardly until the end face of the tubular upper mandrel impacts the end face of the upper tubular spacer ring 3606 .
- the setting tool assembly 32 is brought back into engagement with the packer assembly 36 until the engagement shoulder 3208 e of the other end of the tubular stinger 3208 engages the collet fingers 3650 d of the end of the tubular sliding sleeve valve 3650 .
- further downward displacement of the tubular stinger 3208 displaces the tubular sliding sleeve valve 3650 downwardly until the radial flow ports, 3650 b and 3650 c , of the tubular sliding sleeve valve are aligned with the flow ports, 3646 e and 3646 f , of the tubular lower mandrel 3646 .
- a hardenable fluidic sealing material 36116 may then be injected into the setting tool assembly 32 and the packer assembly 36 through the longitudinal passages 3202 a , 3204 b , 3206 b , 3208 b , and 3650 a of the tubular adaptor 3202 , tubular upper mandrel 3204 , tubular mandrel 3206 , tubular stinger 3208 , and tubular sliding sleeve valve 3650 , respectively.
- the hardenable fluidic sealing material may then flow out of the packer assembly 36 through the upper flow ports, 3658 d and 3658 e , into the annulus between the expandable wellbore casing 100 and the wellbore 102 .
- the tubular sliding sleeve valve 3650 may then be returned to its original position, with the radial flow ports, 3650 b and 3650 c , of the tubular sliding sleeve valve out of alignment with the flow ports, 3646 e and 3646 f , of the tubular lower mandrel 3646 .
- the hardenable fluidic sealing material 36116 may then be allowed to cure before, during, or after the continued operation of the system 10 to further radially expand and plastically deform the expandable wellbore casing.
- the packer assembly 36 includes an upper tubular spacer ring 36200 receives and mates with the end of the tubular upper mandrel 3604 and includes an angled end face 36200 a that includes a plurality of spaced apart radial grooves 36200 b and another end face that is positioned proximate to an end face of the tubular upper adaptor 3602 is coupled to the tubular upper mandrel by shear pins, 36202 a , 36202 b , 36202 c , and 36202 d .
- a lower tubular spacer ring 36204 that includes an angled end face 36204 a that includes a plurality of spaced apart radial grooves 36204 b receives, mates, and is coupled to the other end of the tubular upper mandrel 3604 and includes another end face that is positioned proximate to an end face of the external flange 3604 i of the tubular upper mandrel 3604 .
- the upper and tubular spacer rings, 3606 and 3610 are fabricated from a composite material.
- An upper tubular slip assembly 36206 that receives and is movably mounted upon the tubular upper mandrel 3604 includes a plurality of substantially identical slip elements 36206 a that each include an exterior arcuate cylindrical surface 36206 aa including mounting holes, 36206 ab , 36206 ac , 36206 ad , 36206 ae , 36206 af , 36206 ag , 36206 ah , 36206 ai , and 36206 aj , and grooves, 36206 aj and 36206 ak , a front end face 36206 al , a rear end face 36206 am including a mounting hole 36206 an , side faces, 36206 ao and 36206 ap , an interior arcuate cylindrical surface 36206 aq that mates with the exterior surface of the tubular upper mandrel 3604 , and an interior tapered surface 36206 ar including a mounting hole 36206 as .
- Mounting pins 36206 at are received within and coupled to the mounting holes 36206 an and are received within corresponding radial grooves 36200 b of the angled end face 36200 a of the upper tubular spacer ring 36200 .
- Retaining pins 36206 au are mounted within and coupled to the mounting holes 36206 as that include heads 36206 av .
- Slip retaining bands, 36206 aw and 36206 ax are received within and coupled to grooves, 36206 aj and 36206 ak , respectively, of the slip elements 36206 a .
- Slip gripping elements 36206 ay , 36206 az , 36206 aaa , 36206 aab , 36206 aac , 36206 aad , 36206 aae , 36206 aaf , and 36206 aag , are mounted within, coupled to, and extend out of the mounting holes, 36206 ab , 36206 ac , 36206 ad , 36206 ae , 36206 af , 36206 ag , 36206 ah , 36206 ai , and 36206 aj , respectively.
- the adjacent exterior arcuate cylindrical surfaces 36206 aa of the identical slip elements 36206 a of the upper tubular slip assembly 36206 together define a substantially contiguous cylindrical surface.
- a lower tubular slip assembly 36208 that receives and is movably mounted upon the tubular upper mandrel 3604 includes a plurality of substantially identical slip elements 36208 a that each include an exterior arcuate cylindrical surface 36208 aa including mounting holes, 36208 ab , 36208 ac , 36208 ad , 36208 ae , 36208 af , 36208 ag , 36208 ah , 36208 ai , and 36208 aj , and grooves, 36208 aj and 36208 ak , a front end face 36208 al , a rear end face 36208 am including a mounting hole 36208 an , side faces, 36208 ao and 36208 ap , an interior arcuate cylindrical surface 36208 aq that mates with the exterior surface of the tubular upper mandrel 3604 , and an interior tapered surface 36208 ar including a mounting hole 36208 as .
- Mounting pins 36208 at are received within and coupled to the mounting holes 36208 an and are received within corresponding radial grooves 36204 b of the angled end face 36204 a of the lower tubular spacer ring 36204 .
- Retaining pins 36208 au are mounted within and coupled to the mounting holes 36208 as that include heads 36208 av .
- Slip retaining bands, 36208 aw and 36208 ax are received within and coupled to grooves, 36208 aj and 36208 ak , respectively, of the slip elements 36208 a .
- Slip gripping elements 36208 ay , 36208 az , 36208 aaa , 36208 aab , 36208 aac , 36208 aad , 36208 aae , 36208 aaf , and 36208 aag , are mounted within, coupled to, and extend out of the mounting holes, 36208 ab , 36208 ac , 36208 ad , 36208 ae , 36208 af , 36208 ag , 36208 ah , 36208 ai , and 36208 aj , respectively.
- the adjacent exterior arcuate cylindrical surfaces 36208 aa of the identical slip elements 36208 a of the upper tubular slip assembly 36208 together define a substantially contiguous cylindrical surface.
- An upper tubular wedge 36210 that receives the tubular upper mandrel 3604 includes an angled front end face 36210 a including spaced apart radial grooves 36210 b , a rear end face 36210 c , an exterior cylindrical surface 36210 d , a plurality of spaced apart faceted tapered exterior surface segments 36210 e that mate with corresponding tapered internal surfaces 36206 ar of corresponding slip elements 36206 a of the upper tubular slip assembly 36206 , and T-shaped exterior grooves 36210 f aligned with the midline of corresponding faceted tapered exterior surface segments that extend from the angled end face to the rear end face that receive and mate with corresponding retaining pins 36206 au of corresponding slip elements of the upper tubular slip assembly.
- the upper tubular wedge 36210 is releasably coupled to the tubular upper mandrel 3604 by shear pins 36211 .
- a lower tubular wedge 36212 that receives the tubular upper mandrel 3604 includes an angled front end face 36212 a including spaced apart radial grooves 36212 b , a rear end face 36212 c , an exterior cylindrical surface 36212 d , a plurality of spaced apart faceted tapered exterior surface segments 36212 e that mate with corresponding tapered internal surfaces 36208 ar of corresponding slip elements 36208 a of the upper tubular slip assembly 36208 , and T-shaped exterior grooves 36212 f aligned with the midline of corresponding faceted tapered exterior surface segments that extend from the angled end face to the rear end face that receive and mate with corresponding retaining pins 36208 au of corresponding slip elements of the lower tubular slip assembly.
- the lower tubular wedge 36212 is releasably coupled to the tubular upper mandrel 3604 by shear pins 36213 .
- An upper tubular extrusion limiter assembly 36214 that receives and is movably mounted upon the tubular upper mandrel 3604 includes a plurality of substantially identical extrusion limiter elements 36214 a that each include an angled front end face 36214 aa having a recessed portion 36214 ab , an angled rear end face 36214 ac that defines a mounting hole 36214 ad , an interior arcuate cylindrical surface 36214 ae that mates with the tubular upper mandrel, and an exterior arcuate cylindrical surface 36214 af including grooves, 36214 ag , 36214 ah , and 36214 ai .
- Disk extrusion preventers 36214 aj are mounted within and coupled to the recessed portions 36214 ab of adjacent extrusion limiter elements 36214 a
- mounting pins 36214 ak are mounted within and coupled to mounting holes 36214 ad of corresponding extrusion limiter elements 36214 a that are received within corresponding radial grooves 36210 b of the front end face 36210 a of the upper tubular wedge 36210 .
- Retaining bands, 36214 al , 36214 am , and 36214 an are positioned within and coupled to the grooves, 36214 ai , 36214 ah , and 36214 ag , respectively, of the extrusion limiter elements 36214 a.
- a lower tubular extrusion limiter assembly 36216 that receives and is movably mounted upon the tubular upper mandrel 3604 includes a plurality of substantially identical extrusion limiter elements 36216 a that each include an angled front end face 36216 aa having a recessed portion 36216 ab , an angled rear end face 36216 ac that defines a mounting hole 36216 ad , an interior arcuate cylindrical surface 36216 ae that mates with the tubular upper mandrel, and an exterior arcuate cylindrical surface 36216 af including grooves, 36216 ag , 36216 ah , and 36216 ai .
- Disk extrusion preventers 36216 aj are mounted within and coupled to the recessed portions 36216 ab of adjacent extrusion limiter elements 36216 a , and mounting pins 36216 ak are mounted within and coupled to mounting holes 36216 ad of corresponding extrusion limiter elements 36216 a that are received within corresponding radial grooves 36212 b of the front end face 36212 a of the lower tubular wedge 36212 .
- Retaining bands, 36216 al , 36216 am , and 36216 an are positioned within and coupled to the grooves, 36216 ag , 36216 ah , and 36216 ai , of the extrusion limiter elements 36216 a.
- the angled end face 3640 b of the upper tubular elastomeric packer element 3640 mates with and is positioned proximate the angled end faces 36214 aa and disk extrusion preventers 36214 aj of the extrusion limiter elements 36214 a of the upper tubular extrusion limiter assembly 36214
- the angled end face 3642 b of the lower tubular elastomeric packer element 3642 mates with and is positioned proximate the angled end faces 36216 aa and disk extrusion preventers 36216 aj of the extrusion limiter elements 36216 a of the lower tubular extrusion limiter assembly 36216 .
- the first step in setting the packer assembly 36 includes pushing the slip elements, 36206 a and 36208 a , of the upper and lower slip assemblies, 36206 and 36208 , respectively, up the upper and lower tubular wedges, 36210 and 36212 , respectively, which breaks the retaining rings, 36206 aw and 36206 ax , and 36208 aw and 36208 ax , respectively, and moves the slip elements outwardly against the interior surface of the expandable wellbore casing 100 .
- the retaining pins, 36206 au and 36208 au , respectively, and the mounting pins, 36206 at and 36208 at, respectively, maintain the slip elements in an evenly spaced apart configuration.
- the mounting pins, 36214 ak and 36216 ak maintain the extrusion limiter elements, 36214 a and 36216 a , of the upper and lower tubular extrusion limiter assemblies, 36214 and 36216 , respectively, in an evenly spaced apart configuration.
- 20 and 20 A to 20 AX is otherwise substantially identical to the operation of the packer assembly described above with reference to FIGS. 19 A 1 to 19 A 5 , 19 B 1 to 19 B 5 , 19 C 1 to 19 C 5 , 19 D 1 to 19 D 5 , 19 E 1 to 19 E 6 , 19 F 1 to 19 F 6 , 19 G 1 to 19 G 6 , and 19 H 1 to 19 H 5 .
- an apparatus for radially expanding and plastically deforming an expandable tubular member includes a support member, a cutting device for cutting the tubular member coupled to the support member, and an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member.
- the apparatus further includes a gripping device for gripping the tubular member coupled to the support member.
- the gripping device comprises a plurality of movable gripping elements.
- the gripping elements are moveable in a radial direction relative to the support member.
- the gripping elements are moveable in an axial direction relative to the support member.
- the gripping elements are moveable in a radial and an axial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction relative to the support member.
- the gripping device grips the tubular member; and, if the tubular member is displaced in a second axial direction, the gripping device does not grip the tubular member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, the gripping elements are biased to remain in the first position.
- the gripping device further includes an actuator for moving the gripping elements from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein the actuator is a fluid powered actuator.
- the apparatus further includes a sealing device for sealing an interface with the tubular member coupled to the support member.
- the sealing device seals an annulus defines between the support member and the tubular member.
- the apparatus further includes a locking device for locking the position of the tubular member relative to the support member.
- the apparatus further includes a packer assembly coupled to the support member.
- the packer assembly includes a packer; and a packer control device for controlling the operation of the packer coupled to the support member.
- the packer includes: a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve movably positioned within the passage of the support member.
- the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the packer.
- the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve positioned within the passage of the support member; and wherein the packer control device includes: a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the sliding sleeve valve.
- the apparatus further includes an actuator for displacing the expansion device relative to the support member.
- the actuator includes a first actuator for pulling the expansion device; and a second actuator for pushing the expansion device.
- the actuator includes means for transferring torsional loads between the support member and the expansion device.
- the first and second actuators include means for transferring torsional loads between the support member and the expansion device.
- the actuator includes a plurality of pistons positioned within corresponding piston chambers.
- the cutting device includes a support member; and a plurality of movable cutting elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member.
- the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the cutting elements includes a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements.
- the first position in the first position, the first set of cutting elements are not axially aligned with the second set of cutting elements.
- the first set of cutting elements are axially aligned with the second set of cutting elements.
- the expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member.
- apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
- the first position in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements.
- the first set of expansion elements in the second position, are axially aligned with the second set of expansion elements.
- the expansion device includes an adjustable expansion device.
- the expansion device includes a plurality of expansion devices.
- at least one of the expansion devices includes an adjustable expansion device.
- the adjustable expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
- the first set of expansion elements in the first position, are not axially aligned with the second set of expansion elements.
- in the second position the first set of expansion elements are axially aligned with the second set of expansion elements.
- An apparatus for radially expanding and plastically deforming an expandable tubular member includes a support member, an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member, and an actuator coupled to the support member for displacing the expansion device relative to the support member.
- the apparatus further includes a cutting device coupled to the support member for cutting the tubular member.
- the cutting device includes a support member; and a plurality of movable cutting elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the cutting elements include a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements.
- the apparatus further includes a gripping device for gripping the tubular member coupled to the support member.
- the gripping device includes a plurality of movable gripping elements.
- the gripping elements are moveable in a radial direction relative to the support member.
- the gripping elements are moveable in an axial direction relative to the support member.
- the gripping elements are moveable in a radial and an axial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction relative to the support member.
- the gripping device grips the tubular member; and wherein, if the tubular member is displaced in a second axial direction, the gripping device does not grip the tubular member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, the gripping elements are biased to remain in the first position.
- the gripping device further includes an actuator for moving the gripping elements from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein the actuator is a fluid powered actuator.
- the apparatus further includes a sealing device for sealing an interface with the tubular member coupled to the support member.
- the sealing device seals an annulus defines between the support member and the tubular member.
- the apparatus further includes a locking device for locking the position of the tubular member relative to the support member.
- the apparatus further includes a packer assembly coupled to the support member.
- the packer assembly includes a packer; and a packer control device for controlling the operation of the packer coupled to the support member.
- the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member, and a sliding sleeve valve movably positioned within the passage of the support member.
- the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the packer.
- the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve positioned within the passage of the support member; and wherein the packer control device comprises: a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the sliding sleeve valve.
- the expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
- the expansion device includes an adjustable expansion device.
- the expansion device includes a plurality of expansion devices.
- at least one of the expansion devices includes an adjustable expansion device.
- the adjustable expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
- the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
- an apparatus for radially expanding and plastically deforming an expandable tubular member includes a support member; an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a sealing assembly for sealing an annulus defined between the support member and the tubular member.
- the apparatus further includes a gripping device for gripping the tubular member coupled to the support member.
- the gripping device includes a plurality of movable gripping elements.
- the gripping elements are moveable in a radial direction relative to the support member.
- the gripping elements are moveable in an axial direction relative to the support member.
- the gripping elements are moveable in a radial and an axial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction relative to the support member.
- the gripping device grips the tubular member; and wherein, if the tubular member is displaced in a second axial direction, the gripping device does not grip the tubular member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, the gripping elements are biased to remain in the first position.
- the gripping device further includes an actuator for moving the gripping elements from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein the actuator is a fluid powered actuator.
- the apparatus further includes a locking device for locking the position of the tubular member relative to the support member.
- the apparatus further includes a packer assembly coupled to the support member.
- the packer assembly includes a packer; and a packer control device for controlling the operation of the packer coupled to the support member.
- the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member, and a sliding sleeve valve movably positioned within the passage of the support member.
- the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the packer.
- the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve positioned within the passage of the support member; and wherein the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the sliding sleeve valve.
- the apparatus further includes an actuator for displacing the expansion device relative to the support member.
- the actuator includes a first actuator for pulling the expansion device; and a second actuator for pushing the expansion device.
- the actuator includes means for transferring torsional loads between the support member and the expansion device.
- the first and second actuators comprise means for transferring torsional loads between the support member and the expansion device.
- the actuator includes a plurality of pistons positioned within corresponding piston chambers.
- the cutting device includes a support member; and a plurality of movable cutting elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member.
- the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the cutting elements include a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements.
- the first position in the first position, the first set of cutting elements are not axially aligned with the second set of cutting elements.
- the first set of cutting elements are axially aligned with the second set of cutting elements.
- the expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the expansion elements includes a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
- the first position in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements.
- the first set of expansion elements in the second position, are axially aligned with the second set of expansion elements.
- the expansion device includes an adjustable expansion device.
- the expansion device includes a plurality of expansion devices.
- at least one of the expansion devices includes an adjustable expansion device.
- the adjustable expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
- the first set of expansion elements in the first position, are not axially aligned with the second set of expansion elements.
- in the second position the first set of expansion elements are axially aligned with the second set of expansion elements.
- an apparatus for radially expanding and plastically deforming an expandable tubular member includes a support member; a first expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a second expansion device for radially expanding and plastically deforming the tubular member coupled to the support member.
- the apparatus further includes a gripping device for gripping the tubular member coupled to the support member.
- the gripping device includes a plurality of movable gripping elements.
- the gripping elements are moveable in a radial direction relative to the support member.
- the gripping elements are moveable in an axial direction relative to the support member.
- the gripping elements are moveable in a radial and an axial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction relative to the support member.
- the gripping device grips the tubular member; and wherein, if the tubular member is displaced in a second axial direction, the gripping device does not grip the tubular member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, the gripping elements are biased to remain in the first position.
- the gripping device further includes an actuator for moving the gripping elements from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein the actuator is a fluid powered actuator.
- the apparatus further includes a sealing device for sealing an interface with the tubular member coupled to the support member.
- the sealing device seals an annulus defines between the support member and the tubular member.
- the apparatus further includes a locking device for locking the position of the tubular member relative to the support member.
- the apparatus further includes a packer assembly coupled to the support member.
- the packer assembly includes a packer; and a packer control device for controlling the operation of the packer coupled to the support member.
- the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve movably positioned within the passage of the support member.
- the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the packer.
- the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve positioned within the passage of the support member; and wherein the packer control device comprises: a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the sliding sleeve valve.
- the apparatus further includes an actuator for displacing the expansion device relative to the support member.
- the actuator includes a first actuator for pulling the expansion device; and a second actuator for pushing the expansion device.
- the actuator includes means for transferring torsional loads between the support member and the expansion device.
- the first and second actuators include means for transferring torsional loads between the support member and the expansion device.
- the actuator includes a plurality of pistons positioned within corresponding piston chambers.
- the apparatus further includes a cutting device for cutting the tubular member coupled to the support member.
- the cutting device includes a support member; and a plurality of movable cutting elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the cutting elements include a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements.
- the first set of cutting elements are not axially aligned with the second set of cutting elements.
- the first set of cutting elements are axially aligned with the second set of cutting elements.
- at least one of the first second expansion devices include a support member; and a plurality of movable expansion elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member.
- the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
- the first position in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements.
- the first set of expansion elements are axially aligned with the second set of expansion elements.
- At least one of the first and second expansion devices comprise a plurality of expansion devices.
- at least one of the first and second expansion device comprise an adjustable expansion device.
- the adjustable expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member.
- the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
- the first set of expansion elements are not axially aligned with the second set of expansion elements.
- the first set of expansion elements are axially aligned with the second set of expansion elements.
- an apparatus for radially expanding and plastically deforming an expandable tubular member includes a support member; an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a packer coupled to the support member.
- the apparatus further includes a gripping device for gripping the tubular member coupled to the support member.
- the gripping device comprises a plurality of movable gripping elements.
- the gripping elements are moveable in a radial direction relative to the support member.
- the gripping elements are moveable in an axial direction relative to the support member.
- the gripping elements are moveable in a radial and an axial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction relative to the support member.
- the gripping device grips the tubular member; and wherein, if the tubular member is displaced in a second axial direction, the gripping device does not grip the tubular member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, the gripping elements are biased to remain in the first position.
- the gripping device further includes an actuator for moving the gripping elements from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein the actuator is a fluid powered actuator.
- the apparatus further includes a sealing device for sealing an interface with the tubular member coupled to the support member.
- the sealing device seals an annulus defines between the support member and the tubular member.
- the apparatus further includes a locking device for locking the position of the tubular member relative to the support member.
- the packer assembly includes a packer; and a packer control device for controlling the operation of the packer coupled to the support member.
- the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve movably positioned within the passage of the support member.
- the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the packer.
- the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve positioned within the passage of the support member; and wherein the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the sliding sleeve valve.
- the apparatus further includes an actuator for displacing the expansion device relative to the support member.
- the actuator includes a first actuator for pulling the expansion device; and a second actuator for pushing the expansion device.
- the actuator includes means for transferring torsional loads between the support member and the expansion device.
- the first and second actuators include means for transferring torsional loads between the support member and the expansion device.
- the actuator includes a plurality of pistons positioned within corresponding piston chambers.
- the apparatus further includes a cutting device coupled to the support member for cutting the tubular member.
- the cutting device includes a support member; and a plurality of movable cutting elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the cutting elements include a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements.
- the expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member.
- the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
- the first position in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements.
- the first set of expansion elements are axially aligned with the second set of expansion elements.
- the expansion device includes an adjustable expansion device. In an exemplary embodiment, the expansion device includes a plurality of expansion devices. In an exemplary embodiment, at least one of the expansion devices comprises an adjustable expansion device. In an exemplary embodiment, the adjustable expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member.
- the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
- the first set of expansion elements are not axially aligned with the second set of expansion elements.
- the first set of expansion elements are axially aligned with the second set of expansion elements.
- An apparatus for radially expanding and plastically deforming an expandable tubular member includes a support member; a cutting device for cutting the tubular member coupled to the support member; a gripping device for gripping the tubular member coupled to the support member; a sealing device for sealing an interface with the tubular member coupled to the support member; a locking device for locking the position of the tubular member relative to the support member; a first adjustable expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; a second adjustable expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; a packer coupled to the support member; and an actuator for displacing one or more of the sealing assembly, first and second adjustable expansion devices, and packer relative to the support member.
- the gripping device includes a plurality of movable gripping elements.
- the gripping elements are moveable in a radial direction relative to the support member.
- the gripping elements are moveable in an axial direction relative to the support member.
- the gripping elements are moveable in a radial and an axial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction relative to the support member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction relative to the support member.
- the gripping device grips the tubular member; and wherein, if the tubular member is displaced in a second axial direction, the gripping device does not grip the tubular member.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, the gripping elements are biased to remain in the first position.
- the gripping device further includes an actuator for moving the gripping elements from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein the actuator is a fluid powered actuator.
- the sealing device seals an annulus defines between the support member and the tubular member.
- the packer assembly includes a packer; and a packer control device for controlling the operation of the packer coupled to the support member.
- the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve movably positioned within the passage of the support member.
- the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the packer.
- the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve positioned within the passage of the support member; and wherein the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the sliding sleeve valve.
- the actuator includes a first actuator for pulling the expansion device; and a second actuator for pushing the expansion device.
- the actuator includes means for transferring torsional loads between the support member and the expansion device.
- the first and second actuators include means for transferring torsional loads between the support member and the expansion device.
- the actuator includes a plurality of pistons positioned within corresponding piston chambers.
- the cutting device includes a support member; and a plurality of movable cutting elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member.
- the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the cutting elements include a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements.
- the first position in the first position, the first set of cutting elements are not axially aligned with the second set of cutting elements.
- the first set of cutting elements are axially aligned with the second set of cutting elements.
- at least one of the adjustable expansion devices include a support member; and a plurality of movable expansion elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
- the first set of expansion elements are not axially aligned with the second set of expansion elements.
- the first set of expansion elements are axially aligned with the second set of expansion elements.
- at least one of the adjustable expansion devices comprise a plurality of expansion devices.
- at least one of the adjustable expansion devices include a support member; and a plurality of movable expansion elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position, wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
- the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
- An apparatus for cutting a tubular member includes a support member; and a plurality of movable cutting elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the cutting elements include a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements.
- the first set of cutting elements in the first position, are not axially aligned with the second set of cutting elements.
- in the second position the first set of cutting elements are axially aligned with the second set of cutting elements.
- An apparatus for engaging a tubular member includes a support member; and a plurality of movable elements coupled to the support member.
- the apparatus further includes an actuator coupled to the support member for moving the elements between a first position and a second position; wherein in the first position, the elements do not engage the tubular member; and wherein in the second position, the elements engage the tubular member.
- the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value.
- the elements include a first set of elements; and a second set of elements; wherein the first set of elements are interleaved with the second set of elements.
- the first set of elements in the first position, are not axially aligned with the second set of elements.
- the first set of elements in the second position, are axially aligned with the second set of elements.
- An apparatus for gripping a tubular member includes a plurality of movable gripping elements.
- the gripping elements are moveable in a radial direction.
- the gripping elements are moveable in an axial direction.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction.
- the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction.
- the gripping device in a first axial direction, grips the tubular member; and wherein, in a second axial direction, the gripping device does not grip the tubular member.
- the apparatus further includes an actuator for moving the gripping elements.
- the gripping elements include a plurality of separate and distinct gripping elements.
- An actuator has been described that includes a tubular housing; a tubular piston rod movably coupled to and at least partially positioned within the housing; a plurality of annular piston chambers defined by the tubular housing and the tubular piston rod; and a plurality of tubular pistons coupled to the tubular piston rod, each tubular piston movably positioned within a corresponding annular piston chamber.
- the actuator further includes means for transmitting torsional loads between the tubular housing and the tubular piston rod.
- An apparatus for controlling a packer includes a tubular support member; one or more drag blocks releasably coupled to the tubular support member; and a tubular stinger coupled to the tubular support member for engaging the packer.
- the apparatus further includes a tubular sleeve coupled to the drag blocks.
- the tubular support member includes one or more axially aligned teeth for engaging the packer.
- a packer has been described that includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve movably positioned within the passage of the support member.
- a method of radially expanding and plastically deforming an expandable tubular member within a borehole having a preexisting wellbore casing includes positioning the tubular member within the borehole in overlapping relation to the wellbore casing; radially expanding and plastically deforming a portion of the tubular member to form a bell section; and radially expanding and plastically deforming a portion of the tubular member above the bell section comprising a portion of the tubular member that overlaps with the wellbore casing; wherein the inside diameter of the bell section is greater than the inside diameter of the radially expanded and plastically deformed portion of the tubular member above the bell section.
- radially expanding and plastically deforming a portion of the tubular member to form a bell section includes positioning an adjustable expansion device within the expandable tubular member; supporting the expandable tubular member and the adjustable expansion device within the borehole; lowering the adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the adjustable expansion device; and displacing the adjustable expansion device upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member, wherein n is greater than or equal to 1.
- a method for forming a mono diameter wellbore casing includes positioning an adjustable expansion device within a first expandable tubular member; supporting the first expandable tubular member and the adjustable expansion device within a borehole; lowering the adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; positioning the adjustable expansion device within a second expandable tubular member; supporting the second expandable tubular member and the adjustable expansion device within the borehole in overlapping relation to the first expandable tubular member; lowering the adjustable expansion device out of the second expandable tubular member; increasing the outside dimension of the adjustable expansion device; and displacing the adjustable expansion device upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole.
- a method for radially expanding and plastically deforming an expandable tubular member within a borehole includes positioning an adjustable expansion device within the expandable tubular member; supporting the expandable tubular member and the adjustable expansion device within the borehole; lowering the adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the adjustable expansion device; displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the borehole; and pressurizing an interior region of the expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the expandable tubular member within the borehole.
- a method for forming a mono diameter wellbore casing includes positioning an adjustable expansion device within a first expandable tubular member; supporting the first expandable tubular member and the adjustable expansion device within a borehole; lowering the adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; pressurizing an interior region of the first expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the first expandable tubular member within the borehole; positioning the adjustable expansion mandrel within a second expandable tubular member; supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member; lowering the adjustable expansion mandrel out of the second expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; displac
- a method for radially expanding and plastically deforming an expandable tubular member within a borehole includes positioning first and second adjustable expansion devices within the expandable tubular member; supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; lowering the first adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- a method for forming a mono diameter wellbore casing includes positioning first and second adjustable expansion devices within a first expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; lowering the first adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; positioning first and second adjustable expansion devices within a second expandable tubular member; supporting the first expandable tubular member and
- a method for radially expanding and plastically deforming an expandable tubular member within a borehole includes positioning first and second adjustable expansion devices within the expandable tubular member; supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; lowering the first adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; pressurizing an interior region of the expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the expandable tubular member by the first adjustable expansion device; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expand
- a method for forming a mono diameter wellbore casing includes positioning first and second adjustable expansion devices within a first expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; lowering the first adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; pressurizing an interior region of the first expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the first expandable tubular member by the first adjustable expansion device; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of
- a method for radially expanding and plastically deforming an expandable tubular member within a borehole includes supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; increasing the size of the adjustable expansion device; and displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member.
- the method further includes reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed.
- the method further includes fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device.
- the method further includes permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member.
- the method further includes injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and a preexisting structure after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
- the method further includes increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
- the method further includes displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
- the method further includes if the end of the other portion of the expandable tubular member overlaps with a preexisting structure, then not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the other portion of the expandable tubular member that overlaps with the preexisting structure.
- a method for forming a mono diameter wellbore casing within a borehole that includes a preexisting wellbore casing includes supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; increasing the size of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting wellbore casing that overlaps with an end of the remaining portion of the expandable tubular member.
- the method further includes reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed. In an exemplary embodiment, the method further includes fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device. In an exemplary embodiment, the method further includes permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member.
- the method further includes injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the borehole after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
- the method further includes increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
- the method further includes displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member.
- the method further includes not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the remaining portion of the expandable tubular member that overlaps with the preexisting wellbore casing after not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
- a method of radially expanding and plastically deforming a tubular member includes positioning the tubular member within a preexisting structure; radially expanding and plastically deforming a lower portion of the tubular member to form a bell section; and radially expanding and plastically deforming a portion of the tubular member above the bell section.
- positioning the tubular member within a preexisting structure includes locking the tubular member to an expansion device.
- the outside diameter of the expansion device is less than the inside diameter of the tubular member.
- the expansion device is positioned within the tubular member.
- the expansion device includes an adjustable expansion device.
- the adjustable expansion device is adjustable to a plurality of sizes.
- the expansion device includes a plurality of expansion devices. In an exemplary embodiment, at least one of the expansion devices includes an adjustable expansion device. In an exemplary embodiment, at least one of the adjustable expansion device is adjustable to a plurality of sizes.
- radially expanding and plastically deforming a lower portion of the tubular member to form a bell section includes lowering an expansion device out of an end of the tubular member; and pulling the expansion device through the end of the tubular member. In an exemplary embodiment, lowering an expansion device out of an end of the tubular member includes lowering the expansion device out of the end of the tubular member; and adjusting the size of the expansion device. In an exemplary embodiment, the adjustable expansion device is adjustable to a plurality of sizes.
- the expansion device includes a plurality of adjustable expansion devices. In an exemplary embodiment, at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
- pulling the expansion device through the end of the tubular member includes gripping the tubular member; and pulling an expansion device through an end of the tubular member.
- gripping the tubular member includes permitting axial displacement of the tubular member in a first direction; and not permitting axial displacement of the tubular member in a second direction.
- pulling the expansion device through the end of the tubular member includes pulling the expansion device through the end of the tubular member using an actuator.
- radially expanding and plastically deforming a portion of the tubular member above the bell section includes lowering an expansion device out of an end of the tubular member; and pulling the expansion device through the end of the tubular member.
- lowering an expansion device out of an end of the tubular member includes lowering the expansion device out of the end of the tubular member; and adjusting the size of the expansion device.
- the adjustable expansion device is adjustable to a plurality of sizes.
- the expansion device includes a plurality of adjustable expansion devices.
- at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
- pulling the expansion device through the end of the tubular member includes gripping the tubular member; and pulling an expansion device through an end of the tubular member.
- gripping the tubular member includes permitting axial displacement of the tubular member in a first direction; and not permitting axial displacement of the tubular member in a second direction.
- pulling the expansion device through the end of the tubular member includes pulling the expansion device through the end of the tubular member using an actuator.
- pulling the expansion device through the end of the tubular member includes pulling the expansion device through the end of the tubular member using fluid pressure.
- pulling the expansion device through the end of the tubular member using fluid pressure includes pressurizing an annulus within the tubular member above the expansion device.
- radially expanding and plastically deforming a portion of the tubular member above the bell section includes fluidicly sealing an end of the tubular member; and pulling the expansion device through the tubular member.
- the expansion device is adjustable.
- the expansion device is adjustable to a plurality of sizes.
- the expansion device comprises a plurality of adjustable expansion devices.
- at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
- pulling the expansion device through the end of the tubular member includes gripping the tubular member; and pulling an expansion device through an end of the tubular member.
- gripping the tubular member includes permitting axial displacement of the tubular member in a first direction; and not permitting axial displacement of the tubular member in a second direction.
- pulling the expansion device through the end of the tubular member includes pulling the expansion device through the end of the tubular member using an actuator.
- pulling the expansion device through the end of the tubular member includes pulling the expansion device through the end of the tubular member using fluid pressure.
- pulling the expansion device through the end of the tubular member using fluid pressure includes pressurizing an annulus within the tubular member above the expansion device.
- radially expanding and plastically deforming a portion of the tubular member above the bell section includes overlapping the portion of the tubular member above the bell section with an end of a preexisting tubular member; and pulling an expansion device through the overlapping portions of the tubular member and the preexisting tubular member.
- the expansion device is adjustable.
- the expansion device is adjustable to a plurality of sizes.
- the expansion device includes a plurality of adjustable expansion devices.
- at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
- pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member includes gripping the tubular member; and pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member.
- gripping the tubular member includes permitting axial displacement of the tubular member in a first direction; and not permitting axial displacement of the tubular member in a second direction.
- pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member includes pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using an actuator.
- pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member includes pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure.
- pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure includes pressurizing an annulus within the tubular member above the expansion device.
- the method further includes cutting an end of the portion of the tubular member that overlaps with the preexisting tubular member.
- the method further includes removing the cut off end of the expandable tubular member from the preexisting structure.
- the method further includes injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the preexisting structure. In an exemplary embodiment, the method further includes cutting off an end of the expandable tubular member. In an exemplary embodiment, the method further includes removing the cut off end of the expandable tubular member from the preexisting structure.
- a method of radially expanding and plastically deforming a tubular member includes applying internal pressure to the inside surface of the tubular member at a plurality of discrete location separated from one another.
- a system for radially expanding and plastically deforming an expandable tubular member within a borehole having a preexisting wellbore casing includes means for positioning the tubular member within the borehole in overlapping relation to the wellbore casing; means for radially expanding and plastically deforming a portion of the tubular member to form a bell section; and means for radially expanding and plastically deforming a portion of the tubular member above the bell section comprising a portion of the tubular member that overlaps with the wellbore casing; wherein the inside diameter of the bell section is greater than the inside diameter of the radially expanded and plastically deformed portion of the tubular member above the bell section.
- means for radially expanding and plastically deforming a portion of the tubular member to form a bell section includes means for positioning an adjustable expansion device within the expandable tubular member; means for supporting the expandable tubular member and the adjustable expansion device within the borehole; means for lowering the adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member, wherein n is greater than or equal to 1.
- a system for forming a mono diameter wellbore casing includes means for positioning an adjustable expansion device within a first expandable tubular member; means for supporting the first expandable tubular member and the adjustable expansion device within a borehole; means for lowering the adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; means for positioning the adjustable expansion device within a second expandable tubular member; means for supporting the second expandable tubular member and the adjustable expansion device within the borehole in overlapping relation to the first expandable tubular member; means for lowering the adjustable expansion device out of the second expandable tubular member, means for increasing the outside dimension of the adjustable expansion device; and means for displacing the adjustable expansion device upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of
- a system for radially expanding and plastically deforming an expandable tubular member within a borehole includes means for positioning an adjustable expansion device within the expandable tubular member; means for supporting the expandable tubular member and the adjustable expansion device within the borehole; means for lowering the adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; means for displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the borehole; and means for pressurizing an interior region of the expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the expandable tubular member within the borehole.
- a system for forming a mono diameter wellbore casing includes means for positioning an adjustable expansion device within a first expandable tubular member, means for supporting the first expandable tubular member and the adjustable expansion device within a borehole; means for lowering the adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; means for pressurizing an interior region of the first expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the first expandable tubular member within the borehole; means for positioning the adjustable expansion mandrel within a second expandable tubular member; means for supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member; means for lowering the adjustable expansion mandrel out of the second expandable tubular tubular
- a system for radially expanding and plastically deforming an expandable tubular member within a borehole includes means for positioning first and second adjustable expansion devices within the expandable tubular member; means for supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; means for lowering the first adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; wherein the outside dimension of the first adjustable expansion device
- a system for forming a mono diameter wellbore casing includes means for positioning first and second adjustable expansion devices within a first expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; means for lowering the first adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; means for positioning first and second adjustable expansion devices within a
- a system for radially expanding and plastically deforming an expandable tubular member within a borehole includes means for positioning first and second adjustable expansion devices within the expandable tubular member; means for supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; means for lowering the first adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; means for pressurizing an interior region of the expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the expandable tubular member by the first adjustable expansion device; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the expandable tubular
- a system for forming a mono diameter wellbore casing includes means for positioning first and second adjustable expansion devices within a first expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; means for lowering the first adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; means for pressurizing an interior region of the first expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the first expandable tubular member by the first adjustable expansion device; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the
- a system for radially expanding and plastically deforming an expandable tubular member within a borehole includes means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; means for increasing the size of the adjustable expansion device; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member.
- the system further includes means for reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed.
- the system further includes means for fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device.
- the system further includes means for permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member.
- the system further includes means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and a preexisting structure after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
- system further includes means for increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
- system further includes means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
- the system further includes if the end of the other portion of the expandable tubular member overlaps with a preexisting structure, then means for not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the other portion of the expandable tubular member that overlaps with the preexisting structure.
- a system for forming a mono diameter wellbore casing within a borehole that includes a preexisting wellbore casing includes means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; means for increasing the size of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting wellbore casing that overlaps with an end of the remaining portion of the expandable tubular member.
- the system further includes means for reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed. In an exemplary embodiment, the system further includes means for fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device. In an exemplary embodiment, the system further includes means for permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member.
- the system further includes means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the borehole after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
- the system further includes means for increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
- the system further includes means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member.
- the system further includes means for not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the remaining portion of the expandable tubular member that overlaps with the preexisting wellbore casing after not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
- a system for radially expanding and plastically deforming a tubular member includes means for positioning the tubular member within a preexisting structure; means for radially expanding and plastically deforming a lower portion of the tubular member to form a bell section; and means for radially expanding and plastically deforming a portion of the tubular member above the bell section.
- positioning the tubular member within a preexisting structure includes means for locking the tubular member to an expansion device.
- the outside diameter of the expansion device is less than the inside diameter of the tubular member.
- the expansion device is positioned within the tubular member.
- the expansion device includes an adjustable expansion device.
- the adjustable expansion device is adjustable to a plurality of sizes.
- the expansion device includes a plurality of expansion devices.
- at least one of the expansion devices includes an adjustable expansion device.
- at least one of the adjustable expansion device is adjustable to a plurality of sizes.
- means for radially expanding and plastically deforming a lower portion of the tubular member to form a bell section includes means for lowering an expansion device out of an end of the tubular member; and means for pulling the expansion device through the end of the tubular member.
- means for lowering an expansion device out of an end of the tubular member includes means for lowering the expansion device out of the end of the tubular member; and means for adjusting the size of the expansion device.
- the adjustable expansion device is adjustable to a plurality of sizes.
- the expansion device includes a plurality of adjustable expansion devices.
- at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
- means for pulling the expansion device through the end of the tubular member includes means for gripping the tubular member; and means for pulling an expansion device through an end of the tubular member.
- means for gripping the tubular member includes means for permitting axial displacement of the tubular member in a first direction; and means for not permitting axial displacement of the tubular member in a second direction.
- means for pulling the expansion device through the end of the tubular member includes means for pulling the expansion device through the end of the tubular member using an actuator.
- means for radially expanding and plastically deforming a portion of the tubular member above the bell section includes means for lowering an expansion device out of an end of the tubular member; and means for pulling the expansion device through the end of the tubular member.
- means for lowering an expansion device out of an end of the tubular member includes means for lowering the expansion device out of the end of the tubular member; and means for adjusting the size of the expansion device.
- the adjustable expansion device is adjustable to a plurality of sizes.
- the expansion device comprises a plurality of adjustable expansion devices.
- at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
- means for pulling the expansion device through the end of the tubular member includes means for gripping the tubular member; and means for pulling an expansion device through an end of the tubular member.
- means for gripping the tubular member includes means for permitting axial displacement of the tubular member in a first direction; and means for not permitting axial displacement of the tubular member in a second direction.
- means for pulling the expansion device through the end of the tubular member includes means for pulling the expansion device through the end of the tubular member using an actuator.
- means for pulling the expansion device through the end of the tubular member includes means for pulling the expansion device through the end of the tubular member using fluid pressure.
- means for pulling the expansion device through the end of the tubular member using fluid pressure includes means for pressurizing an annulus within the tubular member above the expansion device.
- means for radially expanding and plastically deforming a portion of the tubular member above the bell section includes means for fluidicly sealing an end of the tubular member; and means for pulling the expansion device through the tubular member.
- the expansion device is adjustable.
- the expansion device is adjustable to a plurality of sizes.
- the expansion device includes a plurality of adjustable expansion devices.
- at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
- means for pulling the expansion device through the end of the tubular member includes means for gripping the tubular member; and means for pulling an expansion device through an end of the tubular member.
- means for gripping the tubular member includes means for permitting axial displacement of the tubular member in a first direction; and means for not permitting axial displacement of the tubular member in a second direction.
- means for pulling the expansion device through the end of the tubular member includes means for pulling the expansion device through the end of the tubular member using an actuator.
- means for pulling the expansion device through the end of the tubular member includes means for pulling the expansion device through the end of the tubular member using fluid pressure.
- means for pulling the expansion device through the end of the tubular member using fluid pressure includes means for pressurizing an annulus within the tubular member above the expansion device.
- means for radially expanding and plastically deforming a portion of the tubular member above the bell section includes means for overlapping the portion of the tubular member above the bell section with an end of a preexisting tubular member; and means for pulling an expansion device through the overlapping portions of the tubular member and the preexisting tubular member.
- the expansion device is adjustable.
- the expansion device is adjustable to a plurality of sizes.
- the expansion device includes a plurality of adjustable expansion devices.
- at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
- means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member includes means for gripping the tubular member; and means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member.
- means for gripping the tubular member includes means for permitting axial displacement of the tubular member in a first direction; and means for not permitting axial displacement of the tubular member in a second direction.
- means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member includes means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using an actuator.
- means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member includes means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure.
- means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure includes means for pressurizing an annulus within the tubular member above the expansion device.
- the system further includes means for cutting an end of the portion of the tubular member that overlaps with the preexisting tubular member.
- the system further includes means for removing the cut off end of the expandable tubular member from the preexisting structure.
- the system further includes means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the preexisting structure. In an exemplary embodiment, the system further includes means for cutting off an end of the expandable tubular member. In an exemplary embodiment, the system further includes means for removing the cut off end of the expandable tubular member from the preexisting structure.
- a system of radially expanding and plastically deforming a tubular member has been described that includes a support member; and means for applying internal pressure to the inside surface of the tubular member at a plurality of discrete location separated from one another coupled to the support member.
- a method of cutting a tubular member includes positioning a plurality of cutting elements within the tubular member; and bringing the cutting elements into engagement with the tubular member.
- the cutting elements include a first group of cutting elements; and a second group of cutting elements; wherein the first group of cutting elements are interleaved with the second group of cutting elements.
- bringing the cutting elements into engagement with the tubular member includes bringing the cutting elements into axial alignment.
- bringing the cutting elements into engagement with the tubular member further includes pivoting the cutting elements.
- bringing the cutting elements into engagement with the tubular member further includes translating the cutting elements.
- bringing the cutting elements into engagement with the tubular member further includes pivoting the cutting elements; and translating the cutting elements.
- bringing the cutting elements into engagement with the tubular member includes rotating the cutting elements about a common axis.
- bringing the cutting elements into engagement with the tubular member includes pivoting the cutting elements about corresponding axes; translating the cutting elements; and rotating the cutting elements about a common axis.
- the method further includes preventing the cutting elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value.
- preventing the cutting elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value includes sensing the inside diameter of the tubular member.
- a method of gripping a tubular member includes positioning a plurality of gripping elements within the tubular member; bringing the gripping elements into engagement with the tubular member.
- bringing the gripping elements into engagement with the tubular member includes displacing the gripping elements in an axial direction; and displacing the gripping elements in a radial direction.
- the method further includes biasing the gripping elements against engagement with the tubular member.
- a method of operating an actuator has been described that includes pressurizing a plurality of pressure chamber.
- the method further includes transmitting torsional loads.
- a method of injecting a hardenable fluidic sealing material into an annulus between a tubular member and a preexisting structure includes positioning the tubular member into the preexisting structure; sealing off an end of the tubular member; operating a valve within the end of the tubular member; and injecting a hardenable fluidic sealing material through the valve into the annulus between the tubular member and the preexisting structure.
- a system for cutting a tubular member includes means for positioning a plurality of cutting elements within the tubular member; and means for bringing the cutting elements into engagement with the tubular member.
- the cutting elements include a first group of cutting elements; and a second group of cutting elements; wherein the first group of cutting elements are interleaved with the second group of cutting elements.
- means for bringing the cutting elements into engagement with the tubular member includes means for bringing the cutting elements into axial alignment.
- means for bringing the cutting elements into engagement with the tubular member further includes means for pivoting the cutting elements.
- means for bringing the cutting elements into engagement with the tubular member further includes means for translating the cutting elements.
- means for bringing the cutting elements into engagement with the tubular member further includes means for pivoting the cutting elements; and means for translating the cutting elements.
- means for bringing the cutting elements into engagement with the tubular member includes means for rotating the cutting elements about a common axis.
- means for bringing the cutting elements into engagement with the tubular member includes means for pivoting the cutting elements about corresponding axes; means for translating the cutting elements; and means for rotating the cutting elements about a common axis.
- the system further includes means for preventing the cutting elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value.
- means for preventing the cutting elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value includes means for sensing the inside diameter of the tubular member.
- a system for gripping a tubular member includes means for positioning a plurality of gripping elements within the tubular member; and means for bringing the gripping elements into engagement with the tubular member.
- means for bringing the gripping elements into engagement with the tubular member includes means for displacing the gripping elements in an axial direction; and means for displacing the gripping elements in a radial direction.
- the system further includes means for biasing the gripping elements against engagement with the tubular member.
- An actuator system has been described that includes a support member; and means for pressurizing a plurality of pressure chambers coupled to the support member.
- the system further includes means for transmitting torsional loads.
- a system for injecting a hardenable fluidic sealing material into an annulus between a tubular member and a preexisting structure includes means for positioning the tubular member into the preexisting structure; means for sealing off an end of the tubular member; means for operating a valve within the end of the tubular member; and means for injecting a hardenable fluidic sealing material through the valve into the annulus between the tubular member and the preexisting structure.
- a method of engaging a tubular member includes positioning a plurality of elements within the tubular member; and bringing the elements into engagement with the tubular member.
- the elements include a first group of elements; and a second group of elements; wherein the first group of elements are interleaved with the second group of elements.
- bringing the elements into engagement with the tubular member includes bringing the elements into axial alignment.
- bringing the elements into engagement with the tubular member further includes pivoting the elements.
- bringing the elements into engagement with the tubular member further includes translating the elements.
- bringing the elements into engagement with the tubular member further includes pivoting the elements; and translating the elements.
- bringing the elements into engagement with the tubular member includes rotating the elements about a common axis. In an exemplary embodiment, bringing the elements into engagement with the tubular member includes pivoting the elements about corresponding axes; translating the elements; and rotating the elements about a common axis. In an exemplary embodiment, the method further includes preventing the elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, preventing the elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value includes sensing the inside diameter of the tubular member.
- a system for engaging a tubular member includes means for positioning a plurality of elements within the tubular member; and means for bringing the elements into engagement with the tubular member.
- the elements include a first group of elements; and a second group of elements; wherein the first group of elements are interleaved with the second group of elements.
- means for bringing the elements into engagement with the tubular member includes means for bringing the elements into axial alignment.
- means for bringing the elements into engagement with the tubular member further includes means for pivoting the elements.
- means for bringing the elements into engagement with the tubular member further includes means for translating the elements.
- means for bringing the elements into engagement with the tubular member further includes means for pivoting the elements; and means for translating the elements.
- means for bringing the elements into engagement with the tubular member includes means for rotating the elements about a common axis.
- means for bringing the elements into engagement with the tubular member includes means for pivoting the elements about corresponding axes; means for translating the elements; and means for rotating the elements about a common axis.
- the system further includes means for preventing the elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value.
- means for preventing the elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value includes means for sensing the inside diameter of the tubular member.
- teachings of the present illustrative embodiments may be used to provide a wellbore casing, a pipeline, or a structural support.
- the elements and teachings of the various illustrative embodiments may be combined in whole or in part in some or all of the illustrative embodiments.
- one or more of the elements and teachings of the various illustrative embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.
Abstract
An apparatus for radially expanding and plastically deforming a tubular member.
Description
- The present application claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/461,038, attorney docket no. 25791.273, filed on Apr. 7, 2003, the disclosure of which is incorporated herein by reference.
- The present application is a continuation-in-part of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on Nov. 12, 2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on Feb. 29, 2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22, 2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, (6) PCT patent application serial number PCT/US03/18530, attorney docket number 25791.108.02, filed on Jun. 11, 2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on Sep. 23, 2003, filed on Sep. 22, 2003, (9) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, (10) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and (11) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference.
- This application is related to the following co-pending applications: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claims priority from provisional application 60/121,702, filed on Feb. 25, 1999, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claims priority from provisional application 60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul. 1, 2002, which claims priority from provisional application 60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,907, filed on Feb. 26, 1999, (9) U.S. Pat. No. 6,557,640, which was filed as patent application Ser. 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PCT/US04/06246, attorney docket no. 25791.238.02, filed on Feb. 26, 2004, (123) PCT patent application serial number PCT/US04/______, attorney docket number 25791.40.02, filed on Mar. 15, 2004, (124) PCT patent application serial number PCT/US04/______, attorney docket number 25791.236.02, filed on Mar. 15, 2004, (125) PCT patent application serial number PCT/US04/______, attorney docket number 25791.262.02, filed on Mar. 18, 2004, (126) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, (127) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, (128) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, and (129) PCT patent application serial number PCT/US04/______, attorney docket number 25791.272.02, filed on ______, the disclosures of which are incorporated herein by reference.
- This invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration.
- According to one aspect of the present invention, an apparatus for radially expanding and plastically deforming an expandable tubular member is provided that includes a support member, a cutting device for cutting the tubular member coupled to the support member, and an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member.
- According to another aspect of the present invention, an apparatus for radially expanding and plastically deforming an expandable tubular member is provided that includes a support member, an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member, and an actuator coupled to the support member for displacing the expansion device relative to the support member.
- According to another aspect of the present invention, an apparatus for radially expanding and plastically deforming an expandable tubular member is provided that includes a support member; an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a sealing assembly for sealing an annulus defined between the support member and the tubular member.
- According to another aspect of the present invention, an apparatus for radially expanding and plastically deforming an expandable tubular member is provided that includes a support member; a first expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a second expansion device for radially expanding and plastically deforming the tubular member coupled to the support member.
- According to another aspect of the present invention, an apparatus for radially expanding and plastically deforming an expandable tubular member is provided that includes a support member; an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a packer coupled to the support member.
- According to another aspect of the present invention, an apparatus for radially expanding and plastically deforming an expandable tubular member is provided that includes a support member; a cutting device for cutting the tubular member coupled to the support member; a gripping device for gripping the tubular member coupled to the support member; a sealing device for sealing an interface with the tubular member coupled to the support member; a locking device for locking the position of the tubular member relative to the support member; a first adjustable expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; a second adjustable expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; a packer coupled to the support member; and an actuator for displacing one or more of the sealing assembly, first and second adjustable expansion devices, and packer relative to the support member.
- According to another aspect of the present invention, an apparatus for cutting a tubular member is provided that includes a support member; and a plurality of movable cutting elements coupled to the support member.
- According to another aspect of the present invention, an apparatus for engaging a tubular member is provided that includes a support member; and a plurality of movable elements coupled to the support member.
- According to another aspect of the present invention, an apparatus for gripping a tubular member is provided that includes a plurality of movable gripping elements.
- According to another aspect of the present invention, an actuator is provided that includes a tubular housing; a tubular piston rod movably coupled to and at least partially positioned within the housing; a plurality of annular piston chambers defined by the tubular housing and the tubular piston rod; and a plurality of tubular pistons coupled to the tubular piston rod, each tubular piston movably positioned within a corresponding annular piston chamber.
- According to another aspect of the present invention, an apparatus for controlling a packer is provided that includes a tubular support member; one or more drag blocks releasably coupled to the tubular support member; and a tubular stinger coupled to the tubular support member for engaging the packer.
- According to another aspect of the present invention, a packer is provided that includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve movably positioned within the passage of the support member.
- According to another aspect of the present invention, a method of radially expanding and plastically deforming an expandable tubular member within a borehole having a preexisting wellbore casing is provided that includes positioning the tubular member within the borehole in overlapping relation to the wellbore casing; radially expanding and plastically deforming a portion of the tubular member to form a bell section; and radially expanding and plastically deforming a portion of the tubular member above the bell section comprising a portion of the tubular member that overlaps with the wellbore casing; wherein the inside diameter of the bell section is greater than the inside diameter of the radially expanded and plastically deformed portion of the tubular member above the bell section.
- According to another aspect of the present invention, a method for forming a mono diameter wellbore casing is provided that includes positioning an adjustable expansion device within a first expandable tubular member; supporting the first expandable tubular member and the adjustable expansion device within a borehole; lowering the adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; positioning the adjustable expansion device within a second expandable tubular member; supporting the second expandable tubular member and the adjustable expansion device within the borehole in overlapping relation to the first expandable tubular member; lowering the adjustable expansion device out of the second expandable tubular member; increasing the outside dimension of the adjustable expansion device; and displacing the adjustable expansion device upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole.
- According to another aspect of the present invention, a method for radially expanding and plastically deforming an expandable tubular member within a borehole is provided that includes positioning an adjustable expansion device within the expandable tubular member; supporting the expandable tubular member and the adjustable expansion device within the borehole; lowering the adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the adjustable expansion device; displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the borehole; and pressurizing an interior region of the expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the expandable tubular member within the borehole.
- According to another aspect of the present invention, a method for forming a mono diameter wellbore casing is provided that includes positioning an adjustable expansion device within a first expandable tubular member; supporting the first expandable tubular member and the adjustable expansion device within a borehole; lowering the adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; pressurizing an interior region of the first expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the first expandable tubular member within the borehole; positioning the adjustable expansion mandrel within a second expandable tubular member; supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member; lowering the adjustable expansion mandrel out of the second expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole; and pressurizing an interior region of the second expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the second expandable tubular member within the borehole.
- According to another aspect of the present invention, a method for radially expanding and plastically deforming an expandable tubular member within a borehole is provided that includes positioning first and second adjustable expansion devices within the expandable tubular member; supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; lowering the first adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- According to another aspect of the present invention, a method for forming a mono diameter wellbore casing is provided that includes positioning first and second adjustable expansion devices within a first expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; lowering the first adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; positioning first and second adjustable expansion devices within a second expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion devices within the borehole in overlapping relation to the first expandable tubular member; lowering the first adjustable expansion device out of the second expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform a lower portion of the second expandable tubular member; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the second expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; and displacing the second adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform portions of the second expandable tubular member above the lower portion of the second expandable tubular member; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- According to another aspect of the present invention, a method for radially expanding and plastically deforming an expandable tubular member within a borehole is provided that includes positioning first and second adjustable expansion devices within the expandable tubular member; supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; lowering the first adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; pressurizing an interior region of the expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the expandable tubular member by the first adjustable expansion device; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; and pressurizing an interior region of the expandable tubular member above the second adjustable expansion device during the radial expansion of the portions of the expandable tubular member above the lower portion of the expandable tubular member by the second adjustable expansion device; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- According to another aspect of the present invention, a method for forming a mono diameter wellbore casing is provided that includes positioning first and second adjustable expansion devices within a first expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; lowering the first adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; pressurizing an interior region of the first expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the first expandable tubular member by the first adjustable expansion device; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; pressurizing an interior region of the first expandable tubular member above the second adjustable expansion device during the radial expansion of the portions of the first expandable tubular member above the lower portion of the first expandable tubular member by the second adjustable expansion device; positioning first and second adjustable expansion devices within a second expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion devices within the borehole in overlapping relation to the first expandable tubular member; lowering the first adjustable expansion device out of the second expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform a lower portion of the second expandable tubular member; pressurizing an interior region of the second expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the second expandable tubular member by the first adjustable expansion device; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the second expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform portions of the second expandable tubular member above the lower portion of the second expandable tubular member; and pressurizing an interior region of the second expandable tubular member above the second adjustable expansion device during the radial expansion of the portions of the second expandable tubular member above the lower portion of the second expandable tubular member by the second adjustable expansion device; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- According to another aspect of the present invention, a method for radially expanding and plastically deforming an expandable tubular member within a borehole is provided that includes supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; increasing the size of the adjustable expansion device; and displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member.
- According to another aspect of the present invention, a method for forming a mono diameter wellbore casing within a borehole that includes a preexisting wellbore casing is provided that includes supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; increasing the size of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting wellbore casing that overlaps with an end of the remaining portion of the expandable tubular member.
- According to another aspect of the present invention, a method of radially expanding and plastically deforming a tubular member is provided that includes positioning the tubular member within a preexisting structure; radially expanding and plastically deforming a lower portion of the tubular member to form a bell section; and radially expanding and plastically deforming a portion of the tubular member above the bell section.
- According to another aspect of the present invention, a method of radially expanding and plastically deforming a tubular member is provided that includes applying internal pressure to the inside surface of the tubular member at a plurality of discrete location separated from one another.
- According to another aspect of the present invention, a system for radially expanding and plastically deforming an expandable tubular member within a borehole having a preexisting wellbore casing is provided that includes means for positioning the tubular member within the borehole in overlapping relation to the wellbore casing; means for radially expanding and plastically deforming a portion of the tubular member to form a bell section; and means for radially expanding and plastically deforming a portion of the tubular member above the bell section comprising a portion of the tubular member that overlaps with the wellbore casing; wherein the inside diameter of the bell section is greater than the inside diameter of the radially expanded and plastically deformed portion of the tubular member above the bell section.
- According to another aspect of the present invention, a system for forming a mono diameter wellbore casing is provided that includes means for positioning an adjustable expansion device within a first expandable tubular member; means for supporting the first expandable tubular member and the adjustable expansion device within a borehole; means for lowering the adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; means for positioning the adjustable expansion device within a second expandable tubular member; means for supporting the second expandable tubular member and the adjustable expansion device within the borehole in overlapping relation to the first expandable tubular member; means for lowering the adjustable expansion device out of the second expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; and means for displacing the adjustable expansion device upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole.
- According to another aspect of the present invention, a system for radially expanding and plastically deforming an expandable tubular member within a borehole is provided that includes means for positioning an adjustable expansion device within the expandable tubular member; means for supporting the expandable tubular member and the adjustable expansion device within the borehole; means for lowering the adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; means for displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the borehole; and means for pressurizing an interior region of the expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the expandable tubular member within the borehole.
- According to another aspect of the present invention, a system for forming a mono diameter wellbore casing is provided that includes means for positioning an adjustable expansion device within a first expandable tubular member; means for supporting the first expandable tubular member and the adjustable expansion device within a borehole; means for lowering the adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; means for pressurizing an interior region of the first expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the first expandable tubular member within the borehole; means for positioning the adjustable expansion mandrel within a second expandable tubular member; means for supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member; means for lowering the adjustable expansion mandrel out of the second expandable tubular member; means for increasing the outside dimension of the adjustable expansion mandrel; means for displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole; and means for pressurizing an interior region of the second expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the second expandable tubular member within the borehole.
- According to another aspect of the present invention, a system for radially expanding and plastically deforming an expandable tubular member within a borehole is provided that includes means for positioning first and second adjustable expansion devices within the expandable tubular member; means for supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; means for lowering the first adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- According to another aspect of the present invention, a system for forming a mono diameter wellbore casing is provided that includes means for positioning first and second adjustable expansion devices within a first expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; means for lowering the first adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; means for positioning first and second adjustable expansion devices within a second expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion devices within the borehole in overlapping relation to the first expandable tubular member; means for lowering the first adjustable expansion device out of the second expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform a lower portion of the second expandable tubular member; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the second expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; and means for displacing the second adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform portions of the second expandable tubular member above the lower portion of the second expandable tubular member; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- According to another aspect of the present invention, a system for radially expanding and plastically deforming an expandable tubular member within a borehole is provided that includes means for positioning first and second adjustable expansion devices within the expandable tubular member; means for supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; means for lowering the first adjustable expansion device out of the expandable tubular member, means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; means for pressurizing an interior region of the expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the expandable tubular member by the first adjustable expansion device; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; and means for pressurizing an interior region of the expandable tubular member above the second adjustable expansion device during the radial expansion of the portions of the expandable tubular member above the lower portion of the expandable tubular member by the second adjustable expansion device; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- According to another aspect of the present invention, a system for forming a mono diameter wellbore casing is provided that includes means for positioning first and second adjustable expansion devices within a first expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; means for lowering the first adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; means for pressurizing an interior region of the first expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the first expandable tubular member by the first adjustable expansion device; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; means for pressurizing an interior region of the first expandable tubular member above the second adjustable expansion device during the radial expansion of the portions of the first expandable tubular member above the lower portion of the first expandable tubular member by the second adjustable expansion device; means for positioning first and second adjustable expansion devices within a second expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion devices within the borehole in overlapping relation to the first expandable tubular member; means for lowering the first adjustable expansion device out of the second expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform a lower portion of the second expandable tubular member; means for pressurizing an interior region of the second expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the second expandable tubular member by the first adjustable expansion device; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the second expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform portions of the second expandable tubular member above the lower portion of the second expandable tubular member; and means for pressurizing an interior region of the second expandable tubular member above the second adjustable expansion device during the radial expansion of the portions of the second expandable tubular member above the lower portion of the second expandable tubular member by the second adjustable expansion device; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- According to another aspect of the present invention, a system for radially expanding and plastically deforming an expandable tubular member within a borehole is provided that includes means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; means for increasing the size of the adjustable expansion device; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member.
- According to another aspect of the present invention, a system for forming a mono diameter wellbore casing within a borehole that includes a preexisting wellbore casing is provided that includes means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; means for increasing the size of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting wellbore casing that overlaps with an end of the remaining portion of the expandable tubular member.
- According to another aspect of the present invention, a system for radially expanding and plastically deforming a tubular member is provided that includes means for positioning the tubular member within a preexisting structure; means for radially expanding and plastically deforming a lower portion of the tubular member to form a bell section; and means for radially expanding and plastically deforming a portion of the tubular member above the bell section.
- According to another aspect of the present invention, a system of radially expanding and plastically deforming a tubular member is provided that includes a support member; and means for applying internal pressure to the inside surface of the tubular member at a plurality of discrete location separated from one another coupled to the support member.
- According to another aspect of the present invention, a method of cutting a tubular member is provided that includes positioning a plurality of cutting elements within the tubular member; and bringing the cutting elements into engagement with the tubular member.
- According to another aspect of the present invention, a method of gripping a tubular member is provided that includes positioning a plurality of gripping elements within the tubular member; bringing the gripping elements into engagement with the tubular member. In an exemplary embodiment, bringing the gripping elements into engagement with the tubular member includes displacing the gripping elements in an axial direction; and displacing the gripping elements in a radial direction.
- According to another aspect of the present invention, a method of operating an actuator is provided that includes pressurizing a plurality of pressure chamber.
- According to another aspect of the present invention, a method of injecting a hardenable fluidic sealing material into an annulus between a tubular member and a preexisting structure is provided that includes positioning the tubular member into the preexisting structure; sealing off an end of the tubular member; operating a valve within the end of the tubular member; and injecting a hardenable fluidic sealing material through the valve into the annulus between the tubular member and the preexisting structure.
- According to another aspect of the present invention, a system for cutting a tubular member is provided that includes means for positioning a plurality of cutting elements within the tubular member; and means for bringing the cutting elements into engagement with the tubular member.
- According to another aspect of the present invention, a system for gripping a tubular member is provided that includes means for positioning a plurality of gripping elements within the tubular member;, and means for bringing the gripping elements into engagement with the tubular member.
- According to another aspect of the present invention, an actuator system is provided that includes a support member; and means for pressurizing a plurality of pressure chambers coupled to the support member. In an exemplary embodiment, the system further includes means for transmitting torsional loads.
- According to another aspect of the present invention, a system for injecting a hardenable fluidic sealing material into an annulus between a tubular member and a preexisting structure is provided that includes means for positioning the tubular member into the preexisting structure; means for sealing off an end of the tubular member; means for operating a valve within the end of the tubular member; and means for injecting a hardenable fluidic sealing material through the valve into the annulus between the tubular member and the preexisting structure.
- According to another aspect of the present invention, a method of engaging a tubular member is provided that includes positioning a plurality of elements within the tubular member; and bringing the elements into engagement with the tubular member.
- According to another aspect of the present invention, a system for engaging a tubular member is provided that includes means for positioning a plurality of elements within the tubular member; and means for bringing the elements into engagement with the tubular member. In an exemplary embodiment, the elements include a first group of elements; and a second group of elements; wherein the first group of elements are interleaved with the second group of elements.
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FIG. 1 is a fragmentary cross-sectional illustration of an embodiment of a system for radially expanding and plastically deforming wellbore casing, including a tubular support member, a casing cutter, a ball gripper for gripping a wellbore casing, a force multiplier tension actuator, a safety sub, a cup sub, a casing lock, an extension actuator, a bell section adjustable expansion cone assembly, a casing section adjustable expansion cone assembly, a packer setting tool, a packer, a stinger, and an expandable wellbore casing, during the placement of the system within a wellbore. -
FIG. 2 is a fragmentary cross-sectional illustration of the system ofFIG. 1 during the subsequent displacement of the bell section adjustable expansion cone assembly, the casing section adjustable expansion cone assembly, the packer setting tool, the packer, and the stinger downwardly out of the end of the expandable wellbore casing and the expansion of the size of the bell section adjustable expansion cone assembly and the casing section adjustable expansion cone assembly. -
FIG. 3 is a fragmentary cross-sectional illustration of the system ofFIG. 2 during the subsequent operation of the tension actuator to displace the bell section adjustable expansion cone assembly upwardly into the end of the expandable wellbore casing to form a bell section in the end of the expandable wellbore casing. -
FIG. 4 is a fragmentary cross-sectional illustration of the system ofFIG. 3 during the subsequent reduction of the bell section adjustable expansion cone assembly. -
FIG. 5 is a fragmentary cross-sectional illustration of the system ofFIG. 4 during the subsequent upward displacement of the expanded casing section adjustable expansion cone assembly to radially expand the expandable wellbore casing. -
FIG. 6 is a fragmentary cross-sectional illustration of the system ofFIG. 5 during the subsequent lowering of the tubular support member, casing cutter, ball gripper, a force multiplier tension actuator, safety sub, cup sub, casing lock, extension actuator, bell section adjustable expansion cone assembly, casing section adjustable expansion cone assembly, packer setting tool, packer, and stinger and subsequent setting of the packer within the expandable wellbore casing above the bell section. -
FIG. 7 is a fragmentary cross-sectional illustration of the system ofFIG. 6 during the subsequent injection of fluidic materials into the system to displace the expanded casing section adjustable expansion cone assembly upwardly through the expandable wellbore casing to radially expand and plastically deform the expandable wellbore casing. -
FIG. 8 is a fragmentary cross-sectional illustration of the system ofFIG. 7 during the subsequent injection of fluidic materials into the system to displace the expanded casing section adjustable expansion cone assembly upwardly through the expandable wellbore casing and a surrounding preexisting wellbore casing to radially expand and plastically deform the overlapping expandable wellbore casing and the surrounding preexisting wellbore casing. -
FIG. 9 is a fragmentary cross-sectional illustration of the system ofFIG. 8 during the subsequent operation of the casing cutter to cut off an end of the expandable wellbore casing. -
FIG. 10 is a fragmentary cross-sectional illustration of the system ofFIG. 9 during the subsequent removal of the cut off end of the expandable wellbore casing. -
FIGS. 11-1 and 11-2, 11A1 to 11A2, 11B1 to 11B2, 11C, 11D, 11E, 11F, 11G, 11H, 11I, 11 j, 11K, 11L, 11M, 11N, 11O, 11P, 11Q, 11R, 11S, 11T, 11U, 11V, 11W, 11X, 11Y, 11Z1 to 11Z4, 11AA1 to 11AA4, 11AB1 to 11AB4, 11AC1 to 11AC4, 11AD, and 11AE are fragmentary cross-sectional and perspective illustrations of an exemplary embodiment of a casing cutter assembly. - FIGS. 12A1 to 12A4 and 12C1 to 12C4 are fragmentary cross-sectional illustrations of an exemplary embodiment of a ball gripper assembly.
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FIG. 12B is a top view of a portion of the ball gripper assembly of FIGS. 12A1 to 12A4 and 12C1 to 12C4. - FIGS. 13A1 to 13A8 and 13B1 to 13B7 are fragmentary cross-sectional illustrations of an exemplary embodiment of a tension actuator assembly.
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FIG. 14A is a fragmentary cross-sectional illustrations of an exemplary embodiment of a safety sub assembly. -
FIGS. 14A, 14B and 14C are fragmentary cross-sectional and perspective illustrations of an exemplary embodiment of a cup seal assembly. -
FIGS. 15-1 and 15-2, 15A1 to 15A2, 15B to 15B2, 15C, 15D, 15E, 15F, 15G, 15H, 151, 15 j, 15K, 15L, 15M, 15N, 150, 15P, 15R, 15S, 15T, 15U, 15V, 15W, 15×, 15Y, 15Z1 to 15Z4, 15AA1 to 15AA4, 15AB1 to 15AB4, 15AC1 to 15AC4, 15AD, and 15AE are fragmentary cross-sectional and perspective illustrations of an exemplary embodiment of an adjustable bell section expansion cone assembly. -
FIGS. 16-1 and 16-2, 16A1 to 16A2, 16B1 to 16B2, 16C, 16D, 16E, 16F, 16G, 16H, 161, 16 j, 16K, 16L, 16M, 16N, 160, 16P, 16R, 16S, 16T, 16U, 16V, 16W, 16×, 16Y, 16Z1-16Z4, 16AA1 to 16AA4, 16AB1 to 16AB4, 16AC1 to 16AC4, 16AD, and 16AE are fragmentary cross-sectional and perspective illustrations of an exemplary embodiment of an adjustable casing expansion cone assembly. -
FIGS. 17A to 17C is a fragmentary cross-sectional illustration of an exemplary embodiment of a packer setting tool assembly. -
FIGS. 18-1 to 18-5 is a fragmentary cross-sectional illustration of an exemplary embodiment of a packer assembly. - FIGS. 19A1 to 19A5, 19B1 to 19B5, 19C1 to 19C5, 19D1 to 19D5, 19E1 to 19E6, 19F1 to 19F6, 19G1 to 19G6, and 19H1 to 19H5, are fragmentary cross-sectional illustrations of an exemplary embodiment of the operation of the packer setting tool and the packer assembly of
FIGS. 17A to 17C and 18-1 to 18-5. -
FIGS. 20 and 20 A to 20AX are fragmentary perspective and cross-sectional illustrations of an alternative embodiment of the packer assembly. - Referring initially to
FIGS. 1-10 , an exemplary embodiment of asystem 10 for radially expanding and plastically deforming a wellbore casing includes a conventionaltubular support 12 having an end that is coupled to an end of acasing cutter assembly 14. In an exemplary embodiment, thecasing cutter assembly 14 may be, or may include elements, of one or more conventional commercially available casing cutters for cutting wellbore casing, or equivalents thereof. - An end of a
ball gripper assembly 16 is coupled to another end of thecasing cutter assembly 14. In an exemplary embodiment, theball gripper assembly 14 may be, or may include elements, of one or more conventional commercially available ball grippers, or other types of gripping devices, for gripping wellbore casing, or equivalents thereof. - An end of a
tension actuator assembly 18 is coupled to another end of theball gripper assembly 16. In an exemplary embodiment, thetension actuator assembly 18 may be, or may include elements, of one or more conventional commercially actuators, or equivalents thereof. - An end of a
safety sub assembly 20 is coupled to another end of thetension actuator assembly 18. In an exemplary embodiment, thesafety sub assembly 20 may be, or may include elements, of one or more conventional apparatus that provide quick connection and/or disconnection of tubular members, or equivalents thereof. - An end of a sealing
cup assembly 22 is coupled to another end of thesafety sub assembly 20. In an exemplary embodiment, the sealingcup assembly 22 may be, or may include elements, of one or more conventional sealing cup assemblies, or other types of sealing assemblies, that sealingly engage the interior surfaces of surrounding tubular members, or equivalents thereof. - An end of a
casing lock assembly 24 is coupled to another end of the sealingcup assembly 22. In an exemplary embodiment, thecasing lock assembly 24 may be, or may include elements, of one or more conventional casing lock assemblies that lock the position of wellbore casing, or equivalents thereof. - An end of an
extension actuator assembly 26 is coupled to another end of thecasing lock assembly 24. In an exemplary embodiment, theextension actuator assembly 26 may be, or may include elements, of one or more conventional actuators, or equivalents thereof. - An end of an adjustable bell section
expansion cone assembly 28 is coupled to another end of theextension actuator assembly 26. In an exemplary embodiment, the adjustable bell sectionexpansion cone assembly 28 may be, or may include elements, of one or more conventional adjustable expansion devices for radially expanding and plastically deforming wellbore casing, or equivalents thereof. - An end of an adjustable casing
expansion cone assembly 30 is coupled to another end of the adjustable bell sectionexpansion cone assembly 28. In an exemplary embodiment, the adjustable casingexpansion cone assembly 30 may be, or may include elements, of one or more conventional adjustable expansion devices for radially expanding and plastically deforming wellbore casing, or equivalents thereof. - An end of a packer
setting tool assembly 32 is coupled to another end of the adjustable casingexpansion cone assembly 30. In an exemplary embodiment, the packersetting tool assembly 32 may be, or may include elements, of one or more conventional adjustable expansion devices for controlling the operation of a conventional packer, or equivalents thereof. - An end of a
stinger assembly 34 is coupled to another end of the packersetting tool assembly 32. In an exemplary embodiment, thestinger assembly 34 may be, or may include elements, of one or more conventional devices for engaging a conventional packer, or equivalents thereof. - An end of a
packer assembly 36 is coupled to another end of thestinger assembly 34. In an exemplary embodiment, thepacker assembly 36 may be, or may include elements, of one or more conventional packers. - In an exemplary embodiment, one or more of the elements of the
system 10 may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements of the system. - As illustrated in
FIG. 1 , in an exemplary embodiment, during operation of thesystem 10, anexpandable wellbore casing 100 is coupled to and supported by thecasing lock assembly 24 of the system. Thesystem 10 is then positioned within awellbore 102 that traverses asubterranean formation 104 and includes apreexisting wellbore casing 106. - As illustrated in
FIG. 2 , in an exemplary embodiment, theextension actuator assembly 26 is then operated to move the adjustable bell sectionexpansion cone assembly 28, adjustable casingexpansion cone assembly 30, packersetting tool assembly 32,stinger assembly 34,packer assembly 36 downwardly in adirection 108 and out of an end of theexpandable wellbore casing 100. After the adjustable bell sectionexpansion cone assembly 28 and adjustable casingexpansion cone assembly 30 have been moved to a position out of the end of theexpandable wellbore casing 100, the adjustable bell section expansion cone assembly and adjustable casing expansion cone assembly are then operated to increase the outside diameters of the expansion cone assemblies. In an exemplary embodiment, the increased outside diameter of the adjustable bell sectionexpansion cone assembly 28 is greater than the increased outside diameter of the adjustable casingexpansion cone assembly 30. - As illustrated in
FIG. 3 , in an exemplary embodiment, theball gripper assembly 16 is then operated to engage and hold the position of theexpandable tubular member 100 stationary relative to thetubular support member 12. Thetension actuator assembly 18 is then operated to move the adjustable bell sectionexpansion cone assembly 28, adjustable casingexpansion cone assembly 30, packersetting tool assembly 32,stinger assembly 34,packer assembly 36 upwardly in adirection 110 into and through the end of theexpandable wellbore casing 100. As a result, the end of theexpandable wellbore casing 100 is radially expanded and plastically deformed by the adjustable bell sectionexpansion cone assembly 28 to form abell section 112. In an exemplary embodiment, during the operation of thesystem 10 described above with reference toFIG. 3 , thecasing lock assembly 24 may or may not be coupled to theexpandable wellbore casing 100. - In an exemplary embodiment, the length of the end of the
expandable wellbore casing 100 that is radially expanded and plastically deformed by the adjustable bell sectionexpansion cone assembly 28 is limited by the stroke length of thetension actuator assembly 18. In an exemplary embodiment, once thetension actuator assembly 18 completes a stroke, theball gripper assembly 16 is operated to release theexpandable tubular member 100, and thetubular support 12 is moved upwardly to permit the tension actuator assembly to be re-set. In this manner, the length of thebell section 112 can be further extended by continuing to stroke and then re-set the position of thetension actuator assembly 18. Note, that, during the upward movement of thetubular support 12 to re-set the position of thetension actuator assembly 18, the expandabletubular wellbore casing 100 is supported by the expansion surfaces of the adjustable bell sectionexpansion cone assembly 28. - As illustrated in
FIG. 4 , in an exemplary embodiment, thecasing lock assembly 24 is then operated to engage and maintain the position of theexpandable wellbore casing 100 stationary relative to thetubular support 12. The adjustable bell sectionexpansion cone assembly 28, adjustable casingexpansion cone assembly 30, packersetting tool assembly 32,stinger assembly 34, andpacker assembly 36 are displaced downwardly into thebell section 112 in adirection 114 relative to theexpandable wellbore casing 100 by operating theextension actuator 26 and/or by displacing thesystem 10 downwardly in thedirection 114 relative to the expandable wellbore casing. After the adjustable bell sectionexpansion cone assembly 28 and adjustable casingexpansion cone assembly 30 have been moved downwardly in thedirection 114 into thebell section 112 of theexpandable wellbore casing 100, the adjustable bell section expansion cone assembly is then operated to decrease the outside diameter of the adjustable bell section expansion cone assembly. In an exemplary embodiment, the decreased outside diameter of the adjustable bell sectionexpansion cone assembly 28 is less than the increased outside diameter of the adjustable casingexpansion cone assembly 30. In an exemplary embodiment, during the operation of the system illustrated and described above with reference toFIG. 4 , theball gripper 16 may or may not be operated to engage theexpandable wellbore casing 100. - As illustrated in
FIG. 5 , in an exemplary embodiment, thecasing lock assembly 24 is then disengaged from theexpandable wellbore casing 100 andfluidic material 116 is then injected into thesystem 10 through thetubular support 12 to thereby pressurize anannulus 118 defined within the expandable wellbore casing below thecup sub assembly 22. As a result, a pressure differential is created across thecup seal assembly 22 that causes the cup seal assembly to apply a tensile force in thedirection 120 to thesystem 10. As a result, thesystem 10 is displaced upwardly in thedirection 120 relative to theexpandable wellbore casing 100 thereby pulling the adjustable casingexpansion cone assembly 30 upwardly in thedirection 120 through the expandable wellbore casing thereby radially expanding and plastically deforming the expandable wellbore casing. - In an exemplary embodiment, the
tension actuator assembly 16 may also be operated during the injection of thefluidic material 116 to displace the adjustable casingexpansion cone assembly 30 upwardly relative to thetubular support 12. As a result, additional expansion forces may be applied to theexpandable wellbore casing 100. - As illustrated in
FIG. 6 , in an exemplary embodiment, the radial expansion and plastic deformation of the expandable wellbore casing using the adjustable casingexpansion cone assembly 30 continues until thepacker assembly 36 is positioned within a portion of the expandable tubular member above thebell section 112. Thepacker assembly 36 may then be operated to engage the interior surface of theexpandable wellbore casing 100 above thebell section 112. - In an exemplary embodiment, after the
packer assembly 36 is operated to engage the interior surface of theexpandable wellbore casing 100 above thebell section 112, a hardenablefluidic sealing material 122 may then be injected into thesystem 10 through thetubular support 12 and then out of the system through the packer assembly to thereby permit the annulus between the expandable wellbore casing and thewellbore 102 to be filled with the hardenable fluidic sealing material. The hardenablefluidic sealing material 122 may then be allowed to cure to form a fluid tight annulus between theexpandable wellbore casing 100 and thewellbore 102, before, during, or after the completion of the radial expansion and plastic deformation of the expandable wellbore casing. - As illustrated in
FIG. 7 , in an exemplary embodiment, thefluidic material 116 is then re-injected into thesystem 10 through thetubular support 12 to thereby re-pressurize theannulus 118 defined within the expandable wellbore casing below thecup sub assembly 22. As a result, a pressure differential is once again created across thecup seal assembly 22 that causes the cup seal assembly to once again apply a tensile force in thedirection 120 to thesystem 10. As a result, thesystem 10 is displaced upwardly in thedirection 120 relative to theexpandable wellbore casing 100 thereby pulling the adjustable casingexpansion cone assembly 30 upwardly in thedirection 120 through the expandable wellbore casing thereby radially expanding and plastically deforming the expandable wellbore casing and disengaging thestinger assembly 34 from thepacker assembly 36. In an exemplary embodiment, during this operational mode, thepacker assembly 36 prevents the flow of fluidic materials out of theexpandable wellbore casing 100. As a result, the pressurization of theannulus 118 is rapid and efficient thereby enhancing the operational efficiency of the subsequent radial expansion and plastic deformation of theexpandable wellbore casing 100. - In an exemplary embodiment, the
tension actuator assembly 16 may also be operated during the re-injection of thefluidic material 116 to displace the adjustable casingexpansion cone assembly 30 upwardly relative to thetubular support 12. As a result, additional expansion forces may be applied to theexpandable wellbore casing 100. - As illustrated in
FIG. 8 , in an exemplary embodiment, the radial expansion and plastic deformation of the expandable wellbore casing using the adjustable casingexpansion cone assembly 30 continues until the adjustable casing expansion c/oneassembly 30 reaches theportion 124 of theexpandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106. At which point, thesystem 10 may radially expand theportion 124 of theexpandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106 and the surrounding portion of the preexisting wellbore casing. Consequently, in an exemplary embodiment, during the radial expansion of theportion 124 of theexpandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106, thetension actuator assembly 16 is also operated to displace the adjustable casingexpansion cone assembly 30 upwardly relative to thetubular support 12. As a result, additional expansion forces may be applied to theexpandable wellbore casing 100 and the preexistingwellbore casing 106 during the radial expansion of theportion 124 of the expandable wellbore casing that overlaps with the preexisting wellbore casing. - As illustrated in
FIG. 9 , in an exemplary embodiment, the entire length of theportion 124 of theexpandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106 is not radially expanded and plastically deformed. Rather, only part of theportion 124 of theexpandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106 is radially expanded and plastically deformed. The remaining part of theportion 124 of theexpandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106 is then cut away by operating thecasing cutter assembly 14. - As illustrated in
FIG. 10 , the remaining part of theportion 124 of theexpandable wellbore casing 100 that overlaps with the preexistingwellbore casing 106 that is cut away by operating thecasing cutter assembly 14 is then also carried out of thewellbore 102 using the casing cutter assembly. - Furthermore, in an exemplary embodiment, the inside diameter of the
expandable wellbore casing 100 above thebell section 112 is equal to the inside diameter of the portion of the preexistingwellbore casing 106 that does not overlap with theexpandable wellbore casing 100. As a result, a wellbore casing is constructed that includes overlapping wellbore casings that together define an internal passage having a constant cross-sectional area. - In an exemplary embodiment, one or more of the operational elements of the
system 10 may be omitted, at least in part, and/or combined, at least in part, with one or more of the other operational elements of the system. - In several exemplary embodiments, the
system 10 includes one or more of the methods and apparatus disclosed in one or more of the following: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claims priority from provisional application 60/121,702, filed on Feb. 25, 1999, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claims priority from provisional application 60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul. 1, 2002, which claims priority from provisional application 60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,907, filed on Feb. 26, 1999, (9) U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (10) U.S. patent application Ser. No. 09/981,916, attorney docket no. 25791.18, filed on Oct. 18, 2001 as a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed as application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claims priority from provisional application 60/131,106, filed on Apr. 26, 1999, (12) U.S. patent application Ser. No. 10/030,593, attorney docket no. 25791.25.08, filed on Jan. 8, 2002, which claims priority from provisional application 60/146,203, filed on Jul. 29, 1999, (13) U.S. provisional patent application Ser. No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999, (14) U.S. patent application Ser. No. 10/111,982, attorney docket no. 25791.27.08, filed on Apr. 30, 2002, which claims priority from provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (15) U.S. provisional patent application Ser. No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999, (16) U.S. provisional patent application Ser. No. 60/438,828, attorney docket no. 25791.31, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875, which was filed as application Ser. No. 09/679,907, attorney docket no. 25791.34.02, on Oct. 5, 2000, which claims priority from provisional patent application Ser. No. 60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (18) U.S. patent application Ser. No. 10/089,419, filed on Mar. 27, 2002, attorney docket no. 25791.36.03, which claims priority from provisional patent application Ser. No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999, (19) U.S. patent application Ser. No. 09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02, which claims priority from provisional patent application Ser. No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999, (20) U.S. patent application Ser. No. 10/303,992, filed on Nov. 22, 2002, attorney docket no. 25791.38.07, which claims priority from provisional patent application Ser. No. 60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (21) U.S. provisional patent application Ser. No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, (22) U.S. provisional patent application Ser. No. 60/455,051, attorney docket no. 25791.40, filed on Mar. 14, 2003, (23) PCT application US02/2477, filed on Jun. 26, 2002, attorney docket no. 25791.44.02, which claims priority from U.S. provisional patent application Ser. No. 60/303,711, attorney docket no. 25791.44, filed on Jul. 6, 2001, (24) U.S. patent application Ser. No. 10/311,412, filed on Dec. 12, 2002, attorney docket no. 25791.45.07, which claims priority from provisional patent application Ser. No. 60/221,443, attorney docket no. 25791.45, filed on Jul. 28, 2000, (25) U.S. patent application Ser. No. 10/______, filed on Dec. 18, 2002, attorney docket no. 25791.46.07, which claims priority from provisional patent application Ser. No. 60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000, (26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22, 2003, attorney docket no. 25791.47.03, which claims priority from provisional patent application Ser. No. 60/233,638, attorney docket no. 25791.47, filed on Sep. 18, 2000, (27) U.S. patent application Ser. No. 10/406,648, filed on Mar. 31, 2003, attorney docket no. 25791.48.06, which claims priority from provisional patent application Ser. No. 60/237,334, attorney docket no. 25791.48, filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on Feb. 14, 2002, attorney docket no. 25791.50.02, which claims priority from U.S. provisional patent application Ser. No. 60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001, (29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13, 2003, attorney docket no. 25791.51.06, which claims priority from provisional patent application Ser. No. 60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001, (30) U.S. patent application Ser. No. 10/465,831, filed on Jun. 13, 2003, attorney docket no. 25791.52.06, which claims priority from U.S. provisional patent application Ser. No. 60/259,486, attorney docket no. 25791.52, filed on Jan. 3, 2001, (31) U.S. provisional patent application Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney docket no. 25791.53, (32) U.S. Pat. No. 6,470,966, which was filed as patent application Ser. No. 09/850,093, filed on May 7, 2001, attorney docket no. 25791.55, as a divisional application of U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (33) U.S. Pat. No. 6,561,227, which was filed as patent application Ser. No. 09/852,026, filed on May 9, 2001, attorney docket no. 25791.56, as a divisional application of U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (34) U.S. patent application Ser. No. 09/852,027, filed on May 9, 2001, attorney docket no. 25791.57, as a divisional application of U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (35) PCT Application US02/25608, attorney docket no. 25791.58.02, filed on Aug. 13, 2002, which claims priority from provisional application 60/318,021, filed on Sep. 7, 2001, attorney docket no. 25791.58, (36) PCT Application US02/24399, attorney docket no. 25791.59.02, filed on Aug. 1, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/313,453, attorney docket no. 25791.59, filed on Aug. 20, 2001, (37) PCT Application US02/29856, attorney docket no. 25791.60.02, filed on Sep. 19, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/326,886, attorney docket no. 25791.60, filed on Oct. 3, 2001, (38) PCT Application US02/20256, attorney docket no. 25791.61.02, filed on Jun. 26, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/303,740, attorney docket no. 25791.61, filed on Jul. 16, 2001, (39) U.S. patent application Ser. No. 09/962,469, filed on Sep. 25, 2001, attorney docket no. 25791.62, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (40) U.S. patent application Ser. No. 09/962,470, filed on Sep. 25, 2001, attorney docket no. 25791.63, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (41) U.S. patent application Ser. No. 09/962,471, filed on Sep. 25, 2001, attorney docket no. 25791.64, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (42) U.S. patent application Ser. No. 09/962,467, filed on Sep. 25, 2001, attorney docket no. 25791.65, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (43) U.S. patent application Ser. No. 09/962,468, filed on Sep. 25, 2001, attorney docket no. 25791.66, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (44) PCT application US 02/25727, filed on Aug. 14, 2002, attorney docket no. 25791.67.03, which claims priority from U.S. provisional patent application Ser. No. 60/317,985, attorney docket no. 25791.67, filed on Sep. 6, 2001, and U.S. provisional patent application Ser. No. 60/318,386, attorney docket no. 25791.67.02, filed on Sep. 10, 2001, (45) PCT application US 02/39425, filed on Dec. 10, 2002, attorney docket no. 25791.68.02, which claims priority from U.S. provisional patent application Ser. No. 60/343,674, attorney docket no. 25791.68, filed on Dec. 27, 2001, (46) U.S. utility patent application Ser. No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, which is a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (47) U.S. utility patent application Ser. No. 10/516,467, attorney docket no. 25791.70, filed on Dec. 10, 2001, which is a continuation application of U.S. utility patent application Ser. No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, which is a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (48) PCT application US 03/00609, filed on Jan. 9, 2003, attorney docket no. 25791.71.02, which claims priority from U.S. provisional patent application Ser. No. 60/357,372, attorney docket no. 25791.71, filed on Feb. 15, 2002, (49) U.S. patent application Ser. No. 10/074,703, attorney docket no. 25791.74, filed on Feb. 12, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (50) U.S. patent application Ser. No. 10/074,244, attorney docket no. 25791.75, filed on Feb. 12, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (51) U.S. patent application Ser. No. 10/076,660, attorney docket no. 25791.76, filed on Feb. 15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (52) U.S. patent application Ser. No. 10/076,661, attorney docket no. 25791.77, filed on Feb. 15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (53) U.S. patent application Ser. No. 10/076,659, attorney docket no. 25791.78, filed on Feb. 15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (54) U.S. patent application Ser. No. 10/078,928, attorney docket no. 25791.79, filed on Feb. 20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (55) U.S. patent application Ser. No. 10/078,922, attorney docket no. 25791.80, filed on Feb. 20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (56) U.S. patent application Ser. No. 10/078,921, attorney docket no. 25791.81, filed on Feb. 20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (57) U.S. patent application Ser. No. 10/261,928, attorney docket no. 25791.82, filed on Oct. 1, 2002, which is a divisional of U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (58) U.S. patent application Ser. No. 10/079,276, attorney docket no. 25791.83, filed on Feb. 20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (59) U.S. patent application Ser. No. 10/262,009, attorney docket no. 25791.84, filed on Oct. 1, 2002, which is a divisional of U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (60) U.S. patent application Ser. No. 10/092,481, attorney docket no. 25791.85, filed on Mar. 7, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (61) U.S. patent application Ser. No. 10/261,926, attorney docket no. 25791.86, filed on Oct. 1, 2002, which is a divisional of U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (62) PCT application US 02/36157, filed on Nov. 12, 2002, attorney docket no. 25791.87.02, which claims priority from U.S. provisional patent application Ser. No. 60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001, (63) PCT application US 02/36267, filed on Nov. 12, 2002, attorney docket no. 25791.88.02, which claims priority from U.S. provisional patent application Ser. No. 60/339,013, attorney docket no. 25791.88, filed on Nov. 12, 2001, (64) PCT application US 03/11765, filed on Apr. 16, 2003, attorney docket no. 25791.89.02, which claims priority from U.S. provisional patent application Ser. No. 60/383,917, attorney docket no. 25791.89, filed on May 29, 2002, (65) PCT application US 03/15020, filed on May 12, 2003, attorney docket no. 25791.90.02, which claims priority from U.S. provisional patent application Ser. No. 60/391,703, attorney docket no. 25791.90, filed on Jun. 26, 2002, (66) PCT application US 02/39418, filed on Dec. 10, 2002, attorney docket no. 25791.92.02, which claims priority from U.S. provisional patent application Ser. No. 60/346,309, attorney docket no. 25791.92, filed on Jan. 7, 2002, (67) PCT application US 03/06544, filed on Mar. 4, 2003, attorney docket no. 25791.93.02, which claims priority from U.S. provisional patent application Ser. No. 60/372,048, attorney docket no. 25791.93, filed on Apr. 12, 2002, (68) U.S. patent application Ser. No. 10/331,718, attorney docket no. 25791.94, filed on Dec. 30, 2002, which is a divisional U.S. patent application Ser. No. 09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02, which claims priority from provisional patent application Ser. No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999, (69) PCT application US 03/04837, filed on Feb. 29, 2003, attorney docket no. 25791.95.02, which claims priority from U.S. provisional patent application Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13, 2002, (70) U.S. patent application Ser. No. 10/261,927, attorney docket no. 25791.97, filed on Oct. 1, 2002, which is a divisional of U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (71) U.S. patent application Ser. No. 10/262,008, attorney docket no. 25791.98, filed on Oct. 1, 2002, which is a divisional of U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (72) U.S. patent application Ser. No. 10/261,925, attorney docket no. 25791.99, filed on Oct. 1, 2002, which is a divisional of U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (73) U.S. patent application Ser. No. 10/199,524, attorney docket no. 25791.100, filed on Jul. 19, 2002, which is a continuation of U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (74) PCT application US 03/10144, filed on Mar. 28, 2003, attorney docket no. 25791.101.02, which claims priority from U.S. provisional patent application Ser. No. 60/372,632, attorney docket no. 25791.101, filed on Apr. 15, 2002, (75) U.S. provisional patent application Ser. No. 60/412,542, attorney docket no. 25791.102, filed on Sep. 20, 2002, (76) PCT application US 03/14153, filed on May 6, 2003, attorney docket no. 25791.104.02, which claims priority from U.S. provisional patent application Ser. No. 60/380,147, attorney docket no. 25791.104, filed on May 6, 2002, (77) PCT application US 03/19993, filed on Jun. 24, 2003, attorney docket no. 25791.106.02, which claims priority from U.S. provisional patent application Ser. No. 60/397,284, attorney docket no. 25791.106, filed on Jul. 19, 2002, (78) PCT application US 03/13787, filed on May 5, 2003, attorney docket no. 25791.107.02, which claims priority from U.S. provisional patent application Ser. No. 60/387,486, attorney docket no. 25791.107, filed on Jun. 10, 2002, (79) PCT application US 03/18530, filed on Jun. 11, 2003, attorney docket no. 25791.108.02, which claims priority from U.S. provisional patent application Ser. No. 60/387,961, attorney docket no. 25791.108, filed on Jun. 12, 2002, (80) PCT application US 03/20694, filed on Jul. 1, 2003, attorney docket no. 25791.110.02, which claims priority from U.S. provisional patent application Ser. No. 60/398,061, attorney docket no. 25791.110, filed on Jul. 24, 2002, (81) PCT application US 03/20870, filed on Jul. 2, 2003, attorney docket no. 25791.111.02, which claims priority from U.S. provisional patent application Ser. No. 60/399,240, attorney docket no. 25791.111, filed on Jul. 29, 2002, (82) U.S. provisional patent application Ser. No. 60/412,487, attorney docket no. 25791.112, filed on Sep. 20, 2002, (83) U.S. provisional patent application Ser. No. 60/412,488, attorney docket no. 25791.114, filed on Sep. 20, 2002, (84) U.S. patent application Ser. No. 10/280,356, attorney docket no. 25791.115, filed on Oct. 25, 2002, which is a continuation of U.S. Pat. No. 6,470,966, which was filed as patent application Ser. No. 09/850,093, filed on May 7, 2001, attorney docket no. 25791.55, as a divisional application of U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (85) U.S. provisional patent application Ser. No. 60/412,177, attorney docket no. 25791.117, filed on Sep. 20, 2002, (86) U.S. provisional patent application Ser. No. 60/412,653, attorney docket no. 25791.118, filed on Sep. 20, 2002, (87) U.S. provisional patent application Ser. No. 60/405,610, attorney docket no. 25791.119, filed on Aug. 23, 2002, (88) U.S. provisional patent application Ser. No. 60/405,394, attorney docket no. 25791.120, filed on Aug. 23, 2002, (89) U.S. provisional patent application Ser. No. 60/412,544, attorney docket no. 25791.121, filed on Sep. 20, 2002, (90) PCT application US 03/24779, filed on Aug. 8, 2003, attorney docket no. 25791.125.02, which claims priority from U.S. provisional patent application Ser. No. 60/407,442, attorney docket no. 25791.125, filed on Aug. 30, 2002, (91) U.S. provisional patent application Ser. No. 60/423,363, attorney docket no. 25791.126, filed on Dec. 10, 2002, (92) U.S. provisional patent application Ser. No. 60/412,196, attorney docket no. 25791.127, filed on Sep. 20, 2002, (93) U.S. provisional patent application Ser. No. 60/412,187, attorney docket no. 25791.128, filed on Sep. 20, 2002, (94) U.S. provisional patent application Ser. No. 60/412,371, attorney docket no. 25791.129, filed on Sep. 20, 2002, (95) U.S. patent application Ser. No. 10/382,325, attorney docket no. 25791.145, filed on Mar. 5, 2003, which is a continuation of U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (96) U.S. patent application Ser. No. 10/624,842, attorney docket no. 25791.151, filed on Jul. 22, 2003, which is a divisional of U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claims priority from provisional application 60/119,611, filed on Feb. 11, 1999, (97) U.S. provisional patent application Ser. No. 60/431,184, attorney docket no. 25791.157, filed on Dec. 5, 2002, (98) U.S. provisional patent application Ser. No. 60/448,526, attorney docket no. 25791.185, filed on Feb. 18, 2003, (99) U.S. provisional patent application Ser. No. 60/461,539, attorney docket no. 25791.186, filed on Apr. 9, 2003, (100) U.S. provisional patent application Ser. No. 60/462,750, attorney docket no. 25791.193, filed on Apr. 14, 2003, (101) U.S. provisional patent application Ser. No. 60/436,106, attorney docket no. 25791.200, filed on Dec. 23, 2002, (102) U.S. provisional patent application Ser. No. 60/442,942, attorney docket no. 25791.213, filed on Jan. 27, 2003, (103) U.S. provisional patent application Ser. No. 60/442,938, attorney docket no. 25791.225, filed on Jan. 27, 2003, (104) U.S. provisional patent application Ser. No. 60/418,687, attorney docket no. 25791.228, filed on Apr. 18, 2003, (105) U.S. provisional patent application Ser. No. 60/454,896, attorney docket no. 25791.236, filed on Mar. 14, 2003, (106) U.S. provisional patent application Ser. No. 60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003, (107) U.S. provisional patent application Ser. No. 60/451,152, attorney docket no. 25791.239, filed on Mar. 9, 2003, (108) U.S. provisional patent application Ser. No. 60/455,124, attorney docket no. 25791.241, filed on Mar. 17, 2003, (109) U.S. provisional patent application Ser. No. 60/453,678, attorney docket no. 25791.253, filed on Mar. 11, 2003, (110) U.S. patent application Ser. No. 10/421,682, attorney docket no. 25791.256, filed on Apr. 23, 2003, which is a continuation of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (111) U.S. provisional patent application Ser. No. 60/457,965, attorney docket no. 25791.260, filed on Mar. 27, 2003, (112) U.S. provisional patent application Ser. No. 60/455,718, attorney docket no. 25791.262, filed on Mar. 18, 2003, (113) U.S. Pat. No. 6,550,821, which was filed as patent application Ser. No. 09/811,734, filed on Mar. 19, 2001, (114) U.S. patent application Ser. No. 10/436,467, attorney docket no. 25791.268, filed on May 12, 2003, which is a continuation of U.S. Pat. No. 6,604,763, which was filed as application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claims priority from provisional application 60/131,106, filed on Apr. 26, 1999, (115) U.S. provisional patent application Ser. No. 60/459,776, attorney docket no. 25791.270, filed on Apr. 2, 2003, (116) U.S. provisional patent application Ser. No. 60/461,094, attorney docket no. 25791.272, filed on Apr. 8, 2003, (117) U.S. provisional patent application Ser. No. 60/461,038, attorney docket no. 25791.273, filed on Apr. 7, 2003, (118) U.S. provisional patent application Ser. No. 60/463,586, attorney docket no. 25791.277, filed on Apr. 17, 2003, (119) U.S. provisional patent application Ser. No. 60/472,240, attorney docket no. 25791.286, filed on May 20, 2003, (120) U.S. patent application Ser. No. 10/619,285, attorney docket no. 25791.292, filed on Jul. 14, 2003, which is a continuation-in-part of U.S. utility patent application Ser. No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, which is a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (121) U.S. utility patent application Ser. No. 10/418,688, attorney docket no. 25791.257, which was filed on Apr. 18, 2003, as a division of U.S. utility patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (122) PCT patent application serial no. PCT/US04/06246, attorney docket no. 25791.238.02, filed on Feb. 26, 2004, (123) PCT patent application serial number PCT/US04/______, attorney docket number 25791.40.02, filed on Mar. 15, 2004, (124) PCT patent application serial number PCT/US04/______, attorney docket number 25791.236.02, filed on Mar. 15, 2004, (125) PCT patent application serial number PCT/US04/______, attorney docket number 25791.262.02, filed on Mar. 18, 2004, (126) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, (127) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, (128) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, and (129) PCT patent application serial number PCT/US04/______, attorney docket number 25791.272.02, filed on ______, the disclosures of which are incorporated herein by reference. - In an exemplary embodiment, the
casing cutter assembly 14 is provided and operates substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, filed on Sep. 22, 2003, and/or (2) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (3) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (4) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference. - In an exemplary embodiment, as illustrated in
FIGS. 11-1 and 11-2, 11A1 to 11 A2, 11B1 to 11B2, 11C, 11D, 11E, 11F, 11G, 11H, 11I, 11 j, 11K, 11L, 11M, 11N, 11O, 11P, 11Q, 11R, 11S, 11T, 11U, 11V, 11W, 11X, 11Y, 11Z1 to 11Z4, 11AA1 to 11AA4, 11AB1 to 11AB4, 11AC1 to 11AC4, 11AD, and 11AE, thecasing cutter assembly 14 includes an upper tubular tool joint 14002 that defines alongitudinal passage 14002 a and mounting holes, 14002 b and 14002 c, and includes an internal threadedconnection 14002 d, an innerannular recess 14002 e, an inner annular recess 14002 f, and an internal threadedconnection 14002 g. Atubular torque plate 14004 that defines alongitudinal passage 14004 a and includes circumferentially spaced apartteeth 14004 b is received within, mates with, and is coupled to the internalannular recess 14002 e of the uppertubular tool joint 14002. - Circumferentially spaced apart teeth 14006 a of an end of a tubular
lower mandrel 14006 that defines alongitudinal passage 14006 b, aradial passage 14006 ba, and aradial passage 14006 bb and includes an external threadedconnection 14006 c, anexternal flange 14006 d, an externalannular recess 14006 e having astep 14006 f at one end, an externalannular recess 14006 g,external teeth 14006 h, an external threadedconnection 14006 i, and an externalannular recess 14006 j engage the circumferentially spaced apartteeth 14004 b of thetubular torque plate 14004. An internal threadedconnection 14008 a of an end of atubular toggle bushing 14008 that defines alongitudinal passage 14008 b, an upperlongitudinal slot 14008 c, a lowerlongitudinal slot 14008 d, mounting holes, 14008 e, 14008 f, 14008 g, 14008 h, 14008 i, 14008 j, 14008 k, 14008 l, 14008 m, 14008 n, 14008 o, 14008 p, 14008 q, 14008 r, 14008 s, 14008 t, 14008 u, 14008 v, 14008 w, 14008×, 14008 xa, and 14008 xb, and includes an externalannular recess 14008 y, internalannular recess 14008 z, externalannular recess 14008 aa, and an externalannular recess 14008 ab receives and is coupled to the external threadedconnection 14006 c of the tubularlower mandrel 14006. - A sealing
element 14010 is received within the externalannular recess 14008 y of thetubular toggle bushing 14008 for sealing the interface between the tubular toggle bushing and the uppertubular tool joint 14002. A sealingelement 14012 is received within the internalannular recess 14008 z of thetubular toggle bushing 14008 for sealing the interface between the tubular toggle bushing and the tubularlower mandrel 14006. - Mounting screws, 14014 a and 14014 b, mounted within and coupled to the mounting holes, 14008 w and 14008 x, respectively, of the
tubular toggle bushing 14008 are also received within the mounting holes, 14002 b and 14002 c, of the uppertubular tool joint 14002. Mounting pins, 14016 a, 14016 b, 14016 c, 14016 d, and 14016 e, are mounted within the mounting holes, 14008 e, 14008 f, 14008 g, 14008 h, and 14008 i, respectively. Mounting pins, 14018 a, 14018 b, 14018 c, 14018 d, and 14018 e, are mounted within the mounting holes, 14008 t, 14008 s, 14008 r, 14008 q, and 14008 p, respectively. Mounting screws, 14020 a and 14020 b, are mounted within the mounting holes, 14008 u and 14008 v, respectively. - A first
upper toggle link 14022 defines mounting holes, 14022 a and 14022 b, for receiving the mounting pins, 14016 a and 14016 b, and includes a mountingpin 14022 c at one end. A firstlower toggle link 14024 defines mounting holes, 14024 a, 14024 b, and 14024 c, for receiving the mounting pins, 14022 c, 14016 c, and 14016 d, respectively and includes anengagement arm 14024 d. Afirst trigger 14026 defines a mountinghole 14026 a for receiving the mountingpin 14016 e and includes anengagement arm 14026 b at one end, anengagement member 14026 c, and anengagement arm 14026 d at another end. - A second
upper toggle link 14028 defines mounting holes, 14028 a and 14028 b, for receiving the mounting pins, 14018 a and 14018 b, and includes a mounting pin 14028 c at one end. A secondlower toggle link 14030 defines mounting holes, 14030 a, 14030 b, and 14030 c, for receiving the mounting pins, 14028 c, 14018 c, and 14018 d, respectively and includes anengagement arm 14030 d. Asecond trigger 14032 defines a mountinghole 14032 a for receiving the mountingpin 14018 e and includes anengagement arm 14032 b at one end, anengagement member 14032 c, and anengagement arm 14032 d at another end. - An end of a
tubular spring housing 14034 that defines alongitudinal passage 14034 a, mounting holes, 14034 b and 14034 c, and mounting holes, 14034 ba and 14034 ca, and includes aninternal flange 14034 d and an internalannular recess 14034 e at one end, and aninternal flange 14034 f, an internalannular recess 14034 g, an internalannular recess 14034 h, and an external threaded connection 14034 i at another end receives and mates with the end of thetubular toggle bushing 14008. Mounting screws, 14035 a and 14035 b, are mounted within and coupled to the mounting holes, 14008 xb and 14008 xa, respectively, of thetubular toggle bushing 14008 and are received within the mounting holes, 14034 ba and 14034 ca, respectively, of thetubular spring housing 14034. - A tubular
retracting spring ring 14036 that defines mounting holes, 14036 a and 14036 b, receives and mates with a portion of the tubularlower mandrel 14006 and is received within and mates with a portion of thetubular spring housing 14034. Mounting screws, 14038 a and 14038 b, are mounted within and coupled to the mounting holes, 14036 a and 14036 b, respectively, of the tubularretracting spring ring 14036 and extend into the mounting holes, 14034 b and 14034 c, respectively, of thetubular spring housing 14034. - Casing diameter sensor springs, 14040 a and 14040 b, are positioned within the longitudinal slots, 14008 c and 1408 d, respectively, of the
tubular toggle bushing 14008 that engage the engagement members, 14026 c and 14032 c, and engagement arms, 14026 d and 14032 d, of the first and second triggers, 14026 and 14032, respectively. Aninner flange 14042 a of an end of atubular spring washer 14042 mates with and receives a portion of the tubularlower mandrel 14006 and an end face of the inner flange of the tubular spring washer is positioned proximate and end face of theexternal flange 14006 d of the tubular lower mandrel. Thetubular spring washer 14042 is further received within thelongitudinal passage 14034 a of thetubular spring housing 14034. - An end of a retracting
spring 14044 that receives the tubularlower mandrel 14006 is positioned within thetubular spring washer 14042 in contact with theinternal flange 14042 a of the tubular spring washer and the other end of the retracting spring is positioned in contact with an end face of the tubularretracting spring ring 14036. - A sealing
element 14046 is received within the externalannular recess 14006 j of the tubularlower mandrel 14006 for sealing the interface between the tubular lower mandrel and thetubular spring housing 14034. A sealingelement 14048 is received within the internalannular recess 14034 h of thetubular spring housing 14034 for sealing the interface between the tubular spring housing and the tubularlower mandrel 14006. - An internal threaded
connection 14050 a of an end of a tubularupper hinge sleeve 14050 that includes aninternal flange 14050 b and aninternal pivot 14050 c receives and is coupled to the external threaded connection 14034 i of the end of thetubular spring housing 14034. - An
external flange 14052 a of abase member 14052 b of anupper cam assembly 14052, that is mounted upon and receives the lowertubular mandrel 14006, that includes aninternal flange 14052 c that is received within the externalannular recess 14006 e of the lowertubular mandrel 14006 and a plurality of circumferentially spaced apartcam arms 14052 d extending from the base member mates with and is received within the tubularupper hinge sleeve 14050. Thebase member 14052 b of theupper cam assembly 14052 further includes a plurality of circumferentially spaced apartteeth 14052 f that mate with and are received within a plurality of circumferentially spaced apartteeth 14034 j provided on the end face of thetubular spring housing 14034 and an end face of theexternal flange 14052 a of the base member of the upper cam assembly is positioned in opposing relation to an end face of theinternal flange 14050 b of the tubularupper hinge sleeve 14050. Each of thecam arms 14052 d of theupper cam assembly 14052 include external cam surfaces 14052 e. In an exemplary embodiment, theteeth 14052 f of thebase member 14052 b of theupper cam assembly 14052 and theteeth 14034 j provided on the end face of thetubular spring housing 14034 permit torsional loads to be transmitted between the tubular spring housing and the upper cam assembly. - A plurality of circumferentially spaced apart upper
casing cutter segments 14054 are mounted upon and receive the lowertubular mandrel 14006 and each include anexternal pivot recess 14054 a for mating with and receiving theinternal pivot 14050 c of the tubularupper hinge sleeve 14050 and anexternal flange 14054 b and are pivotally mounted within the tubular upper hinge sleeve and are interleaved with the circumferentially spaced apartcam arms 14052 d of theupper cam assembly 14052. Acasing cutter element 14056 is coupled to and supported by the upper surface of each uppercasing cutter segments 14054 proximate theexternal flange 14054 b. - A plurality of circumferentially spaced apart lower
casing cutter segments 14058 are mounted upon and receive the lowertubular mandrel 14006, are interleaved among the uppercasing cutter segments 14054, are oriented in the opposite direction to the uppercasing cutter segments 14054, each include anexternal pivot recess 14058 a, and are positioned in opposing relation to corresponding circumferentially spaced apartcam arms 14052 d of theupper cam assembly 14052. - A
lower cam assembly 14060 is mounted upon and receives the lowertubular mandrel 14006 that includes abase member 14060 a having anexternal flange 14060 b, a plurality of circumferentially spaced apartcam arms 14060 d that extend from the base member that each include external cam surfaces 14060 e and define mountingholes base member 14060 a of thelower cam assembly 14060 further includes a plurality of circumferentially spaced apartteeth 14060 h. The circumferentially spaced apartcam arms 14060 d of thelower cam assembly 14060 are interleaved among the lowercasing cutter segments 14058 and the circumferentially spaced apartcam arms 14052 d of theupper cam assembly 14052 and positioned in opposing relation to corresponding uppercasing cutter segments 14054. - Mounting screws, 14062 a, 14062 b, 14062 c, and 14062 e, are mounted within the corresponding mounting holes, 14060 f and 14060 g, of the
lower cam assembly 14060 and are received within the externalannular recess 14006 g of thelower cam assembly 14060. - A tubular
lower hinge sleeve 14064 that receives the lowercasing cutter segments 14058 and thelower cam assembly 14060 includes aninternal flange 14064 a for engaging theexternal flange 14060 b of the base member of thelower cam assembly 14060, aninternal pivot 14064 b for engaging and receiving theexternal pivot recess 14058 a of the lowercasing cutter segments 14058 thereby pivotally mounting the lower casing cutter segments within the tubular lower hinge sleeve, and an internal threadedconnection 14064 c. - An external threaded
connection 14066 a of an end of atubular sleeve 14066 that defines mounting holes, 14066 b and 14066 c, and includes an internalannular recess 14066 d having ashoulder 14066 e, aninternal flange 14066 f, and an internal threadedconnection 14066 g at another end is received within and coupled to the internal threadedconnection 14064 c of the tubularlower hinge sleeve 14064. An external threadedconnection 14068 a of an end of atubular member 14068 that defines alongitudinal passage 14068 b and mounting holes, 14068 c and 14068 d, and includes an externalannular recess 14068 e, and an external threadedconnection 14068 f at another end is received within and is coupled to the internal threadedconnection 14066 g of thetubular sleeve 14066. - Mounting screws, 14070 a and 14070 b, are mounted in and coupled to the mounting holes, 14068 c and 14068 d, respectively, of the
tubular member 14068 that also extend into the mounting holes, 14066 b and 14066 c, respectively, of thetubular sleeve 14066. A sealingelement 14072 is received within the externalannular recess 14068 e of thetubular member 14068 for sealing the interface between the tubular member and thetubular sleeve 14066. - An internal threaded
connection 14074 a of atubular retracting piston 14074 that defines alongitudinal passage 14074 b and includes an internal annular recess 14074 c and an externalannular recess 14074 d receives and is coupled to the external threadedconnection 14006 i of the tubularlower mandrel 14006. A sealingelement 14076 is received within the externalannular recess 14074 d of thetubular retracting piston 14074 for sealing the interface between the tubular retracting piston and thetubular sleeve 14066. A sealingelement 14078 is received within the internal annular recess 14074 c of thetubular retracting piston 14074 for sealing the interface between the tubular retracting piston and the tubularlower mandrel 14006. - Locking
dogs 14080 mate with and receive theexternal teeth 14006 h of the tubularlower mandrel 14006. Aspacer ring 14082 is positioned between an end face of the lockingdogs 14080 and an end face of thelower cam assembly 14060. Arelease piston 14084 mounted upon the tubularlower mandrel 14006 defines aradial passage 14084 a for mounting aburst disk 14086 includes sealing elements, 14084 b, 14084 c, and 14084 d. The sealing elements, 14084 b and 14084 d, sealing the interface between therelease piston 14084 and the tubularlower mandrel 14006. An end face of therelease piston 14084 is positioned in opposing relation to an end face of the lockingdogs 14080. - A
release sleeve 14088 that receives and is mounted upon the lockingdogs 14080 and therelease piston 14084 includes aninternal flange 14088 a at one end that sealingly engages the tubularlower mandrel 14006. Abypass sleeve 14090 that receives and is mounted upon therelease sleeve 14088 includes aninternal flange 14090 a at one end. - In an exemplary embodiment, during operation of the
casing cutter assembly 14, the retractingspring 14044 is compressed and thereby applies a biasing spring force in adirection 14092 from the lowertubular mandrel 14006 to thetubular spring housing 14034 that, in the absence of other forces, moves and/or maintains theupper cam assembly 14052 and the uppercasing cutter segments 14054 out of engagement with the lowercasing cutter segments 14058 and thelower cam assembly 14060. In an exemplary embodiment, during operation of thecasing cutter assembly 14, an external threadedconnection 12 a of an end of thetubular support member 12 is coupled to the internal threadedconnection 14002 d of the upper tubular tool joint 14002 and an internal threadedconnection 16 a of an end of theball gripper assembly 16 is coupled to the external threadedconnection 14068 f of thetubular member 14068. - The
upper cam assembly 14052 and the uppercasing cutter segments 14054 may be brought into engagement with the lowercasing cutter segments 14058 and thelower cam assembly 14060 by pressurizing anannulus 14094 defined between the lowertubular mandrel 14006 and thetubular spring housing 14034. In particular, injection of fluidic materials into thecam cutter assembly 14 through thelongitudinal passage 14006 b of the lowertubular mandrel 14006 and into theradial passage 14006 ba may pressurize theannulus 14094 thereby creating sufficient operating pressure to generate a force in adirection 14096 sufficient to overcome the biasing force of the retractingspring 14044. As a result, thespring housing 14034 may be displaced in thedirection 14096 relative to the lowertubular mandrel 14006 thereby displacing the tubularupper hinge sleeve 14050,upper cam assembly 14052, and uppercasing cutter segments 14054 in thedirection 14096. - In an exemplary embodiment, as illustrated in
FIGS. 11P, 11Q and 11R, the displacement of theupper cam assembly 14052 and uppercasing cutter segments 14054 in thedirection 14096 will cause the lowercasing cutter segments 14058 to ride up the cam surfaces of the cam arms of theupper cam assembly 14052 while also pivoting about the lowertubular hinge segment 14064, and will also cause the uppercasing cutter segments 14054 to ride up the cam surfaces of the cam arms of thelower cam assembly 14060 while also pivoting about the uppertubular hinge segment 14050. - In an exemplary embodiment, during the operation of the
casing cutter assembly 14, when the upper and lower casing cutter segments, 14054 and 14058, brought into axial alignment in a radially expanded position, the casing cutter elements of the casing cutter segments are brought into intimate contact with the interior surface of a pre-selected portion of theexpandable wellbore casing 100. Thecasing cutter assembly 14 may then be rotated to thereby cause the casing cutter elements to cut through the expandable wellbore casing. The portion of theexpandable wellbore casing 100 cut away from the remaining portion on the expandable wellbore casing may then be carried out of thewellbore 102 with the cut away portion of the expandable wellbore casing supported by the casing cutter elements. - In an exemplary embodiment, the
upper cam assembly 14052 and the uppercasing cutter segments 14054 may be moved out of engagement with the lowercasing cutter segments 14058 and thelower cam assembly 14060 by reducing the operating pressure within theannulus 14094. - In an alternative embodiment, as illustrated in
FIGS. 11S, 11T , 11U and 11V, during operation of thecasing cutter assembly 14, theupper cam assembly 14052 and the uppercasing cutter segments 14054 may also be moved out of engagement with the lowercasing cutter segments 14058 and thelower cam assembly 14060 by sensing the operating pressure within thelongitudinal passage 14006 b of the lowertubular mandrel 14006. In particular, as illustrated inFIG. 11T , if the operating pressure within thelongitudinal passage 14006 b andradial passage 14006 bb of the lowertubular mandrel 14006 exceeds a predetermined value, theburst disc 14086 will open thepassage 14084 a thereby pressurizing the interior of thetubular release sleeve 14088 thereby displacing thetubular release sleeve 14088 downwardly in adirection 14092 away from engagement with the lockingdogs 14080. - As a result, as illustrated in
FIG. 11U , the lockingdogs 14080 are displaced outwardly in the radial directed and thereby released from engagement with the lowertubular mandrel 14006 thereby permitting the lowercasing cutter segments 14058 and thelower cam assembly 14060 to be displaced downwardly relative to the lower tubular mandrel. - As a result, as illustrated in
FIG. 11V , the operating pressure within the lowertubular mandrel 14066 may then cause the lower tubular mandrel to be displaced downwardly in thedirection 14094 relative to the tubularlower mandrel 14006 and theretracting piston 14074. As a result, the lowertubular mandrel 14066, the lowercasing cutter segments 14058, thelower cam assembly 14060, and tubularlower hinge sleeve 14064 are displaced downwardly in thedirection 14094 relative to thetubular spring housing 14034 thereby moving the lowercasing cutter segments 14058 and thelower cam assembly 14060 out of engagement with theupper cam assembly 14052 and the uppercasing cutter segments 14054. - In an exemplary embodiment, as illustrated in
FIGS. 11W, 11X , and 11Y, during operation of thecasing cutter assembly 14, thecasing cutter assembly 14 senses the diameter of theexpandable wellbore casing 100 using the upper toggle links, 14022 and 14028, lower toggle links, 14024 and 14030, and triggers, 14026 and 14032, and then prevents the engagement of theupper cam assembly 14052 and the uppercasing cutter segments 14054 with the lowercasing cutter segments 14058 and thelower cam assembly 14060. - In particular, as illustrated in
FIG. 11W , anytime the upper toggle links, 14022 and 14028, and lower toggle links, 14024 and 14030, are positioned within a portion of theexpandable wellbore casing 100 that has been radially expanded and plastically deformed by thesystem 10, the triggers, 14026 and 14032, will be pivoted by the engagement arms, 14024 d and 14030 d, of the lower toggle links, 14024 and 14030, to a position in which the triggers will no longer engage theinternal flange 14034 d of the end of thetubular spring housing 14034 thereby permitting the displacement of the tubular spring housing in thedirection 14096. As a result, theupper cam assembly 14052 and the uppercasing cutter segments 14054 can be brought into engagement with the lowercasing cutter segments 14058 and thelower cam assembly 14060. In an exemplary embodiment, the upper toggle links, 14022 and 14028, and the lower toggle links, 14024 and 14030, are spring biased towards the position illustrated inFIG. 11W . - Conversely, as illustrated in
FIG. 11X , anytime the upper toggle links, 14022 and 14028, and lower toggle links, 14024 and 14030, are positioned within a portion of theexpandable wellbore casing 100 that has not been radially expanded and plastically deformed by thesystem 10, the triggers, 14026 and 14032, will be maintained in a position in which the triggers will engage theinternal flange 14034 d of the end of thetubular spring housing 14034 thereby preventing the displacement of the tubular spring housing in thedirection 14096. As a result, theupper cam assembly 14052 and the uppercasing cutter segments 14054 cannot be brought into engagement with the lowercasing cutter segments 14058 and thelower cam assembly 14060. In an exemplary embodiment, the triggers, 14026 and 14032, are spring biased towards the position illustrated inFIG. 11X . - In an exemplary embodiment, as illustrated in
FIG. 11Y , thetubular spring housing 14034 may be displaced upwardly in thedirection 14098 even if the upper toggle links, 14022 and 14028, and lower toggle links, 14024 and 14030, are positioned within a portion of theexpandable wellbore casing 100 that has not been radially expanded and plastically deformed by thesystem 10. - In an exemplary embodiment, as illustrated in FIGS. 11Z1 to 11Z4, 11AA1 to 11AA4, 11AB1 to 11AB4, 11AC1 to 11AC4, 11AD, and 11AE, the
tubular spring housing 14034 of thecasing cutter assembly 14 defines internalannular recesses 14034 k and 14034 l, spaced apart by aninternal flange 14034 m, thetubular toggle bushing 14008 defines an externalannular recess 14008 ac, and the casing cutter assembly further includes pins, 14100 a and 14100 b and 14102 a and 14102 b, mounted inholes shot deactivation device 14104 mounted on the tubular toggle bushing between the pins, 14100 a and 14100 b and 14102 a and 14102 b. - The one-
shot deactivation device 14104 includes atubular body 14104 a that defines radial holes, 14104 b and 14014 c, and includes an externalannular recess 14104 d at one end, a centrally positionedexternal flange 14104 e, a centrally positioned internalannular recess 14104 f, and an externalannular recess 14104 g at another end. Anengagement member 14106 that includes abase member 14106 a having atapered end 14106 b and akey member 14106 c having atapered end 14106 d is received within a portion of the internalannular recess 14104 f of thetubular body 14104 a and an engagement member 14108 that includes abase member 14108 a having atapered end 14108 b and akey member 14108 c having atapered end 14108 d is received within an opposite portion of the internalannular recess 14104 f of thetubular body 14104 a. Spring members, 14110 and 14112, are received within theannular recess 14104 f of thetubular body 14104 a for biasing the base members,base member tubular body 14104 a. - In an exemplary embodiment, during operation of the
casing cutter assembly 14, as illustrated in FIGS. 11Z1 to 11Z4, the one-shot deactivation device 14104 are positioned proximate and in intimate contact with the pins, 14102 a and 14102 b, with the tapered ends, 14106 b and 14108 b, of the base members, 14106 a and 14108 a, of the engagement members, 14106 and 14108, received within the externalannular recess 14008 ac of thetubular toggle bushing 14008. When the one-shot deactivation device 14104 is positioned as illustrated inFIG. 11Z , the externalannular recess 14104 d of thetubular body 14104 a of the one-shot deactivation device is moved out of engagement with the engagement arms, 14026 d and 14032 d, of the triggers, 14026 and 14032, respectively. As a result, the triggers, 14026 and 14032, may operate normally as described above with reference toFIGS. 11W, 11X , and 11Y. - Conversely, in an exemplary embodiment, during operation of the
casing cutter assembly 14, as illustrated in FIGS. 11AA1 to 11AA4, the one-shot deactivation device 14104 are positioned proximate and in intimate contact with the pins, 14100 a and 14100 b, with the tapered ends, 14106 b and 14108 b, of the base members, 14106 a and 14108 a, of the engagement members, 14106 and 14108, not received within the externalannular recess 14008 ac of thetubular toggle bushing 14008. When the one-shot deactivation device 14104 is positioned as illustrated in FIGS. 11AA1 to 11AA4, the externalannular recess 14104 d of thetubular body 14104 a of the one-shot deactivation device is moved into engagement with the engagement arms, 14026 d and 14032 d, of the triggers, 14026 and 14032, respectively. As a result, the triggers, 14026 and 14032, are deactivated and may not operate normally as described above with reference toFIGS. 11W, 11X , and 11Y. - In an alternative embodiment, the elements of the
casing cutter assembly 14 that sense the diameter of theexpandable wellbore casing 100 may be disabled or omitted or adjusted to sense any pre-selected internal diameter of the expandable wellbore casing. - In an exemplary embodiment, the
ball gripper assembly 16 is provided and operates substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22, 2003, (2) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, and/or (3) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (4) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (5) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference. - In an exemplary embodiment, as illustrated in FIGS. 12A1 to 12A4, 12B and 12C1 to 12C4, the
ball gripper assembly 16 includes anupper mandrel 1602 that defines alongitudinal passage 1602 a and aradial passage 1602 b and includes an internal threadedconnection 1602 c at one end, anexternal flange 1602 d at an intermediate portion that includes an externalannular recess 1602 e having ashoulder 1602 f and an externalradial hole 1602 g, an externalannular recess 1602 h, an externalannular recess 1602 i, an externalannular recess 1602 j having atapered end 1602 k including an externalannular recess 1602 ka, an externalannular recess 16021, and an externalannular recess 1602 m, and an externalannular recess 1602 n, an external radial hole 1602 o, an externalannular recess 1602 p, and an external annular recess 1602 q at another end. - An
upper tubular bushing 1604 defines an internally threadedradial opening 1604 a and includes anexternal flange 1604 b having an externalannular recess 1604 c and an internalannular recess 1604 d mates with and receives theexternal flange 1602 d of theupper mandrel 1602. In particular, the internalannular recess 1604 d of theupper tubular bushing 1604 mates with theshoulder 1602 f of the externalannular recess 1602 e of theupper mandrel 1602. Ascrew 1606 that is threadably coupled to the internally threadedradial opening 1604 a of theupper tubular bushing 1604 extends into the externalradial hole 1602 g of theexternal flange 1602 d of theupper mandrel 1602. - A
deactivation tubular sleeve 1608 defines aradial passage 1608 a and includes an internalannular recess 1608 b that mates with and receives an end of the externalannular recess 1604 c of theexternal flange 1604 b of theupper tubular bushing 1604, an internalannular recess 1608 c that mates with and receives theexternal flange 1602 d of theupper mandrel 1602, an internalannular recess 1608 d, an internalannular recess 1608 e, and an internalannular recess 1608 f. Adeactivation spring 1610 is received within anannulus 1612 defined between the internalannular recess 1608 b of thedeactivation tubular sleeve 1608, an end face of the externalannular recess 1604 c of theexternal flange 1604 b of theupper tubular bushing 1604, and the externalannular recess 1602 h of theexternal flange 1602 d of theupper mandrel 1602. - A sealing
member 1614 is received with the externalannular recess 1602 i of theexternal flange 1602 d of theupper mandrel 1602 for sealing the interface between the upper mandrel and thedeactivation tubular sleeve 1608. Anannular spacer element 1616 is received within the externalannular recess 1602 ka of thetapered end 1602 k of the externalannular recess 1602 j of theupper mandrel 1602. - One or more
inner engagement elements 1618 a of atubular coglet 1618 engage and are received within the externalannular recess 1602 ka of thetapered end 1602 k of the externalannular recess 1602 j of theupper mandrel 1602 and one or moreouter engagement elements 1618 b of the coglet engage and are received within the internalannular recess 1608 d of thedeactivation tubular sleeve 1608. - An external
annular recess 1620 a of an end of atubular coglet prop 1620 that includes aninner flange 1620 b receives and mates with the inner surfaces of theouter engagement elements 1618 b of thecoglet 1618. The end of thetubular coglet prop 1620 further receives and mates with the externalannular recess 1602 j of theexternal flange 1602 d of theupper mandrel 1602. Asealing element 1622 is received within the external annular recess 1602 l of theupper mandrel 1602 for sealing the interface between the upper mandrel and thetubular coglet prop 1620. - An end of a
tubular bumper sleeve 1624 that includes internal and external flanges, 1624 a and 1624 b, and ahole 1624 c at another end mates with and receives the externalannular recess 1602 m of theexternal flange 1602 d of theupper mandrel 1602. Acoglet spring 1626 is received within anannulus 1628 defined between the externalannular recess 1602 m of theexternal flange 1602 d of theupper mandrel 1602, thetubular coglet prop 1620, theinner flange 1620 b of the tubular coglet prop, an end face of thetubular bumper sleeve 1624, and the internalannular recess 1608 c of thedeactivation tubular sleeve 1608. - A
tubular ball race 1628 that defines a plurality of taperedannular recesses 1628 a and an internally threadedradial opening 1628 b and includes one or moreaxial engagement elements 1628 c at one end and one or moreaxial engagement elements 1628 d at another end receives and mates with the other end of theupper mandrel 1602. In an exemplary embodiment, theaxial engagement elements 1628 c of thetubular ball race 1628 are received within and are coupled to thehole 1624 c of thetubular bumper sleeve 1624. An end of atubular activation sleeve 1630 that defines a plurality ofradial openings 1630 a, aradial opening 1630 b, aradial opening 1630 c, and includes an internalannular recess 1630 d receives and mates with thetubular ball race 1628. In an exemplary embodiment, an end face of an end of thetubular activation sleeve 1630 is positioned proximate and in opposing relation to an end face of an end of thedeactivation sleeve 1608. In an exemplary embodiment, theradial openings 1630 a are aligned with and positioned in opposing relation to corresponding of taperedannular recesses 1628 a of thetubular ball race 1628, and the radial openings are also narrowed in cross section in the radial direction for reasons to be described. -
Balls 1632 are received within each of the of taperedannular recesses 1628 a and correspondingradial openings 1630 a of thetubular ball race 1628 andtubular activation sleeve 1630, respectively. In an exemplary embodiment, the narrowed cross sections of theradial openings 1630 a of thetubular activation sleeve 1630 will permit theballs 1632 to be displaced outwardly in the radial direction until at least a portion of the balls extends beyond the outer perimeter of the tubular activation sleeve to thereby permit engagement of the balls with an outer structure such as, for example, a wellbore casing. - A
lower mandrel 1634 that defines alongitudinal passage 1634 a and an internally threadedradial passage 1634 b at one end and includes internal annular recesses, 1634 c and 1634 d, for receiving and mating with the external annular recesses, 1602 p and 1602 q, of theupper mandrel 1602, an internalannular recess 1634 e, anexternal flange 1634 f, and an externally threadedconnection 1634 g at another end. In an exemplary embodiment, as illustrated inFIG. 12B , the end of thelower mandrel 1634 further includeslongitudinal recesses 1634 h for receiving and mating with correspondingaxial engagement elements 1628 d of thetubular ball race 1628. Asealing element 1635 is received within the internalannular recess 1634 d of thelower mandrel 1634 for sealing an interface between the lower mandrel and the externalannular recess 1602 p of theupper mandrel 1602. - A
tubular spring retainer 1636 that defines aradial passage 1636 a and includes an externalannular recess 1636 b at one end mates with and receives the end of thelower mandrel 1634 and is positioned proximate an end face of theexternal flange 1634 f of the lower mandrel. Atubular spring retainer 1638 receives and mates with the end of thelower mandrel 1634 and is received and mates with the internalannular recess 1630 d of thetubular activation sleeve 1630. - An
activation spring 1640 is received within anannulus 1642 defined an end face of thetubular spring retainer 1638, an end face of thespring retainer 1636, the internalannular recess 1630 d of thetubular activation sleeve 1630, and the end of thelower mandrel 1634. Aretainer screw 1642 is received within and is threadably coupled to the internally threadedradial opening 1634 b of thelower mandrel 1634 that also extends into the external radial hole 1602 o of theupper mandrel 1602. - During operation of the
ball gripper assembly 16, in an exemplary embodiment, as illustrated in FIGS. 12A1 to 12A4, the ball gripper assembly may be positioned within theexpandable wellbore casing 100 and the internally threadedconnection 1602 c of theupper mandrel 1602 may be coupled to an externally threadedconnection 14 a of an end of thecasing cutter assembly 14 and the externally threadedconnection 1634 g of thelower mandrel 1634 may be coupled to an internally threadedconnection 18 a of an end of thetension actuator assembly 18. - In an alternative embodiment, the internally threaded
connection 1602 c of theupper mandrel 1602 may be coupled to an externally threaded connection of an end of thetension actuator assembly 18 and the externally threadedconnection 1634 g of thelower mandrel 1634 may be coupled to an internally threaded connection of an end ofcasing cutter assembly 14. - In an exemplary embodiment, the
deactivation spring 1610 has a greater spring rate than theactivation spring 1640. As a result, in an initial operating mode, as illustrated in FIGS. 12A1 to 12A4, a biasing spring force is applied to thedeactivation sleeve 1608 andactivation sleeve 1630 in adirection 1644 that maintains the activation sleeve in a position relative to thetubular ball race 1628 that maintains theballs 1632 within the radially inward portions of the corresponding taperedannular recesses 1628 a of the tubular ball race such that the balls do not extend beyond the perimeter of the activation sleeve to engage theexpandable wellbore casing 100. - As illustrated in FIGS. 12C1 to 12C4, in an exemplary embodiment, the
ball gripper 16 may be operated to engage the interior surface of theexpandable wellbore casing 100 by injecting afluidic material 1650 into the ball gripper assembly through thelongitudinal passages - In particular, when the longitudinal and radial passages, 1602 a and 1602 b, respectively, of the
upper mandrel 1602 are pressurized by the injection of thefluidic material 1650, the internalannular recess 1608 c of thedeactivation tubular sleeve 1608 is pressurized. When the operating pressure of thefluidic material 1650 within the internalannular recess 1608 c of thedeactivation tubular sleeve 1608 is sufficient to overcome the biasing spring force of thedeactivation spring 1610, the deactivation tubular sleeve is displaced in adirection 1652. As a result, the spring force provided by theactivation spring 1640 then may displace theactivation tubular sleeve 1630 in thedirection 1652 thereby moving theballs 1632 on the corresponding taperedannular recesses 1628 a of thetubular ball race 1628 outwardly in a radial direction into engagement with the interior surface of theexpandable wellbore casing 100. In an exemplary embodiment, the operating pressure of thefluidic material 1650 sufficient to overcome the biasing spring force of thedeactivation spring 1610 was about 100 psi. - In an exemplary embodiment, when the operating pressure of the
fluidic material 1650 is reduced, the operating pressure of thefluidic material 1650 within the internalannular recess 1608 c of thedeactivation tubular sleeve 1608 is no longer sufficient to overcome the biasing spring force of thedeactivation spring 1610, and the deactivation tubular sleeve and theactivation tubular sleeve 1630 are displaced in a direction opposite to thedirection 1652 thereby moving theballs 1632 radially inwardly and out of engagement with the interior surface of theexpandable wellbore casing 100. - In an exemplary embodiment, the
ball gripper assembly 16 is operated to engage the interior surface of theexpandable wellbore casing 100 in combination with the operation of thetension actuator assembly 18 to apply an upward tensile force to one or more elements of thesystem 10 coupled to and positioned below the tension actuator assembly. As a result, a reaction force comprising a downward tensile force is applied to thelower mandrel 1634 of theball gripper assembly 16 in a direction opposite to thedirection 1652 during the operation of thetension actuator assembly 18. Consequently, due to the geometry of the tapered 1628 a of thetubular ball race 1628, theballs 1632 are driven up the taperedannular recesses 1628 a of thetubular ball race 1628 with increased force and the contact force between theballs 1632 and the interior surface of theexpandable wellbore casing 100 is significantly increased thereby correspondingly increasing the gripping force and effect of the ball gripper assembly. - In an exemplary embodiment, the
ball gripper assembly 16 may be operated to radially expand and plastically deform discrete portions of theexpandable wellbore casing 100 by controlling the amount of contact force applied to the interior surface of the expandable wellbore casing by theballs 1632 of the ball gripper assembly. In an experimental test of an exemplary embodiment of theball gripper assembly 16, an expandable wellbore casing was radially expanded and plastically deformed. This was an unexpected result. - In an exemplary embodiment, the
tension actuator assembly 18 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, and/or (2) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22, 2003, and/or (3) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, and/or (4) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on Sep. 23, 2003, and/or (5) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (6) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (7) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference. - In an exemplary embodiment, as illustrated in FIGS. 13A1 to 13A8 and 13B1 to 13B7, the
tension actuator assembly 18 includes an uppertubular support member 18002 that defines alongitudinal passage 18002 a, and external internally threaded radial openings, 18002 b and 18002 c, and an externalannular recess 18002 d and includes an internally threadedconnection 18002 e at one end and anexternal flange 18002 f, an externalannular recess 18002 g having an externally threaded connection, and an internalannular recess 18002 h having an internally threaded connection at another end. An end of atubular actuator barrel 18004 that defines radial passages, 18004 a and 18004 b, at one end and radial passages, 18004 c and 18004 d, includes an internally threadedconnection 18004 e at one end that mates with, receives, and is threadably coupled to the externalannular recess 18002 g of the uppertubular support member 18002 and abuts and end face of theexternal flange 18002 f of the upper tubular support member and an internally threadedconnection 18004 f at another end. - Torsional locking pins, 18006 a and 18006 b, are coupled to and mounted within the external radial mounting holes, 18002 b and 18002 c, respectively, of the upper tubular support member and received within the radial passages, 18004 a and 18004 b, of the end of the
tubular actuator barrel 18004. The other end of thetubular actuator barrel 18004 receives and is threadably coupled to an end of atubular barrel connector 18008 that defines an internalannular recess 18008 a, external radial mounting holes, 18008 b and 18008 c, radial passages, 18008 d and 18008 e, and external radial mounting holes, 18008 f and 18008 g and includes circumferentially spaced apartteeth 18008 h at one end. A sealingcartridge 18010 is received within and coupled to the internalannular recess 18008 a of thetubular barrel connector 18008 for fluidicly sealing the interface between the tubular barrel connector and the sealing cartridge. Torsional locking pins, 18012 a and 18012 b, are coupled to and mounted within the external radial mounting holes, 18008 b and 18008 c, respectively, of thetubular barrel connector 18008 and received within the radial passages, 18004 c and 18004 d, of thetubular actuator barrel 18004. - A
tubular member 18014 that defines alongitudinal passage 18014 a having one or moreinternal splines 18014 b at one end and circumferentially spaced apartteeth 18014 c at another end for engaging the circumferentially spaced apartteeth 18008 h of thetubular barrel connector 18008 mates with and is received within theactuator barrel 18004 and the one end of the tubular member abuts an end face of the other end of the uppertubular support member 18002 and at another end abuts and end face of thetubular barrel connector 18008. Atubular guide member 18016 that defines alongitudinal passage 18016 a having a taperedopening 18016 aa, and radial passages, 18016 b and 18016 c, includes anexternal flange 18016 d having an externally threaded connection at one end that is received within and coupled to the internalannular recess 18002 h of the uppertubular support member 18002. - The other end of the
tubular barrel connector 18008 is threadably coupled to and is received within an end of atubular actuator barrel 18018 that defines alongitudinal passage 18018 a, radial passages, 18018 b and 18018 c, and radial passages, 18018 d and 18018 e. Torsional locking pins, 18020 a and 18020 b, are coupled to and mounted within the external radial mounting holes, 18008 f and 18008 g, respectively, of thetubular barrel connector 18008 and received within the radial passages, 18018 b and 18018 c, of thetubular actuator barrel 18018. The other end of thetubular actuator barrel 18018 receives and is threadably coupled to an end of atubular barrel connector 18022 that defines an internalannular recess 18022 a, external radial mounting holes, 18022 b and 18022 c, radial passages, 18022 d and 18022 e, and external radial mounting holes, 18022 f and 18022 g. A sealingcartridge 18024 is received within and coupled to the internalannular recess 18022 a of thetubular barrel connector 18022 for fluidicly sealing the interface between the tubular barrel connector and the sealing cartridge. Torsional locking pins, 18024 a and 18024 b, are coupled to and mounted within the external radial mounting holes, 18022 b and 18022 c, respectively, of thebarrel connector 18022 and received within the radial passages, 18018 d and 18018 e, of thetubular actuator barrel 18018. - The other end of the
tubular barrel connector 18022 is threadably coupled to and is received within an end of atubular actuator barrel 18026 that defines alongitudinal passage 18026 a, radial passages, 18026 b and 18026 c, and radial passages, 18026 d and 18026 e. Torsional locking pins, 18028 a and 18028 b, are coupled to and mounted within the external radial mounting holes, 18022 f and 18022 g, respectively, of thetubular barrel connector 18022 and received within the radial passages, 18026 b and 18026 c, of thetubular actuator barrel 18026. The other end of thetubular actuator barrel 18026 receives and is threadably coupled to an end of atubular barrel connector 18030 that defines an internalannular recess 18030 a, external radial mounting holes, 18030 b and 18030 c, radial passages, 18030 d and 18030 e, and external radial mounting holes, 18030 f and 18030 g. A sealingcartridge 18032 is received within and coupled to the internalannular recess 18030 a of thetubular barrel connector 18030 for fluidicly sealing the interface between the tubular barrel connector and the sealing cartridge. Torsional locking pins, 18034 a and 18034 b, are coupled to and mounted within the external radial mounting holes, 18030 b and 18030 c, respectively, of thetubular barrel connector 18030 and received within the radial passages, 18026 d and 18026 e, of thetubular actuator barrel 18026. - The other end of the
tubular barrel connector 18030 is threadably coupled to and is received within an end of atubular actuator barrel 18036 that defines alongitudinal passage 18036 a, radial passages, 18036 b and 18036 c, and radial passages, 18036 d and 18036 e. Torsional locking pins, 18038 a and 18038 b, are coupled to and mounted within the external radial mounting holes, 18030 f and 18030 g, respectively, of thetubular barrel connector 18030 and received within the radial passages, 18036 b and 18036 c, of thetubular actuator barrel 18036. The other end of thetubular actuator barrel 18036 receives and is threadably coupled to an end of atubular barrel connector 18040 that defines an internalannular recess 18040 a, external radial mounting holes, 18040 b and 18040 c, radial passages, 18040 d and 18040 e, and external radial mounting holes, 18040 f and 18040 g. A sealingcartridge 18042 is received within and coupled to the internalannular recess 18040 a of thetubular barrel connector 18040 for fluidicly sealing the interface between the tubular barrel connector and the sealing cartridge. Torsional locking pins, 18044 a and 18044 b, are coupled to and mounted within the external radial mounting holes, 18040 b and 18040 c, respectively, of thetubular barrel connector 18040 and received within the radial passages, 18036 d and 18036 e, of thetubular actuator barrel 18036. - The other end of the
tubular barrel connector 18040 is threadably coupled to and is received within an end of atubular actuator barrel 18046 that defines alongitudinal passage 18046 a, radial passages, 18046 b and 18046 c, and radial passages, 18046 d and 18046 e. Torsional locking pins, 18048 a and 18048 b, are coupled to and mounted within the external radial mounting holes, 18040 f and 18040 g, respectively, of thetubular barrel connector 18040 and received within the radial passages, 18046 b and 18046 c, of thetubular actuator barrel 18046. The other end of thetubular actuator barrel 18046 receives and is threadably coupled to an end of atubular barrel connector 18050 that defines an internalannular recess 18050 a, external radial mounting holes, 18050 b and 18050 c, radial passages, 18050 d and 18050 e, and external radial mounting holes, 18050 f and 18050 g. A sealingcartridge 18052 is received within and coupled to the internalannular recess 18050 a of thetubular barrel connector 18050 for fluidicly sealing the interface between the tubular barrel connector and the sealing cartridge. Torsional locking pins, 18054 a and 18054 b, are coupled to and mounted within the external radial mounting holes, 18050 b and 18050 c, respectively, of thetubular barrel connector 18050 and received within the radial passages, 18046 d and 18046 e, of thetubular actuator barrel 18046. - The other end of the
tubular barrel connector 18050 is threadably coupled to and is received within an end of atubular actuator barrel 18056 that defines alongitudinal passage 18056 a, radial passages, 18056 b and 18056 c, and radial passages, 18056 d and 18056 e. Torsional locking pins, 18058 a and 18058 b, are coupled to and mounted within the external radial mounting holes, 18050 f and 18050 g, respectively, of thetubular barrel connector 18050 and received within the radial passages, 18056 b and 18056 c, of thetubular actuator barrel 18056. The other end of thetubular actuator barrel 18056 receives and is threadably coupled to an end of a tubularlower stop 18060 that defines an internalannular recess 18060 a, external radial mounting holes, 18060 b and 18060 c, and an internalannular recess 18060 d that includes one or more circumferentially spaced apart lockingteeth 18060 e at one end and one or more circumferentially spaced apart lockingteeth 18060 f at the other end. A sealingcartridge 18062 is received within and coupled to the internalannular recess 18060 a of the tubularlower stop 18060 for fluidicly sealing the interface between the tubular lower stop and the sealing cartridge. Torsional locking pins, 18064 a and 18064 b, are coupled to and mounted within the external radial mounting holes, 18060 b and 18060 c, respectively, of the tubularlower stop 18060 and received within the radial passages, 18056 d and 18056 e, of thetubular actuator barrel 18056. - A
connector tube 18066 that defines alongitudinal passage 18066 a and radial mounting holes, 18066 b and 18066 c, and includesexternal splines 18066 d at one end for engaging theinternal splines 18014 b of thetubular member 18014 and radial mounting holes, 18066 e and 18066 f, at another end is received within and sealingly and movably engages the interior surface of the sealingcartridge 18010 mounted within theannular recess 18008 a of thetubular barrel connector 18008. In this manner, during longitudinal displacement of theconnector tube 18066 relative to thetubular barrel connector 18008, a fluidic seal is maintained between the exterior surface of the connector tube and the interior surface of the tubular barrel connector. An end of theconnector tube 18066 also receives and mates with the other end of thetubular guide member 18016. Mounting screws, 18068 a and 18068 b, are coupled to and received within the radial mounting holes, 18066 b and 18066 c, respectively of theconnector tube 18066. - The other end of the
connector tube 18066 is received within and threadably coupled to an end of atubular piston 18070 that defines alongitudinal passage 18070 a, radial mounting holes, 18070 b and 18070 c, radial passages, 18070 d and 18070 e, and radial mounting holes, 18070 f and 18070 g, that includes aflange 18070 h at one end. A sealingcartridge 18072 is mounted onto and sealingly coupled to the exterior of thetubular piston 18070 proximate theflange 18070 h. The sealingcartridge 18072 also mates with and sealingly engages the interior surface of thetubular actuator barrel 18018. In this manner, during longitudinal displacement of thetubular piston 18070 relative to theactuator barrel 18018, a fluidic seal is maintained between the exterior surface of the piston and the interior surface of the actuator barrel. Mounting screws, 18074 a and 18074 b, are coupled to and mounted within the external radial mounting holes, 18070 b and 18070 c, respectively, of thetubular piston 18070 and received within the radial passages, 18066 e and 18066 f, of theconnector tube 18066. - The other end of the
tubular piston 18070 receives and is threadably coupled to an end of aconnector tube 18076 that defines alongitudinal passage 18076 a, radial mounting holes, 18076 b and 18076 c, at one end and radial mounting holes, 18076 d and 18076 e, at another end. Theconnector tube 18076 is received within and sealingly and movably engages the interior surface of the sealingcartridge 18024 mounted within theannular recess 18022 a of thetubular barrel connector 18022. In this manner, during longitudinal displacement of theconnector tube 18076 relative to thetubular barrel connector 18022, a fluidic seal is maintained between the exterior surface of the connector tube and the interior surface of the barrel connector. Mounting screws, 18078 a and 18078 b, are coupled to and mounted within the external radial mounting holes, 18070 f and 18070 g, respectively, of thetubular piston 18070 and received within the radial passages, 18076 b and 18076 c, of theconnector tube 18076. - The other end of the
connector tube 18076 is received within and threadably coupled to an end of atubular piston 18080 that defines alongitudinal passage 18080 a, radial mounting holes, 18080 b and 18080 c, radial passages, 18080 d and 18080 e, and radial mounting holes, 18080 f and 18080 g, that includes aflange 18080 h at one end. A sealingcartridge 18082 is mounted onto and sealingly coupled to the exterior of thetubular piston 18080 proximate theflange 18080 h. The sealingcartridge 18082 also mates with and sealingly engages the interior surface of thetubular actuator barrel 18026. In this manner, during longitudinal displacement of thetubular piston 18080 relative to thetubular actuator barrel 18026, a fluidic seal is maintained between the exterior surface of the piston and the interior surface of the actuator barrel. Mounting screws, 18084 a and 18084 b, are coupled to and mounted within the external radial mounting holes, 18080 b and 18080 c, respectively, of thetubular piston 18080 and received within the radial passages, 18076 e and 18076 f, of theconnector tube 18076. - The other end of the
tubular piston 18080 receives and is threadably coupled to an end of aconnector tube 18086 that defines alongitudinal passage 18086 a, radial mounting holes, 18086 b and 18086 c, at one end and radial mounting holes, 18086 d and 18086 e, at another end. Theconnector tube 18086 is received within and sealingly and movably engages the interior surface of the sealingcartridge 18032 mounted within theannular recess 18030 a of thetubular barrel connector 18030. In this manner, during longitudinal displacement of theconnector tube 18086 relative to thetubular barrel connector 18030, a fluidic seal is maintained between the exterior surface of the connector tube and the interior surface of the barrel connector. Mounting screws, 18088 a and 18088 b, are coupled to and mounted within the external radial mounting holes, 18080 f and 18080 g, respectively, of thetubular piston 18080 and received within the radial passages, 18086 b and 18086 c, of theconnector tube 18086. - The other end of the
connector tube 18086 is received within and threadably coupled to an end of atubular piston 18090 that defines alongitudinal passage 18090 a, radial mounting holes, 18090 b and 18090 c, radial passages, 18090 d and 18090 e, and radial mounting holes, 18090 f and 18090 g, that includes aflange 18090 h at one end. A sealingcartridge 18092 is mounted onto and sealingly coupled to the exterior of thetubular piston 18090 proximate theflange 18090 h. The sealingcartridge 18092 also mates with and sealingly engages the interior surface of thetubular actuator barrel 18036. In this manner, during longitudinal displacement of thetubular piston 18090 relative to thetubular actuator barrel 18036, a fluidic seal is maintained between the exterior surface of the piston and the interior surface of the actuator barrel. Mounting screws, 18094 a and 18094 b, are coupled to and mounted within the external radial mounting holes, 18090 b and 18090 c, respectively, of thetubular piston 18090 and received within the radial passages, 18086 e and 18086 f, of theconnector tube 18086. - The other end of the
tubular piston 18090 receives and is threadably coupled to an end of aconnector tube 18096 that defines alongitudinal passage 18096 a, radial mounting holes, 18096 b and 18096 c, at one end and radial mounting holes, 18096 d and 18096 e, at another end. Theconnector tube 18096 is received within and sealingly and movably engages the interior surface of the sealingcartridge 18042 mounted within theannular recess 18040 a of thetubular barrel connector 18040. In this manner, during longitudinal displacement of theconnector tube 18096 relative to thetubular barrel connector 18040, a fluidic seal is maintained between the exterior surface of the connector tube and the interior surface of the barrel connector. Mounting screws, 18098 a and 18098 b, are coupled to and mounted within the external radial mounting holes, 18090 f and 18090 g, respectively, of thetubular piston 18090 and received within the radial passages, 18096 b and 18096 c, of theconnector tube 18096. - The other end of the
connector tube 18096 is received within and threadably coupled to an end of atubular piston 18100 that defines alongitudinal passage 18100 a, radial mounting holes, 18100 b and 18100 c, radial passages, 18100 d and 18100 e, and radial mounting holes, 18100 f and 18100 g, that includes aflange 18100 h at one end. A sealingcartridge 18102 is mounted onto and sealingly coupled to the exterior of thetubular piston 18100 proximate theflange 18100 h. The sealingcartridge 18102 also mates with and sealingly engages the interior surface of thetubular actuator barrel 18046. In this manner, during longitudinal displacement of thetubular piston 18100 relative to thetubular actuator barrel 18046, a fluidic seal is maintained between the exterior surface of the piston and the interior surface of the actuator barrel. Mounting screws, 18104 a and 18104 b, are coupled to and mounted within the external radial mounting holes, 18100 b and 18100 c, respectively, of thetubular piston 18100 and received within the radial passages, 18096 e and 18096 f, of theconnector tube 18096. - The other end of the
tubular piston 18100 receives and is threadably coupled to an end of aconnector tube 18106 that defines alongitudinal passage 18106 a, radial mounting holes, 18106 b and 18106 c, at one end and radial mounting holes, 18106 d and 18106 e, at another end. Theconnector tube 18106 is received within and sealingly and movably engages the interior surface of the sealingcartridge 18052 mounted within theannular recess 18050 a of thetubular barrel connector 18050. In this manner, during longitudinal displacement of theconnector tube 18106 relative to thetubular barrel connector 18050, a fluidic seal is maintained between the exterior surface of the connector tube and the interior surface of the barrel connector. Mounting screws, 18108 a and 18108 b, are coupled to and mounted within the external radial mounting holes, 18100 f and 18100 g, respectively, of thetubular piston 18100 and received within the radial passages, 18106 b and 18106 c, of theconnector tube 18106. - The other end of the
connector tube 18106 is received within and threadably coupled to an end of atubular piston 18110 that defines alongitudinal passage 18110 a, radial mounting holes, 18110 b and 18110 c, radial passages, 18110 d and 18110 e, radial mounting holes, 18110 f and 18110 g, that includes aflange 18110 h at one end and circumferentially spaced teeth 18110 i at another end for engaging the one or more circumferentially spaced apart lockingteeth 18060 e of the tubularlower stop 18060. A sealingcartridge 18112 is mounted onto and sealingly coupled to the exterior of thetubular piston 18110 proximate theflange 18110 h. The sealingcartridge 18112 also mates with and sealingly engages the interior surface of theactuator barrel 18056. In this manner, during longitudinal displacement of thetubular piston 18110 relative to theactuator barrel 18056, a fluidic seal is maintained between the exterior surface of the piston and the interior surface of the actuator barrel. Mounting screws, 18114 a and 18114 b, are coupled to and mounted within the external radial mounting holes, 18110 b and 18110 c, respectively, of thetubular piston 18110 and received within the radial passages, 18106 d and 18106 e, of theconnector tube 18106. - The other end of the
tubular piston 18110 receives and is threadably coupled to an end of aconnector tube 18116 that defines alongitudinal passage 18116 a, radial mounting holes, 18116 b and 18116 c, at one end and radial mounting holes, 18116 d and 18116 e, at another end that includes anexternal flange 18116 f that includes circumferentially spaced apartteeth 18116 g that extend from an end face of the external flange for engaging theteeth 18060 f of the tubularlower stop 18060, and an externally threadedconnection 18116 h at another end. Theconnector tube 18116 is received within and sealingly and movably engages the interior surface of the sealingcartridge 18062 mounted within theannular recess 18060 a of the lowertubular stop 18060. In this manner, during longitudinal displacement of theconnector tube 18116 relative to the lowertubular stop 18060, a fluidic seal is maintained between the exterior surface of the connector tube and the interior surface of the lower tubular stop. Mounting screws, 18118 a and 18118 b, are coupled to and mounted within the external radial mounting holes, 18110 f and 18110 g, respectively, of thetubular piston 18110 and received within the radial passages, 18116 b and 18116 c, of theconnector tube 18116. - In an exemplary embodiment, as illustrated in FIGS. 13A1 to 13A8, the internally threaded
connection 18002 e of the uppertubular support member 18002 receives and is coupled to the externally threaded connection 1234 g of the lower mandrel 1234 of theball grabber assembly 16 and the externally threadedconnection 18116 h of theconnector tube 18116 is received within and is coupled to an internally threadedconnection 20 a of an end of thesafety sub assembly 20. - In an exemplary embodiment, as illustrated in FIGS. 13A1 to 13A8, during operation of the
tension actuator assembly 18, the tension actuator assembly is positioned within theexpandable wellbore casing 100 andfluidic material 18200 is injected into the tension actuator assembly through thepassages fluidic material 18200 will also pass through the radial passages, 18070 d and 18070 e, 18080 d and 18080 e, 18090 d and 18090 e, 18100 d and 18100 e, 18110 d and 18110 e, of the tubular pistons, 18070, 18080, 18090, 18100, and 18110, respectively, into annular piston chambers, 18202, 18204, 18206, 18208, 18208, and 18210. - As illustrated in FIGS. 13B1 to 13B7, the operating pressure of the
fluidic material 18200 may then be increased by, for example, controllably blocking or limiting the flow of the fluidic material through thepassage 18116 a and/or increasing the operating pressure of the outlet of a pumping device for injecting thefluidic material 18200 into thetension actuator assembly 18. As a result, of the increased operating pressure of thefluidic material 18200 within thetension actuator assembly 18, the operating pressures of the annular piston chambers, 18202, 18204, 18206, 18208, 18208, and 18210, will be increased sufficiently to displace the tubular pistons, 18070, 18080, 18090, 18100, and 18110, upwardly in thedirection 18212 thereby also displacing theconnector tube 18116. As a result, a upward tensile force is applied to all elements of thesystem 10 coupled to and positioned below theconnector tube 18116. In an exemplary embodiment, during the upward displacement of the tubular pistons, 18070, 18080, 18090, 18100, and 18110, fluidic materials displaced by the tubular pistons within discharge annular chambers, 18214, 18216, 18218, 18220, and 18222 are exhausted out of thetension actuator assembly 18 through the radial passages, 18008 d and 18008 e, 18022 d and 18022 e, 18030 d and 18030 e, 18040 d and 18040 e, 18050 d and 18050 e, respectively. Furthermore, in an exemplary embodiment, the upward displacement of the tubular pistons, 18070, 18080, 18090, 18100, and 18110, further causes theexternal splines 18066 d of theconnector tube 18066 to engage theinternal splines 18014 b of thetubular member 18014 and the circumferentially spaced apartteeth 18116 g of theconnector tube 18116 to engage the circumferentially spacedteeth 18060 f of the tubularlower stop 18060. As a result of the interaction of theexternal splines 18066 d of theconnector tube 18066 to engage theinternal splines 18014 b of thetubular member 18014 and the circumferentially spaced apartteeth 18116 g of theconnector tube 18116 to engage the circumferentially spacedteeth 18060 f of the tubularlower stop 18060, torsional loads may be transmitted through thetension actuator assembly 18. - In an exemplary embodiment, as illustrated in
FIG. 14A , thesafety sub assembly 20 includes atubular body 200 a that defines alongitudinal passage 200 b and includes anexternal flange 200 c and an internalannular recess 200 d at one end, and external annular recesses, 200 e, 200 f, 200 g, and 200 h at another end. A sealingmember 202 is positioned within the externalannular recess 200 h at the other end of thetubular body 200 a. - In an exemplary embodiment, as illustrated in
FIGS. 14A, 14B and 14C, the sealingcup assembly 22 includes anupper tubular mandrel 2202 that defines alongitudinal passage 2202 a and internally threaded radial mounting holes, 2202 b and 2202 c, and includes an internalannular recess 2202 d at one end, an internalannular recess 2202 e, an internalannular recess 2202 f, an internal annular recess 2202 g, and an internally threaded internalannular recess 2202 h and an external flange 2202 i at another end. The internal annular recesses, 2202 d, 2202 e, and 2202 f, of theupper tubular mandrel 2202 of the sealingcup assembly 22 receive, mate with, and are coupled to the other end of thetubular body 200 a of thesafety sub assembly 20. - An externally threaded end of a lower
tubular mandrel 2204 that defines alongitudinal passage 2204 a and includes an externalannular recess 2204 b at one end, an external annular recess 2204 c, an external flange 2204 d, an externalannular recess 2204 e, an externally threaded external flange 2204 f, and an external annular recess 2204 g at another end mates with, is received within, and is coupled to the internal annular recesses, 2202 g and 2202 h, of the other end of theupper tubular mandrel 2202. - Mounting screws, 2250 a and 2205 b, are received within and coupled to the mounting holes, 2202 c and 2202 b, respectively, of the
tubular mandrel 2202 that extend into and engage the external annular recess 2204 c of the lowertubular mandrel 2204. - A tubular
cup seal spacer 2206 receives and is mounted upon the lowertubular mandrel 2204 proximate the external flange 2202 i of theupper tubular mandrel 2202. A tubularcup seal retainer 2208 that includes an internal flange 2208 a at one end receives and is mounted upon the lowertubular mandrel 2204 proximate the tubularcup seal spacer 2206. A tubular cup seal retainer 2210 that includes an internal flange 2210 a at one end receives and is mounted upon the lowertubular mandrel 2204 proximate the other end of the tubularcup seal retainer 2208. In an exemplary embodiment, the tubular cup seal retainer 2210 is nested within the other end of the tubularcup seal retainer 2208. Atubular cup seal 2212 that includes an internal flange 2212 a at one end receives and is mounted upon the lowertubular mandrel 2204 proximate the other end of the tubular cup seal retainer 2210. In an exemplary embodiment, thetubular cup seal 2212 is nested within the other end of the tubular cup seal retainer 2210. - A sealing
member 2211 is received within the externalannular recess 2204 b of the lowertubular mandrel 2204 for sealing the interface between the lower tubular mandrel and theupper tubular mandrel 2202. - A
tubular spacer 2214 receives and is mounted upon the lowertubular mandrel 2204 proximate the other end of thetubular cup seal 2212. - A tubular
cup seal spacer 2216 receives and is mounted upon the lowertubular mandrel 2204 proximate the other end of thetubular spacer 2214. A tubularcup seal retainer 2218 that includes an internal flange 2218 a at one end receives and is mounted upon the lowertubular mandrel 2204 proximate the other end of the tubularcup seal spacer 2216. A tubular cup seal retainer 2220 that includes an internal flange 2220 a at one end receives and is mounted upon the lowertubular mandrel 2204 proximate the other end of the tubularcup seal retainer 2218. In an exemplary embodiment, the tubular cup seal retainer 2220 is nested within the other end of the tubularcup seal retainer 2218. Atubular cup seal 2222 that includes an internal flange 2222 a at one end receives and is mounted upon the lowertubular mandrel 2204 proximate the other end of the tubular cup seal retainer 2220. In an exemplary embodiment, thetubular cup seal 2222 is nested within the other end of the tubular cup seal retainer 2220. - A tubular spacer 2224 receives and is mounted upon the lower
tubular mandrel 2204 proximate the other end of thetubular cup seal 2222 at one end and proximate the external flange 2204 d of the lower tubular mandrel at another end. A retaining ring 2226 receives and is mounted upon the other end of the tubular spacer 2224 proximate the external flange 2204 d of the lowertubular mandrel 2204. - In an exemplary embodiment, during operation of the
system 10, the end of thetubular body 200 a of thesafety sub assembly 20 is coupled to and receives and is coupled to an end of thetension actuator assembly 18 and the other end of the lowertubular mandrel 2204 of the sealingcup assembly 22 is received within and is coupled to an end of thecasing lock assembly 24. - In an exemplary embodiment, during operation of the
system 10, the tubular cup seals, 2212 and/or 2222, sealingly engage the interior surface of theexpandable tubular member 100. In this manner, when an annulus defined between thesystem 10 and theexpandable wellbore casing 10, below the tubular cup seals, 2212 and/or 2222, is pressurized, the resulting pressure differential across the tubular cup seals applies an upward tensile force to the system thereby pulling the adjustable bell sectionexpansion cone assembly 28 and/or the adjustable casingexpansion cone assembly 30 through the expandable wellbore casing. In this manner, the adjustable bell sectionexpansion cone assembly 28 and/or the adjustable casingexpansion cone assembly 30, if either or both are adjusted to an outside diameter suitable for a radial expansion operation, may radially expand and plastically deform theexpandable wellbore casing 100. - In an exemplary embodiment, the sealing
cup assembly 22 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on Nov. 12, 2002, and/or (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, and/or (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on Feb. 29, 2003, and/or (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22, 2003, and/or (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, and/or (6) PCT patent application serial number PCT/US03/18530, attorney docket number 25791.108.02, filed on Jun. 11, 2003, and/or (7) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (8) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (9) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference. - In an exemplary embodiment, the
casing lock assembly 24 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, and/or (2) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22, 2003, and/or (3) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, and/or (4) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (5) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (6) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference. - In an exemplary embodiment, the
extension actuator assembly 26 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, and/or (2) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22, 2003, and/or (3) PCT patent application serial number PCT/US ______, attorney docket number 25791.107.02, filed on ______, and/or (4) PCT patent application serial number PCT/US/______, attorney docket number 25791.114.02, filed on ______, and/or (5) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (6) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (7) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference. - In an exemplary embodiment, the adjustable bell section
expansion cone assembly 28 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on Nov. 12, 2002, and/or (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, and/or (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on Feb. 29, 2003, and/or (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22, 2003, and/or (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, and/or (6) PCT patent application serial number PCT/US03/18530, attorney docket number 25791.108.02, filed on Jun. 11, 2003, and/or (7) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (8) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (9) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference. - In an exemplary embodiment, as illustrated in
FIGS. 15-1 and 152, 15A1 to 15A2, 15B1 to 15B2, 15C, 15D, 15E, 15F, 15G, 15H, 15I, 15 j, 15K, 15L, 15M, 15N, 150, 15P, 15R, 15S, 15T, 15U, 15V, 15W, 15X, 15Y, 15Z1 to 15Z4, 15M1 to 15M4, 15AB1 to 15AB4, 15AC1 to 15AC4, 15AD, and 15AE, the adjustable bell sectionexpansion cone assembly 28 includes an upper tubular tool joint 28002 that defines alongitudinal passage 28002 a and mounting holes, 28002 b and 28002 c, and includes an internal threadedconnection 28002 d, an innerannular recess 28002 e, an inner annular recess 28002 f, and an internal threadedconnection 28002 g. Atubular torque plate 28004 that defines alongitudinal passage 28004 a and includes circumferentially spaced apartteeth 28004 b is received within, mates with, and is coupled to the internalannular recess 28002 e of the uppertubular tool joint 28002. - Circumferentially spaced apart teeth 28006 a of an end of a tubular
lower mandrel 28006 that defines alongitudinal passage 28006 b, aradial passage 28006 ba, and aradial passage 28006 bb and includes an external threadedconnection 28006 c, anexternal flange 28006 d, an externalannular recess 28006 e having astep 28006 f at one end, an externalannular recess 28006 g,external teeth 28006 h, an external threadedconnection 28006 i, and an externalannular recess 28006 j engage the circumferentially spaced apartteeth 28004 b of thetubular torque plate 28004. An internal threadedconnection 28008 a of an end of atubular toggle bushing 28008 that defines alongitudinal passage 28008 b, an upperlongitudinal slot 28008 c, a lowerlongitudinal slot 28008 d, mounting holes, 28008 e, 28008 f, 28008 g, 28008 h, 28008 i, 28008 j, 28008 k, 28008 l, 28008 m, 28008 n, 28008 o, 28008 p, 28008 q, 28008 r, 28008 s, 28008 t, 28008 u, 28008 v, 28008 w, 28008 x, 28008 xa, and 28008 xb, and includes an externalannular recess 28008 y, internalannular recess 28008 z, externalannular recess 28008 aa, and an externalannular recess 28008 ab receives and is coupled to the external threadedconnection 28006 c of the tubularlower mandrel 28006. - A sealing
element 28010 is received within the externalannular recess 28008 y of thetubular toggle bushing 28008 for sealing the interface between the tubular toggle bushing and the uppertubular tool joint 28002. A sealingelement 28012 is received within the internalannular recess 28008 z of thetubular toggle bushing 28008 for sealing the interface between the tubular toggle bushing and the tubularlower mandrel 28006. - Mounting screws, 28014 a and 28014 b, mounted within and coupled to the mounting holes, 28008 w and 28008 x, respectively, of the
tubular toggle bushing 28008 are also received within the mounting holes, 28002 b and 28002 c, of the uppertubular tool joint 28002. Mounting pins, 28016 a, 28016 b, 28016 c, 28016 d, and 28016 e, are mounted within the mounting holes, 28008 e, 28008 f, 28008 g, 28008 h, and 28008 i, respectively. Mounting pins, 28018 a, 28018 b, 28018 c, 28018 d, and 28018 e, are mounted within the mounting holes, 28008 t, 28008 s, 28008 r, 28008 q, and 28008 p, respectively. Mounting screws, 28020 a and 28020 b, are mounted within the mounting holes, 28008 u and 28008 v, respectively. - A first
upper toggle link 28022 defines mounting holes, 28022 a and 28022 b, for receiving the mounting pins, 28016 a and 28016 b, and includes a mountingpin 28022 c at one end. A firstlower toggle link 28024 defines mounting holes, 28024 a, 28024 b, and 28024 c, for receiving the mounting pins, 28022 c, 28016 c, and 28016 d, respectively and includes anengagement arm 28024 d. Afirst trigger 28026 defines a mountinghole 28026 a for receiving the mountingpin 28016 e and includes anengagement arm 28026 b at one end, anengagement member 28026 c, and anengagement arm 28026 d at another end. - A second
upper toggle link 28028 defines mounting holes, 28028 a and 28028 b, for receiving the mounting pins, 28018 a and 28018 b, and includes a mounting pin 28028 c at one end. A secondlower toggle link 28030 defines mounting holes, 28030 a, 28030 b, and 28030 c, for receiving the mounting pins, 28028 c, 28018 c, and 28018 d, respectively and includes anengagement arm 28030 d. Asecond trigger 28032 defines a mountinghole 28032 a for receiving the mountingpin 28018 e and includes anengagement arm 28032 b at one end, anengagement member 28032 c, and anengagement arm 28032 d at another end. - An end of a
tubular spring housing 28034 that defines alongitudinal passage 28034 a, mounting holes, 28034 b and 28034 c, and mounting holes, 28034 ba and 28034 ca, and includes aninternal flange 28034 d and an internalannular recess 28034 e at one end, and aninternal flange 28034 f, an internalannular recess 28034 g, an internalannular recess 28034 h, and an external threadedconnection 28034 i at another end receives and mates with the end of thetubular toggle bushing 28008. Mounting screws, 28035 a and 28035 b, are mounted within and coupled to the mounting holes, 28008 xb and 28008 xa, respectively, of thetubular toggle bushing 28008 and are received within the mounting holes, 28034 ba and 28034 ca, respectively, of thetubular spring housing 28034. - A tubular
retracting spring ring 28036 that defines mounting holes, 28036 a and 28036 b, receives and mates with a portion of the tubularlower mandrel 28006 and is received within and mates with a portion of thetubular spring housing 28034. Mounting screws, 28038 a and 28038 b, are mounted within and coupled to the mounting holes, 28036 a and 28036 b, respectively, of the tubularretracting spring ring 28036 and extend into the mounting holes, 28034 b and 28034 c, respectively, of thetubular spring housing 28034. - Casing diameter sensor springs, 28040 a and 28040 b, are positioned within the longitudinal slots, 28008 c and 2808 d, respectively, of the
tubular toggle bushing 28008 that engage the engagement members, 28026 c and 28032 c, and engagement arms, 28026 d and 28032 d, of the first and second triggers, 28026 and 28032, respectively. Aninner flange 28042 a of an end of atubular spring washer 28042 mates with and receives a portion of the tubularlower mandrel 28006 and an end face of the inner flange of the tubular spring washer is positioned proximate and end face of theexternal flange 28006 d of the tubular lower mandrel. Thetubular spring washer 28042 is further received within thelongitudinal passage 28034 a of thetubular spring housing 28034. - An end of a retracting
spring 28044 that receives the tubularlower mandrel 28006 is positioned within thetubular spring washer 28042 in contact with theinternal flange 28042 a of the tubular spring washer and the other end of the retracting spring is positioned in contact with an end face of the tubularretracting spring ring 28036. - A sealing
element 28046 is received within the externalannular recess 28006 j of the tubularlower mandrel 28006 for sealing the interface between the tubular lower mandrel and thetubular spring housing 28034. A sealingelement 28048 is received within the internalannular recess 28034 h of thetubular spring housing 28034 for sealing the interface between the tubular spring housing and the tubularlower mandrel 28006. - An internal threaded
connection 28050 a of an end of a tubularupper hinge sleeve 28050 that includes aninternal flange 28050 b and aninternal pivot 28050 c receives and is coupled to the external threadedconnection 28034 i of the end of thetubular spring housing 28034. - An
external flange 28052 a of abase member 28052 b of anupper cam assembly 28052, that is mounted upon and receives the lowertubular mandrel 28006, that includes aninternal flange 28052 c that is received within the externalannular recess 28006 e of the lowertubular mandrel 28006 and a plurality of circumferentially spaced apart taperedcam arms 28052 d extending from the base member mates with and is received within the tubularupper hinge sleeve 28050. Thebase member 28052 b of theupper cam assembly 28052 further includes a plurality of circumferentially spaced apartteeth 28052 f that mate with and are received within a plurality of circumferentially spaced apart teeth 28034 j provided on the end face of thetubular spring housing 28034 and an end face of theexternal flange 28052 a of the base member of the upper cam assembly is positioned in opposing relation to an end face of theinternal flange 28050 b of the tubularupper hinge sleeve 28050. Each of thecam arms 28052 d of theupper cam assembly 28052 include external cam surfaces 28052 e. In an exemplary embodiment, theteeth 28052 f of thebase member 28052 b of theupper cam assembly 28052 and the teeth 28034 j provided on the end face of thetubular spring housing 28034 permit torsional loads to be transmitted between the tubular spring housing and the upper cam assembly. - A plurality of circumferentially spaced apart
upper expansion segments 28054 are mounted upon and receive the lowertubular mandrel 28006 and each include anexternal pivot recess 28054 a at one end for mating with and receiving theinternal pivot 28050 c of the tubularupper hinge sleeve 28050 and an externaltapered expansion surface 28054 b at another end and are pivotally mounted within the tubular upper hinge sleeve and are interleaved with the circumferentially spaced apartcam arms 28052 d of theupper cam assembly 28052. Theupper expansion segments 28054 are interleaved among thecam arms 28052 d of theupper cam assembly 28052. - A plurality of circumferentially spaced apart
lower expansion segments 28058 are mounted upon and receive the lowertubular mandrel 28006, are interleaved among theupper expansion segments 28054, are oriented in the opposite direction to theupper expansion segments 28054, each include anexternal pivot recess 28058 a at one end and an externaltapered expansion surface 28054 b at another end and are positioned in opposing relation to corresponding circumferentially spaced apartcam arms 28052 d of theupper cam assembly 28052. - A
lower cam assembly 28060 is mounted upon and receives the lowertubular mandrel 28006 that includes abase member 28060 a having anexternal flange 28060 b, a plurality of circumferentially spaced apartcam arms 28060 d that extend from the base member that each include external cam surfaces 28060 e and define mountingholes base member 28060 a of thelower cam assembly 28060 further includes a plurality of circumferentially spaced apartteeth 28060 h. The circumferentially spaced apartcam arms 28060 d of thelower cam assembly 28060 are interleaved among thelower expansion segments 28058 and the circumferentially spaced apartcam arms 28052 d of theupper cam assembly 28052 and positioned in opposing relation to correspondingupper expansion segments 28054. - Mounting screws, 28062 a, 28062 b, 28062 c, and 28062 e, are mounted within the corresponding mounting holes, 28060 f and 28060 g, of the
lower cam assembly 28060 and are received within the externalannular recess 28006 g of thelower cam assembly 28060. - A tubular
lower hinge sleeve 28064 that receives thelower expansion segments 28058 and thelower cam assembly 28060 includes aninternal flange 28064 a for engaging theexternal flange 28060 b of the base member of thelower cam assembly 28060, aninternal pivot 28064 b for engaging and receiving theexternal pivot recess 28058 a of thelower expansion segments 28058 thereby pivotally mounting the lower expansion segments within the tubular lower hinge sleeve, and an internal threadedconnection 28064 c. - An external threaded
connection 28066 a of an end of atubular sleeve 28066 that defines mounting holes, 28066 b and 28066 c, and includes an internalannular recess 28066 d having ashoulder 28066 e, aninternal flange 28066 f, and an internal threadedconnection 28066 g at another end is received within and coupled to the internal threadedconnection 28064 c of the tubularlower hinge sleeve 28064. An external threadedconnection 28068 a of an end of atubular member 28068 that defines alongitudinal passage 28068 b and mounting holes, 28068 c and 28068 d, and includes an externalannular recess 28068 e, and an external threadedconnection 28068 f at another end is received within and is coupled to the internal threadedconnection 28066 g of thetubular sleeve 28066. - Mounting screws, 28070 a and 28070 b, are mounted in and coupled to the mounting holes, 28068 c and 28068 d, respectively, of the
tubular member 28068 that also extend into the mounting holes, 28066 b and 28066 c, respectively, of thetubular sleeve 28066. A sealingelement 28072 is received within the externalannular recess 28068 e of thetubular member 28068 for sealing the interface between the tubular member and thetubular sleeve 28066. - An internal threaded
connection 28074 a of atubular retracting piston 28074 that defines alongitudinal passage 28074 b and includes an internal annular recess 28074 c and an externalannular recess 28074 d receives and is coupled to the external threadedconnection 28006 i of the tubularlower mandrel 28006. A sealingelement 28076 is received within the externalannular recess 28074 d of thetubular retracting piston 28074 for sealing the interface between the tubular retracting piston and thetubular sleeve 28066. A sealingelement 28078 is received within the internal annular recess 28074 c of thetubular retracting piston 28074 for sealing the interface between the tubular retracting piston and the tubularlower mandrel 28006. - Locking
dogs 28080 mate with and receive theexternal teeth 28006 h of the tubularlower mandrel 28006. Aspacer ring 28082 is positioned between an end face of the lockingdogs 28080 and an end face of thelower cam assembly 28060. Arelease piston 28084 mounted upon the tubularlower mandrel 28006 defines aradial passage 28084 a for mounting aburst disk 28086 includes sealing elements, 28084 b, 28084 c, and 28084 d. The sealing elements, 28084 b and 28084 d, sealing the interface between therelease piston 28084 and the tubularlower mandrel 28006. An end face of therelease piston 28084 is positioned in opposing relation to an end face of the lockingdogs 28080. - A
release sleeve 28088 that receives and is mounted upon the lockingdogs 28080 and therelease piston 28084 includes aninternal flange 28088 a at one end that sealingly engages the tubularlower mandrel 28006. Abypass sleeve 28090 that receives and is mounted upon therelease sleeve 28088 includes aninternal flange 28090 a at one end. - In an exemplary embodiment, during operation of the adjustable bell section
expansion cone assembly 28, the retractingspring 28044 is compressed and thereby applies a biasing spring force in adirection 28092 from the lowertubular mandrel 28006 to thetubular spring housing 28034 that, in the absence of other forces, moves and/or maintains theupper cam assembly 28052 and theupper expansion segments 28054 out of engagement with thelower expansion segments 28058 and thelower cam assembly 28060. In an exemplary embodiment, during operation of the adjustable bell sectionexpansion cone assembly 28, an external threadedconnection 26 a of an end of theextension actuator assembly 26 is coupled to the internal threadedconnection 28002 d of the upper tubular tool joint 28002 and an internal threadedconnection 30 a of an end of the adjustable casingexpansion cone assembly 30 is coupled to the external threadedconnection 28068 f of thetubular member 28068. - The
upper cam assembly 28052 and theupper expansion segments 28054 may be brought into engagement with thelower expansion segments 28058 and thelower cam assembly 28060 by pressurizing anannulus 28094 defined between the lowertubular mandrel 28006 and thetubular spring housing 28034. In particular, injection of fluidic materials into the adjustable bell sectionexpansion cone assembly 28 through thelongitudinal passage 28006 b of the lowertubular mandrel 28006 and into theradial passage 28006 ba may pressurize theannulus 28094 thereby creating sufficient operating pressure to generate a force in adirection 28096 sufficient to overcome the biasing force of the retractingspring 28044. As a result, thespring housing 28034 may be displaced in thedirection 28096 relative to the lowertubular mandrel 28006 thereby displacing the tubularupper hinge sleeve 28050,upper cam assembly 28052, andupper expansion segments 28054 in thedirection 28096. - In an exemplary embodiment, as illustrated in
FIGS. 15P and 15R , the displacement of theupper cam assembly 28052 andupper expansion segments 28054 in thedirection 28096 will cause thelower expansion segments 28058 to ride up the cam surfaces 28052 e of thecam arms 28052 d of theupper cam assembly 28052 while also pivoting about the lowertubular hinge segment 28064, and will also cause theupper expansion segments 28054 to ride up the cam surfaces 28060 e of thecam arms 28060 d of thelower cam assembly 28060 while also pivoting about the uppertubular hinge segment 28050. In an exemplary embodiment, when the upper and lower expansion segments, 28054 and 28058, are brought into axial alignment, they define an outer expansion surface that is approximately contiguous in a circumferential direction and which provides an outer expansion surface that at least approximates a conical surface. - In an exemplary embodiment, during the operation of the adjustable bell section
expansion cone assembly 28, when the upper and lower expansion segments, 28054 and 28058, brought into axial alignment into a radially expanded position, the upper and lower expansion segments, 28054 and 28058, are displaced relative to theexpandable wellbore casing 100 to thereby radially expand and plastically deform at least a portion of the expandable wellbore casing. In an exemplary embodiment, during the radial expansion and plastic deformation of theexpandable wellbore casing 100, the adjustable bell sectionexpansion cone assembly 28 may then be rotated relative to the expandable wellbore casing to enhance and/or modify the rate at which the expandable wellbore casing is radially expanded and plastically deformed. - In an exemplary embodiment, the
upper cam assembly 28052 and theupper expansion segments 28054 may be moved out of engagement with thelower expansion segments 28058 and thelower cam assembly 28060 by reducing the operating pressure within theannulus 28094. - In an alternative embodiment, as illustrated in
FIGS. 15S, 15T , 15U and 15V, during operation of the adjustable bell sectionexpansion cone assembly 28, theupper cam assembly 28052 and theupper expansion segments 28054 may also be moved out of engagement with thelower expansion segments 28058 and thelower cam assembly 28060 by sensing the operating pressure within thelongitudinal passage 28006 b of the lowertubular mandrel 28006. In particular, as illustrated inFIG. 15T , if the operating pressure within thelongitudinal passage 28006 b andradial passage 28006 bb of the lowertubular mandrel 28006 exceeds a predetermined value, theburst disc 28086 will open thepassage 28084 a thereby pressurizing the interior of thetubular release sleeve 28088 thereby displacing thetubular release sleeve 28088 downwardly in adirection 28092 away from engagement with the lockingdogs 28080. - As a result, as illustrated in
FIG. 15U , the lockingdogs 28080 are displaced outwardly in the radial directed and thereby released from engagement with the lowertubular mandrel 28006 thereby permitting thelower expansion segments 28058 and thelower cam assembly 28060 to be displaced downwardly relative to the lower tubular mandrel. - As a result, as illustrated in
FIG. 15V , the operating pressure within the lowertubular mandrel 28066 may then cause the lower tubular mandrel to be displaced downwardly in thedirection 28094 relative to the tubularlower mandrel 28006 and theretracting piston 28074. As a result, the lowertubular mandrel 28066, thelower expansion segments 28058, thelower cam assembly 28060, and tubularlower hinge sleeve 28064 are displaced downwardly in thedirection 28094 relative to thetubular spring housing 28034 thereby moving thelower expansion segments 28058 and thelower cam assembly 28060 out of engagement with theupper cam assembly 28052 and theupper expansion segments 28054. - In an exemplary embodiment, as illustrated in
FIGS. 15W, 15X , and 15Y, during operation of the adjustable bell sectionexpansion cone assembly 28, the adjustable bell section expansion cone assembly senses the diameter of theexpandable wellbore casing 100 using the upper toggle links, 28022 and 28028, lower toggle links, 28024 and 28030, and triggers, 28026 and 28032, and then prevents the engagement of theupper cam assembly 28052 and theupper expansion segments 28054 with thelower expansion segments 28058 and thelower cam assembly 28060. - In particular, as illustrated in
FIG. 15W , anytime the upper toggle links, 28022 and 28028, and lower toggle links, 28024 and 28030, are positioned within a portion of theexpandable wellbore casing 100 that has been radially expanded and plastically deformed by thesystem 10, the triggers, 28026 and 28032, will be pivoted by the engagement arms, 28024 d and 28030 d, of the lower toggle links, 28024 and 28030, to a position in which the triggers will no longer engage theinternal flange 28034 d of the end of thetubular spring housing 28034 thereby permitting the displacement of the tubular spring housing in thedirection 28096. As a result, theupper cam assembly 28052 and theupper expansion segments 28054 can be brought into engagement with thelower expansion segments 28058 and thelower cam assembly 28060. In an exemplary embodiment, the upper toggle links, 28022 and 28028, and the lower toggle links, 28024 and 28030, are spring biased towards the position illustrated inFIG. 15W . - Conversely, as illustrated in
FIG. 15X , anytime the upper toggle links, 28022 and 28028, and lower toggle links, 28024 and 28030, are positioned within a portion of theexpandable wellbore casing 100 that has not been radially expanded and plastically deformed by thesystem 10, the triggers, 28026 and 28032, will be maintained in a position in which the triggers will engage theinternal flange 28034 d of the end of thetubular spring housing 28034 thereby preventing the displacement of the tubular spring housing in thedirection 28096. As a result, theupper cam assembly 28052 and theupper expansion segments 28054 cannot be brought into engagement with thelower expansion segments 28058 and thelower cam assembly 28060. In an exemplary embodiment, the triggers, 28026 and 28032, are spring biased towards the position illustrated inFIG. 15X . - In an exemplary embodiment, as illustrated in
FIG. 15Y , thetubular spring housing 28034 may be displaced upwardly in thedirection 28098 even if the upper toggle links, 28022 and 28028, and lower toggle links, 28024 and 28030, are positioned within a portion of theexpandable wellbore casing 100 that has not been radially expanded and plastically deformed by thesystem 10. - In an exemplary embodiment, as illustrated in FIGS. 15Z1 to 15Z4, 15AA1 to 15AA4, 15AB1 to 15AB4, 15AC1 to 15AC4, 15AD, and 15AE, the
tubular spring housing 28034 of the adjustable bell sectionexpansion cone assembly 28 defines internalannular recesses internal flange 28034 m, thetubular toggle bushing 28008 defines an externalannular recess 28008 ac, and the adjustable bell section expansion cone assembly further includes pins, 28100 a and 28100 b and 28102 a and 28102 b, mounted inholes shot deactivation device 28104 mounted on the tubular toggle bushing between the pins, 28100 a and 28100 b and 28102 a and 28102 b. - The one-
shot deactivation device 28104 includes atubular body 28104 a that defines radial holes, 28104 b and 28014 c, and includes an externalannular recess 28104 d at one end, a centrally positionedexternal flange 28104 e, a centrally positioned internalannular recess 28104 f, and an externalannular recess 28104 g at another end. Anengagement member 28106 that includes abase member 28106 a having atapered end 28106 b and akey member 28106 c having atapered end 28106 d is received within a portion of the internalannular recess 28104 f of thetubular body 28104 a and an engagement member 28108 that includes abase member 28108 a having atapered end 28108 b and akey member 28108 c having atapered end 28108 d is received within an opposite portion of the internalannular recess 28104 f of thetubular body 28104 a. Spring members, 28110 and 28112, are received within theannular recess 28104 f of thetubular body 28104 a for biasing the base members,base member tubular body 28104 a. - In an exemplary embodiment, during operation of the adjustable bell section
expansion cone assembly 28, as illustrated in FIGS. 15Z1 to 15Z4, the one-shot deactivation device 28104 are positioned proximate and in intimate contact with the pins, 28102 a and 28102 b, with the tapered ends, 28106 b and 28108 b, of the base members, 28106 a and 28108 a, of the engagement members, 28106 and 28108, received within the externalannular recess 28008 ac of thetubular toggle bushing 28008. When the one-shot deactivation device 28104 is positioned as illustrated in FIGS. 15Z1 to 15Z4, the externalannular recess 28104 d of thetubular body 28104 a of the one-shot deactivation device is moved out of engagement with the engagement arms, 28026 d and 28032 d, of the triggers, 28026 and 28032, respectively. As a result, the triggers, 28026 and 28032, may operate normally as described above with reference toFIGS. 15W, 15X , and 15Y. - Conversely, in an exemplary embodiment, during operation of the adjustable bell section
expansion cone assembly 28, as illustrated in FIGS. 15AA1 to 15AA4, the one-shot deactivation device 28104 are positioned proximate and in intimate contact with the pins, 28100 a and 28100 b, with the tapered ends, 28106 b and 28108 b, of the base members, 28106 a and 28108 a, of the engagement members, 28106 and 28108, not received within the externalannular recess 28008 ac of thetubular toggle bushing 28008. When the one-shot deactivation device 28104 is positioned as illustrated inFIG. 15A A, the externalannular recess 28104 d of thetubular body 28104 a of the one-shot deactivation device is moved into engagement with the engagement arms, 28026 d and 28032 d, of the triggers, 28026 and 28032, respectively. As a result, the triggers, 28026 and 28032, are deactivated and may not operate normally as described above with reference toFIGS. 15W, 15X , and 15Y. - In an alternative embodiment, the elements of the adjustable bell section
expansion cone assembly 28 that sense the diameter of theexpandable wellbore casing 100 may be disabled or omitted or adjusted to sense any pre-selected internal diameter of the expandable wellbore casing. - In an exemplary embodiment, the adjustable casing
expansion cone assembly 30 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on Nov. 12, 2002, and/or (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, and/or (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on Feb. 29, 2003, and/or (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22, 2003, and/or (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, and/or (6) PCT patent application serial number PCT/US03/18530, attorney docket number 25791.108.02, filed on Jun. 11, 2003, and/or (7) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (8) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (9) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference. - In an exemplary embodiment, as illustrated in
FIGS. 16-1 and 16-2, 16A1 to 16A2, 16B1 to 16B2, 16C, 16D, 16E, 16F, 16G, 16H, 161, 16 j, 16K, 16L, 16M, 16N, 160, 16P, 16R, 16S, 16T, 16U, 16V, 16W, 16×, 16Y, 16Z1-16Z4, 16M1 to 16AA4, 16AB1 to 16AB4, 16AC1 to 16AC4, 16AD, and 16AE, the adjustable casingexpansion cone assembly 30 includes an upper tubular tool joint 30002 that defines alongitudinal passage 30002 a and mounting holes, 30002 b and 30002 c, and includes an internal threadedconnection 30002 d, an innerannular recess 30002 e, an inner annular recess 30002 f, and an internal threadedconnection 30002 g. Atubular torque plate 30004 that defines alongitudinal passage 30004 a and includes circumferentially spaced apartteeth 30004 b is received within, mates with, and is coupled to the internalannular recess 30002 e of the uppertubular tool joint 30002. - Circumferentially spaced apart teeth 30006 a of an end of a tubular
lower mandrel 30006 that defines alongitudinal passage 30006 b, aradial passage 30006 ba, and aradial passage 30006 bb and includes an external threadedconnection 30006 c, anexternal flange 30006 d, an externalannular recess 30006 e having astep 30006 f at one end, an externalannular recess 30006 g,external teeth 30006 h, an external threadedconnection 30006 i, and an externalannular recess 30006 j engage the circumferentially spaced apartteeth 30004 b of thetubular torque plate 30004. An internal threadedconnection 30008 a of an end of atubular toggle bushing 30008 that defines alongitudinal passage 30008 b, an upperlongitudinal slot 30008 c, a lowerlongitudinal slot 30008 d, mounting holes, 30008 e, 30008 f, 30008 g, 30008 h, 30008 i, 30008 j, 30008 k, 30008 l, 30008 m, 30008 n, 30008 o, 30008 p, 30008 q, 30008 r, 30008 s, 30008 t, 30008 u, 30008 v, 30008 w, 30008 x, 30008 xa, and 30008 xb, and includes an externalannular recess 30008 y, internalannular recess 30008 z, externalannular recess 30008 aa, and an externalannular recess 30008 ab receives and is coupled to the external threadedconnection 30006 c of the tubularlower mandrel 30006. - A sealing
element 30010 is received within the externalannular recess 30008 y of thetubular toggle bushing 30008 for sealing the interface between the tubular toggle bushing and the uppertubular tool joint 30002. A sealingelement 30012 is received within the internalannular recess 30008 z of thetubular toggle bushing 30008 for sealing the interface between the tubular toggle bushing and the tubularlower mandrel 30006. - Mounting screws, 30014 a and 30014 b, mounted within and coupled to the mounting holes, 30008 w and 30008 x, respectively, of the
tubular toggle bushing 30008 are also received within the mounting holes, 30002 b and 30002 c, of the uppertubular tool joint 30002. Mounting pins, 30016 a, 30016 b, 30016 c, 30016 d, and 30016 e, are mounted within the mounting holes, 30008 e, 30008 f, 30008 g, 30008 h, and 30008 i, respectively. Mounting pins, 30018 a, 30018 b, 30018 c, 30018 d, and 30018 e, are mounted within the mounting holes, 30008 t, 30008 s, 30008 r, 30008 q, and 30008 p, respectively. Mounting screws, 30020 a and 30020 b, are mounted within the mounting holes, 30008 u and 30008 v, respectively. - A first
upper toggle link 30022 defines mounting holes, 30022 a and 30022 b, for receiving the mounting pins, 30016 a and 30016 b, and includes a mountingpin 30022 c at one end. A firstlower toggle link 30024 defines mounting holes, 30024 a, 30024 b, and 30024 c, for receiving the mounting pins, 30022 c, 30016 c, and 30016 d, respectively and includes anengagement arm 30024 d. Afirst trigger 30026 defines a mountinghole 30026 a for receiving the mountingpin 30016 e and includes anengagement arm 30026 b at one end, anengagement member 30026 c, and anengagement arm 30026 d at another end. - A second
upper toggle link 30028 defines mounting holes, 30028 a and 30028 b, for receiving the mounting pins, 30018 a and 30018 b, and includes a mounting pin 30028 c at one end. A secondlower toggle link 30030 defines mounting holes, 30030 a, 30030 b, and 30030 c, for receiving the mounting pins, 30028 c, 30018 c, and 30018 d, respectively and includes anengagement arm 30030 d. Asecond trigger 30032 defines a mountinghole 30032 a for receiving the mountingpin 30018 e and includes anengagement arm 30032 b at one end, anengagement member 30032 c, and anengagement arm 30032 d at another end. - An end of a
tubular spring housing 30034 that defines alongitudinal passage 30034 a, mounting holes, 30034 b and 30034 c, and mounting holes, 30034 ba and 30034 ca, and includes aninternal flange 30034 d and an internalannular recess 30034 e at one end, and aninternal flange 30034 f, an internalannular recess 30034 g, an internalannular recess 30034 h, and an external threadedconnection 30034 i at another end receives and mates with the end of thetubular toggle bushing 30008. Mounting screws, 30035 a and 30035 b, are mounted within and coupled to the mounting holes, 30008 xb and 30008 xa, respectively, of thetubular toggle bushing 30008 and are received within the mounting holes, 30034 ba and 30034 ca, respectively, of thetubular spring housing 30034. - A tubular
retracting spring ring 30036 that defines mounting holes, 30036 a and 30036 b, receives and mates with a portion of the tubularlower mandrel 30006 and is received within and mates with a portion of thetubular spring housing 30034. Mounting screws, 30038 a and 30038 b, are mounted within and coupled to the mounting holes, 30036 a and 30036 b, respectively, of the tubularretracting spring ring 30036 and extend into the mounting holes, 30034 b and 30034 c, respectively, of thetubular spring housing 30034. - Casing diameter sensor springs, 30040 a and 30040 b, are positioned within the longitudinal slots, 30008 c and 3008 d, respectively, of the
tubular toggle bushing 30008 that engage the engagement members, 30026 c and 30032 c, and engagement arms, 30026 d and 30032 d, of the first and second triggers, 30026 and 30032, respectively. Aninner flange 30042 a of an end of atubular spring washer 30042 mates with and receives a portion of the tubularlower mandrel 30006 and an end face of the inner flange of the tubular spring washer is positioned proximate and end face of theexternal flange 30006 d of the tubular lower mandrel. Thetubular spring washer 30042 is further received within thelongitudinal passage 30034 a of thetubular spring housing 30034. - An end of a retracting
spring 30044 that receives the tubularlower mandrel 30006 is positioned within thetubular spring washer 30042 in contact with theinternal flange 30042 a of the tubular spring washer and the other end of the retracting spring is positioned in contact with an end face of the tubularretracting spring ring 30036. - A sealing
element 30046 is received within the externalannular recess 30006 j of the tubularlower mandrel 30006 for sealing the interface between the tubular lower mandrel and thetubular spring housing 30034. A sealingelement 30048 is received within the internalannular recess 30034 h of thetubular spring housing 30034 for sealing the interface between the tubular spring housing and the tubularlower mandrel 30006. - An internal threaded
connection 30050 a of an end of a tubularupper hinge sleeve 30050 that includes aninternal flange 30050 b and aninternal pivot 30050 c receives and is coupled to the external threadedconnection 30034 i of the end of thetubular spring housing 30034. - An
external flange 30052 a of abase member 30052 b of anupper cam assembly 30052, that is mounted upon and receives the lowertubular mandrel 30006, that includes aninternal flange 30052 c that is received within the externalannular recess 30006 e of the lowertubular mandrel 30006 and a plurality of circumferentially spaced apart taperedcam arms 30052 d extending from the base member mates with and is received within the tubularupper hinge sleeve 30050. Thebase member 30052 b of theupper cam assembly 30052 further includes a plurality of circumferentially spaced apartteeth 30052 f that mate with and are received within a plurality of circumferentially spaced apart teeth 30034 j provided on the end face of thetubular spring housing 30034 and an end face of theexternal flange 30052 a of the base member of the upper cam assembly is positioned in opposing relation to an end face of theinternal flange 30050 b of the tubularupper hinge sleeve 30050. Each of thecam arms 30052 d of theupper cam assembly 30052 include external cam surfaces 30052 e. In an exemplary embodiment, theteeth 30052 f of thebase member 30052 b of theupper cam assembly 30052 and the teeth 30034 j provided on the end face of thetubular spring housing 30034 permit torsional loads to be transmitted between the tubular spring housing and the upper cam assembly. - A plurality of circumferentially spaced apart
upper expansion segments 30054 are mounted upon and receive the lowertubular mandrel 30006 and each include anexternal pivot recess 30054 a at one end for mating with and receiving theinternal pivot 30050 c of the tubularupper hinge sleeve 30050 and an externaltapered expansion surface 30054 b at another end and are pivotally mounted within the tubular upper hinge sleeve and are interleaved with the circumferentially spaced apartcam arms 30052 d of theupper cam assembly 30052. Theupper expansion segments 30054 are interleaved among thecam arms 30052 d of theupper cam assembly 30052. - A plurality of circumferentially spaced apart
lower expansion segments 30058 are mounted upon and receive the lowertubular mandrel 30006, are interleaved among theupper expansion segments 30054, are oriented in the opposite direction to theupper expansion segments 30054, each include anexternal pivot recess 30058 a at one end and an externaltapered expansion surface 30054 b at another end and are positioned in opposing relation to corresponding circumferentially spaced apartcam arms 30052 d of theupper cam assembly 30052. - A
lower cam assembly 30060 is mounted upon and receives the lowertubular mandrel 30006 that includes abase member 30060 a having anexternal flange 30060 b, a plurality of circumferentially spaced apartcam arms 30060 d that extend from the base member that each include external cam surfaces 30060 e and define mountingholes base member 30060 a of thelower cam assembly 30060 further includes a plurality of circumferentially spaced apartteeth 30060 h. The circumferentially spaced apartcam arms 30060 d of thelower cam assembly 30060 are interleaved among thelower expansion segments 30058 and the circumferentially spaced apartcam arms 30052 d of theupper cam assembly 30052 and positioned in opposing relation to correspondingupper expansion segments 30054. - Mounting screws, 30062 a, 30062 b, 30062 c, and 30062 e, are mounted within the corresponding mounting holes, 30060 f and 30060 g, of the
lower cam assembly 30060 and are received within the externalannular recess 30006 g of thelower cam assembly 30060. - A tubular
lower hinge sleeve 30064 that receives thelower expansion segments 30058 and thelower cam assembly 30060 includes aninternal flange 30064 a for engaging theexternal flange 30060 b of the base member of thelower cam assembly 30060, aninternal pivot 30064 b for engaging and receiving theexternal pivot recess 30058 a of thelower expansion segments 30058 thereby pivotally mounting the lower expansion segments within the tubular lower hinge sleeve, and an internal threadedconnection 30064 c. - An external threaded
connection 30066 a of an end of atubular sleeve 30066 that defines mounting holes, 30066 b and 30066 c, and includes an internalannular recess 30066 d having ashoulder 30066 e, aninternal flange 30066 f, and an internal threadedconnection 30066 g at another end is received within and coupled to the internal threadedconnection 30064 c of the tubularlower hinge sleeve 30064. An external threadedconnection 30068 a of an end of atubular member 30068 that defines alongitudinal passage 30068 b and mounting holes, 30068 c and 30068 d, and includes an externalannular recess 30068 e, and an external threadedconnection 30068 f at another end is received within and is coupled to the internal threadedconnection 30066 g of thetubular sleeve 30066. - Mounting screws, 30070 a and 30070 b, are mounted in and coupled to the mounting holes, 30068 c and 30068 d, respectively, of the
tubular member 30068 that also extend into the mounting holes, 30066 b and 30066 c, respectively, of thetubular sleeve 30066. A sealingelement 30072 is received within the externalannular recess 30068 e of thetubular member 30068 for sealing the interface between the tubular member and thetubular sleeve 30066. - An internal threaded
connection 30074 a of atubular retracting piston 30074 that defines alongitudinal passage 30074 b and includes an internal annular recess 30074 c and an externalannular recess 30074 d receives and is coupled to the external threadedconnection 30006 i of the tubularlower mandrel 30006. A sealingelement 30076 is received within the externalannular recess 30074 d of thetubular retracting piston 30074 for sealing the interface between the tubular retracting piston and thetubular sleeve 30066. A sealingelement 30078 is received within the internal annular recess 30074 c of thetubular retracting piston 30074 for sealing the interface between the tubular retracting piston and the tubularlower mandrel 30006. - Locking
dogs 30080 mate with and receive theexternal teeth 30006 h of the tubularlower mandrel 30006. Aspacer ring 30082 is positioned between an end face of the lockingdogs 30080 and an end face of thelower cam assembly 30060. Arelease piston 30084 mounted upon the tubularlower mandrel 30006 defines aradial passage 30084 a for mounting aburst disk 30086 includes sealing elements, 30084 b, 30084 c, and 30084 d. The sealing elements, 30084 b and 30084 d, sealing the interface between therelease piston 30084 and the tubularlower mandrel 30006. An end face of therelease piston 30084 is positioned in opposing relation to an end face of the lockingdogs 30080. - A
release sleeve 30088 that receives and is mounted upon the lockingdogs 30080 and therelease piston 30084 includes aninternal flange 30088 a at one end that sealingly engages the tubularlower mandrel 30006. Abypass sleeve 30090 that receives and is mounted upon therelease sleeve 30088 includes aninternal flange 30090 a at one end. - In an exemplary embodiment, during operation of the adjustable casing
expansion cone assembly 30, the retractingspring 30044 is compressed and thereby applies a biasing spring force in adirection 30092 from the lowertubular mandrel 30006 to thetubular spring housing 30034 that, in the absence of other forces, moves and/or maintains theupper cam assembly 30052 and theupper expansion segments 30054 out of engagement with thelower expansion segments 30058 and thelower cam assembly 30060. In an exemplary embodiment, during operation of the adjustable bell sectionexpansion cone assembly 28, an external threadedconnection 20 a of an end of the sealingcup assembly 20 is coupled to the internal threadedconnection 30002 d of the upper tubular tool joint 30002 and an internal threadedconnection 30 a of an end of the adjustable casingexpansion cone assembly 30 is coupled to the external threadedconnection 30068 f of thetubular member 30068. - The
upper cam assembly 30052 and theupper expansion segments 30054 may be brought into engagement with thelower expansion segments 30058 and thelower cam assembly 30060 by pressurizing anannulus 30094 defined between the lowertubular mandrel 30006 and thetubular spring housing 30034. In particular, injection of fluidic materials into the adjustable casingexpansion cone assembly 30 through thelongitudinal passage 30006 b of the lowertubular mandrel 30006 and into theradial passage 30006 ba may pressurize theannulus 30094 thereby creating sufficient operating pressure to generate a force in adirection 30096 sufficient to overcome the biasing force of the retractingspring 30044. As a result, thespring housing 30034 may be displaced in thedirection 30096 relative to the lowertubular mandrel 30006 thereby displacing the tubularupper hinge sleeve 30050,upper cam assembly 30052, andupper expansion segments 30054 in thedirection 30096. - In an exemplary embodiment, as illustrated in
FIGS. 16P, 16Q , and 16R, the displacement of theupper cam assembly 30052 andupper expansion segments 30054 in thedirection 30096 will cause thelower expansion segments 30058 to ride up the cam surfaces 30052 e of thecam arms 30052 d of theupper cam assembly 30052 while also pivoting about the lowertubular hinge segment 30064, and will also cause theupper expansion segments 30054 to ride up the cam surfaces 30060 e of thecam arms 30060 d of thelower cam assembly 30060 while also pivoting about the uppertubular hinge segment 30050. In an exemplary embodiment, when the upper and lower expansion segments, 30054 and 30058, are brought into axial alignment, they define an outer expansion surface that is approximately contiguous in a circumferential direction and which provides an outer expansion surface that at least approximates a conical surface. - In an exemplary embodiment, during the operation of the adjustable casing
expansion cone assembly 30, when the upper and lower expansion segments, 30054 and 30058, brought into axial alignment into a radially expanded position, the upper and lower expansion segments, 30054 and 30058, are displaced relative to theexpandable wellbore casing 100 to thereby radially expand and plastically deform at least a portion of the expandable wellbore casing. In an exemplary embodiment, during the radial expansion and plastic deformation of theexpandable wellbore casing 100, the adjustable casingexpansion cone assembly 30 may then be rotated relative to the expandable wellbore casing to enhance and/or modify the rate at which the expandable wellbore casing is radially expanded and plastically deformed. - In an exemplary embodiment, the
upper cam assembly 30052 and theupper expansion segments 30054 may be moved out of engagement with thelower expansion segments 30058 and thelower cam assembly 30060 by reducing the operating pressure within theannulus 30094. - In an alternative embodiment, as illustrated in
FIGS. 16S, 16T , 16U and 16V, during operation of the adjustable casingexpansion cone assembly 30, theupper cam assembly 30052 and theupper expansion segments 30054 may also be moved out of engagement with thelower expansion segments 30058 and thelower cam assembly 30060 by sensing the operating pressure within thelongitudinal passage 30006 b of the lowertubular mandrel 30006. In particular, as illustrated inFIG. 16T , if the operating pressure within thelongitudinal passage 30006 b andradial passage 30006 bb of the lowertubular mandrel 30006 exceeds a predetermined value, theburst disc 30086 will open thepassage 30084 a thereby pressurizing the interior of thetubular release sleeve 30088 thereby displacing thetubular release sleeve 30088 downwardly in adirection 30092 away from engagement with the lockingdogs 30080. - As a result, as illustrated in
FIG. 16U , the lockingdogs 30080 are displaced outwardly in the radial directed and thereby released from engagement with the lowertubular mandrel 30006 thereby permitting thelower expansion segments 30058 and thelower cam assembly 30060 to be displaced downwardly relative to the lower tubular mandrel. - As a result, as illustrated in
FIG. 16V , the operating pressure within the lowertubular mandrel 30066 may then cause the lower tubular mandrel to be displaced downwardly in thedirection 30094 relative to the tubularlower mandrel 30006 and theretracting piston 30074. As a result, the lowertubular mandrel 30066, thelower expansion segments 30058, thelower cam assembly 30060, and tubularlower hinge sleeve 30064 are displaced downwardly in thedirection 30094 relative to thetubular spring housing 30034 thereby moving thelower expansion segments 30058 and thelower cam assembly 30060 out of engagement with theupper cam assembly 30052 and theupper expansion segments 30054. - In an exemplary embodiment, as illustrated in
FIGS. 16W, 16X , and 16Y, during operation of the adjustable casingexpansion cone assembly 30, the adjustable casing expansion cone assembly senses the diameter of theexpandable wellbore casing 100 using the upper toggle links, 30022 and 30028, lower toggle links, 30024 and 30030, and triggers, 30026 and 30032, and then prevents the engagement of theupper cam assembly 30052 and theupper expansion segments 30054 with thelower expansion segments 30058 and thelower cam assembly 30060. - In particular, as illustrated in
FIG. 16W , anytime the upper toggle links, 30022 and 30028, and lower toggle links, 30024 and 30030, are positioned within a portion of theexpandable wellbore casing 100 that has been radially expanded and plastically deformed by thesystem 10, the triggers, 30026 and 30032, will be pivoted by the engagement arms, 30024 d and 30030 d, of the lower toggle links, 30024 and 30030, to a position in which the triggers will no longer engage theinternal flange 30034 d of the end of thetubular spring housing 30034 thereby permitting the displacement of the tubular spring housing in thedirection 30096. As a result, theupper cam assembly 30052 and theupper expansion segments 30054 can be brought into engagement with thelower expansion segments 30058 and thelower cam assembly 30060. In an exemplary embodiment, the upper toggle links, 30022 and 30028, and the lower toggle links, 30024 and 30030, are spring biased towards the position illustrated inFIG. 16W . - Conversely, as illustrated in
FIG. 16X , anytime the upper toggle links, 30022 and 30028, and lower toggle links, 30024 and 30030, are positioned within a portion of theexpandable wellbore casing 100 that has not been radially expanded and plastically deformed by thesystem 10, the triggers, 30026 and 30032, will be maintained in a position in which the triggers will engage theinternal flange 30034 d of the end of thetubular spring housing 30034 thereby preventing the displacement of the tubular spring housing in thedirection 30096. As a result, theupper cam assembly 30052 and theupper expansion segments 30054 cannot be brought into engagement with thelower expansion segments 30058 and thelower cam assembly 30060. In an exemplary embodiment, the triggers, 30026 and 30032, are spring biased towards the position illustrated inFIG. 16X . - In an exemplary embodiment, as illustrated in
FIG. 16Y , thetubular spring housing 30034 may be displaced upwardly in thedirection 30098 even if the upper toggle links, 30022 and 30028, and lower toggle links, 30024 and 30030, are positioned within a portion of theexpandable wellbore casing 100 that has not been radially expanded and plastically deformed by thesystem 10, - In an exemplary embodiment, as illustrated in FIGS. 16Z1 to 16Z4, 16AA1 to 16AA4, 16AB1 to 16AB4, 16AC1 to 16AC4, 16AD, and 16AE, the
tubular spring housing 30034 of the adjustable casingexpansion cone assembly 30 defines internalannular recesses internal flange 30034 m, thetubular toggle bushing 30008 defines an externalannular recess 30008 ac, and the adjustable casing expansion cone assembly further includes pins, 30100 a and 30100 b and 30102 a and 30102 b, mounted inholes shot deactivation device 30104 mounted on the tubular toggle bushing between the pins, 30100 a and 30100 b and 30102 a and 30102 b. - The one-
shot deactivation device 30104 includes atubular body 30104 a that defines radial holes, 30104 b and 30014 c, and includes an externalannular recess 30104 d at one end, a centrally positionedexternal flange 30104 e, a centrally positioned internalannular recess 30104 f, and an externalannular recess 30104 g at another end. Anengagement member 30106 that includes abase member 30106 a having atapered end 30106 b and akey member 30106 c having atapered end 30106 d is received within a portion of the internalannular recess 30104 f of thetubular body 30104 a and an engagement member 30108 that includes abase member 30108 a having atapered end 30108 b and akey member 30108 c having atapered end 30108 d is received within an opposite portion of the internalannular recess 30104 f of thetubular body 30104 a. Spring members, 30110 and 30112, are received within theannular recess 30104 f of thetubular body 30104 a for biasing the base members,base member tubular body 30104 a. - In an exemplary embodiment, during operation of the adjustable bell section
expansion cone assembly 28, as illustrated inFIG. 16Z , the one-shot deactivation device 30104 are positioned proximate and in intimate contact with the pins, 30102 a and 30102 b, with the tapered ends, 30106 b and 30108 b, of the base members, 30106 a and 30108 a, of the engagement members, 30106 and 30108, received within the externalannular recess 30008 ac of thetubular toggle bushing 30008. When the one-shot deactivation device 30104 is positioned as illustrated inFIG. 16Z , the externalannular recess 30104 d of thetubular body 30104 a of the one-shot deactivation device is moved out of engagement with the engagement arms, 30026 d and 30032 d, of the triggers, 30026 and 30032, respectively. As a result, the triggers, 30026 and 30032, may operate normally as described above with reference toFIGS. 16W, 16X , and 16Y. - Conversely, in an exemplary embodiment, during operation of the adjustable casing
expansion cone assembly 30, as illustrated in FIGS. 16AA1 to 16AA4, the one-shot deactivation device 30104 are positioned proximate and in intimate contact with the pins, 30100 a and 30100 b, with the tapered ends, 30106 b and 30108 b, of the base members, 30106 a and 30108 a, of the engagement members, 30106 and 30108, not received within the externalannular recess 30008 ac of thetubular toggle bushing 30008. When the one-shot deactivation device 30104 is positioned as illustrated in FIGS. 16AA1 to 16AA4, the externalannular recess 30104 d of thetubular body 30104 a of the one-shot deactivation device is moved into engagement with the engagement arms, 30026 d and 30032 d, of the triggers, 30026 and 30032, respectively. As a result, the triggers, 30026 and 30032, are deactivated and may not operate normally as described above with reference toFIGS. 16W, 16X , and 16Y. - In an alternative embodiment, the elements of the adjustable casing
expansion cone assembly 30 that sense the diameter of theexpandable wellbore casing 100 may be disabled or omitted or adjusted to sense any pre-selected internal diameter of the expandable wellbore casing. - In an exemplary embodiment, as illustrated in 17A to 17C, the packer
setting tool assembly 32 includes atubular adaptor 3202 that defines alongitudinal passage 3202 a, radial external mounting holes, 3202 b and 3202 c, radial passages, 3202 d and 3202 e, and includes an external threadedconnection 3202 f at one end and an internalannular recess 3202 g having an internal threaded connection at another end. An external threadedconnection 3204 a of an end of a tubularupper mandrel 3204 that defines alongitudinal passage 3204 b, internally threaded external mounting holes, 3204 c and 3204 d, and includes an externalannular recess 3204 e, externalannular recess 3204 f, externalannular recess 3204 g,external flange 3204 h, external splines 3204 i, and an internal threadedconnection 3204 j at another end is received within and is coupled to the internally threaded connection of the internalannular recess 3202 g of the other end of thetubular adaptor 3202. Mounting screws, 3205 a and 3205 b, are received within and coupled to the mounting holes, 3204 c and 3204 d, of the tubularupper mandrel 3204 that also extend into the radial passages, 3202 d and 3202 e, of thetubular adaptor 3202. - An external threaded
connection 3206 a of an end of amandrel 3206 that defines alongitudinal passage 3206 b and includes an externalannular recess 3206 c and an externalannular recess 3206 d having an external threaded connection is received within and is coupled to the internal threadedconnection 3204 j of the tubularupper mandrel 3204. An internal threadedconnection 3208 a of atubular stinger 3208 that defines alongitudinal passage 3208 b and includes an externalannular recess 3208 c, and an external tapered annular recess 3208 d and anengagement shoulder 3208 e at another end receives and is coupled to the external threaded connection of the externalannular recess 3206 d of themandrel 3206. A sealingmember 3210 is mounted upon and coupled to the externalannular recess 3206 d of themandrel 3206. - An
internal flange 3212 a of a tubular key 3212 that includes an externalannular recess 3212 b at one end and an internalannular recess 3212 c at another end is movably received within and engages the externalannular recess 3204 f of the tubularupper mandrel 3204. Agarter spring 3214 is received within and engages the externalannular recess 3212 b of the tubular key 3212. - An end of a
tubular bushing 3216 that defines alongitudinal passage 3216 a for receiving and mating with theupper mandrel 3204, and radial passages, 3216 b and 3216 c, and includes an external threadedconnection 3216 d at an intermediate portion, and anexternal flange 3216 e, an internalannular recess 3216 f, circumferentially spaced apartteeth 3216 g, and external flanges, 3216 h and 3216 i, at another end is received within and mates with the internalannular recess 3212 c of the tubular key 3212. An internal threadedconnection 3218 a of a tubulardrag block body 3218 that defines alongitudinal passage 3218 b for receiving thetubular bushing 3216, mounting holes, 3218 c and 3218 d, mounting holes, 3218 e and 3218 f, and includes an internal threadedconnection 3218 g at one end, a centrally positioned externalannular recess 3218 h, and an external threadedconnection 3218 i at another end is received within and coupled to the external threadedconnection 3216 d of thetubular bushing 3216. - A
first tubular keeper 3220 that defines mounting holes, 3220 a and 3220 b, is coupled to an end of the tubulardrag block body 3218 by mounting screws, 3222 a and 3222 b, that are received within and are coupled to the mounting holes, 3218 c and 3218 d, of the tubular drag block body. Asecond tubular keeper 3224 that defines mounting holes, 3224 a and 3224 b, is coupled to an end of the tubulardrag block body 3218 by mounting screws, 3226 a and 3226 b, that are received within and are coupled to the mounting holes, 3218 e and 3218 f, of the tubular drag block body. - Drag blocks, 3228 and 3230, that are received within the external
annular recess 3218 h of the tubulardrag block body 3218, include ends that mate with and are received within the end of thefirst tubular keeper 3220, and other ends that mate with and are received within the end of thesecond tubular keeper 3224. The drag blocks, 3228 and 3230, further include internal annular recesses, 3228 a and 3230 a, respectively, that receive and mate with ends of springs, 3232 and 3234, respectively. The springs, 3232 and 3234, also receive and mate with the externalannular recess 3218 h of the tubulardrag block body 3218. - An external threaded
connection 3236 a of an end of a tubular releasingcap extension 3236 that defines alongitudinal passage 3236 b and includes an internalannular recess 3236 c and an internal threadedconnection 3236 d at another end is received within and is coupled to the internal threadedconnection 3218 g of the tubulardrag block body 3218. An external threadedconnection 3238 a of an end of a tubular releasingcap 3238 that defines a longitudinal passage 3238 b and includes an internalannular recess 3238 c is received within and coupled to the internal threadedconnection 3236 d of the tubular releasingcap extension 3236. Asealing element 3240 is received within the internalannular recess 3238 c of the tubular releasingcap 3238 for fluidicly sealing the interface between the tubular releasing cap and theupper mandrel 3204. - An internal threaded
connection 3242 a of an end of atubular setting sleeve 3242 that defines alongitudinal passage 3242 b,radial passage 3242 c, radial passages, 3242 d and 3242 e,radial passage 3242 f, and includes aninternal flange 3242 g at another end receives the external threadedconnection 3218 i of the tubulardrag block body 3218. Aninternal flange 3244 a of atubular coupling ring 3244 that defines alongitudinal passage 3244 b and radial passages, 3244 c and 3244 d, receives and mates with theexternal flange 3216 h of thetubular bushing 3216 and an end face of the internal flange of the tubular coupling ring is positioned proximate and in opposing relation to an end face of theexternal flange 3216 i of the tubular bushing. - An
internal flange 3246 a of atubular retaining collet 3246 that includes a plurality of axially extendingcollet fingers 3246 b, each havinginternal flanges 3246 c at an end of each collet finger, for engaging and receiving thetubular coupling ring 3244 receives and mates withexternal flange 3216 e of thetubular bushing 3216 and an end face of the internal flange of the tubular retaining collet is positioned proximate and in opposing relation to an end face of theexternal flange 3216 h of the tubular bushing. - In an exemplary embodiment, the
packer assembly 36 operates and is provided substantially, at least in part, as disclosed in one or more of the following: (1) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, and/or (2) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on Sep. 23, 2003, and/or (3) PCT patent application serial number PCT/US04/______, attorney docket number 25791.253.02, filed on Mar. 11, 2004, and/or (4) PCT patent application serial number PCT/US04/______, attorney docket number 25791.260.02, filed on Mar. 26, 2004, and/or (5) PCT patent application serial number PCT/US04/______, attorney docket number 25791.270.02, filed on Apr. 2, 2004, the disclosures of which are incorporated herein by reference. - In an exemplary embodiment, as illustrated in
FIGS. 18-1 to 18-5, thepacker assembly 36 includes a tubularupper adaptor 3602 that defines alongitudinal passage 3602 a having a taperedopening 3602 b and mounting holes, 3602 c and 3602 d, that includes a plurality of circumferentially spaced apartteeth 3602 e at one end, anexternal flange 3602 f, and an internal threadedconnection 3602 g at another end. In an exemplary embodiment, the tubularupper adaptor 3602 is fabricated from aluminum. An external threadedconnection 3604 a of an end of a tubularupper mandrel 3604 that defines alongitudinal passage 3604 b, mounting holes, 3604 c and 3604 d, mounting holes, 3604 e and 3604 f, and mounting holes, 3604 g and 3604 h, and includes anexternal flange 3604 i, an internalannular recess 3604 j, and an internal threadedconnection 3604 k at another end is received within and coupled to the internal threadedconnection 3602 g of the tubularupper adaptor 3602. In an exemplary embodiment, the tubularupper mandrel 3604 is fabricated from aluminum. - An upper
tubular spacer ring 3606 that defines mounting holes, 3606 a and 3606 b, receives and mates with the end of the tubularupper mandrel 3604 and includes anangled end face 3606 c and another end face that is positioned proximate to an end face of the tubularupper adaptor 3602 is coupled to the tubular upper mandrel by shear pins, 3608 a and 3608 b, that are mounted within and coupled to the mounting holes, 3604 c and 3606 a, and, 3604 d and 3606 b, respectively, of the tubular upper mandrel and upper tubular spacer ring, respectively. A lowertubular spacer ring 3610 that includes anangled end face 3610 a receives, mates, and is coupled to the other end of the tubularupper mandrel 3604 and includes another end face that is positioned proximate to an end face of theexternal flange 3604 i of the tubularupper mandrel 3604. In an exemplary embodiment, the upper and tubular spacer rings, 3606 and 3610, are fabricated from a composite material. - An
upper tubular slip 3612 that receives and is movably mounted upon the tubularupper mandrel 3604 defines alongitudinal passage 3612 a having a taperedopening 3612 b and includes external annular recesses, 3612 c, 3612 d, 3612 e, 3612 f, and 3612 g, and anangled end face 3612 h that mates with and is positioned proximate theangled end face 3606 c of the uppertubular spacer ring 3606. Slip retaining bands, 3614 a, 3614 b, 3614 c, 3614 d, and 3614 e, are received within and coupled to the external annular recesses, 3612 c, 3612 d, 3612 e, 3612 f, and 3612 g, of theupper tubular slip 3612. Alower tubular slip 3616 that receives and is movably mounted upon the tubularupper mandrel 3604 defines alongitudinal passage 3616 a having a taperedopening 3616 b and includes external annular recesses, 3616 c, 3616 d, 3616 e, 3616 f, and 3616 g, and anangled end face 3616 h that mates with and is positioned proximate theangled end face 3610 a of the lowertubular spacer ring 3610. Slip retaining bands, 3618 a, 3618 b, 3618 c, 3618 d, and 3618 e, are received within and coupled to the external annular recesses, 3616 c, 3616 d, 3616 e, 3616 f, and 3616 g, of thelower tubular slip 3616. In an exemplary embodiment, the upper and lower tubular slips, 3612 and 3616, are fabricated from composite materials, and at least some of the slip retaining bands, 3614 a, 3614 b, 3614 c, 3614 d, 3614 e, 3618 a, 3618 b, 3618 c, 3618 d, and 3618 e are fabricated from carbide insert materials. - An
upper tubular wedge 3620 that defines anlongitudinal passage 3620 a for receiving the tubularupper mandrel 3604 and mounting holes, 3620 b and 3620 c, and includes anangled end face 3620 d at one end that is received within and mates with thetapered opening 3612 b of theupper tubular slip 3612, and anangled end face 3620 e at another end is coupled to the tubular upper mandrel by shear pins, 3622 a and 3622 b, mounted within and coupled to the mounting holes, 3604 e and 3620 b, and, 3604 f and 3620 c, respectively, of the tubular upper mandrel and upper tubular wedge, respectively. Alower tubular wedge 3624 that defines anlongitudinal passage 3624 a for receiving the tubularupper mandrel 3604 and mounting holes, 3624 b and 3624 c, and includes anangled end face 3624 d at one end that is received within and mates with thetapered opening 3616 b of thelower tubular slip 3616, and anangled end face 3624 e at another end is coupled to the tubular upper mandrel by shear pins, 3626 a and 3626 b, mounted within and coupled to the mounting holes, 3604 g and 3624 b, and, 3604 h and 3624 c, respectively, of the tubular upper mandrel and lower tubular wedge, respectively. In an exemplary embodiment, the upper and lower tubular wedges, 3620 and 3624, are fabricated from composite materials. - An upper
tubular extrusion limiter 3628 that defines alongitudinal passage 3628 a for receiving the tubularupper mandrel 3604 includes anangled end face 3628 b at one end that mates with theangled end face 3620 e of theupper tubular wedge 3620, anangled end face 3628 c at anotherend having recesses 3628 d, and external annular recesses, 3628 e, 3628 f and 3628 g. Retaining bands, 3630 a, 3630 b, and 3630 c, are mounted within and coupled to the external annular recesses, 3628 e, 3628 f and 3628 g, respectively, of the uppertubular extrusion limiter 3628. Circular disc-shapedextrusion preventers 3632 are coupled and mounted within therecesses 3628 d. A lowertubular extrusion limiter 3634 that defines alongitudinal passage 3634 a for receiving the tubularupper mandrel 3604 includes anangled end face 3634 b at one end that mates with theangled end face 3624 e of the lowertubular wedge 3624, anangled end face 3634 c at anotherend having recesses 3634 d, and external annular recesses, 3634 e, 3634 f and 3634 g. Retaining bands, 3636 a, 3636 b, and 3636 c, are mounted within and coupled to the external annular recesses, 3634 e, 3634 f and 3634 g, respectively, of the lowertubular extrusion limiter 3634. Circular disc-shapedextrusion preventers 3638 are coupled and mounted within therecesses 3634 d. In an exemplary embodiment, the upper and lower extrusion limiters, 3628 and 3634, are fabricated from composite materials. - An upper tubular
elastomeric packer element 3640 that defines alongitudinal passage 3640 a for receiving the tubularupper mandrel 3604 includes anangled end face 3640 b at one end that mates with and is positioned proximate theangled end face 3628 c of the uppertubular extrusion limiter 3628 and ancurved end face 3640 c at another end. A lower tubularelastomeric packer element 3642 that defines alongitudinal passage 3642 a for receiving the tubularupper mandrel 3604 includes anangled end face 3642 b at one end that mates with and is positioned proximate theangled end face 3634 c of the lowertubular extrusion limiter 3634 and ancurved end face 3642 c at another end. - A central tubular
elastomeric packer element 3644 that defines alongitudinal passage 3644 a for receiving the tubularupper mandrel 3604 includes a curved outer surface 3644 b for mating with and engaging the curved end faces, 3640 c and 3642 c, of the upper and lower tubular elastomeric packer elements, 3640 and 3642, respectively. - An external threaded
connection 3646 a of a tubularlower mandrel 3646 that defines alongitudinal passage 3646 b having throat passages, 3646 c and 3646 d, and flow ports, 3646 e and 3646 f, and a mountinghole 3646 g, and includes an internalannular recess 3646 h at one end, and anexternal flange 3646 i, internalannular recess 3646 j, and internal threadedconnection 3646 k at another end. In an exemplary embodiment, the tubularlower mandrel 3646 is fabricated from aluminum. Asealing element 3648 is received within the innerannular recess 3604 j of the other end of the tubularupper mandrel 3604 for sealing an interface between the tubular upper mandrel and the tubularlower mandrel 3646. - A tubular sliding
sleeve valve 3650 that defines alongitudinal passage 3650 a and radial flow ports, 3650 b and 3650 c, and includescollet fingers 3650 d at one end for engaging the internalannular recess 3646 h of the lowertubular mandrel 3646, an externalannular recess 3650 e, an externalannular recess 3650 f, an externalannular recess 3650 g, and circumferentially spaced apartteeth 3650 h at another end is received within and is slidably coupled to thelongitudinal passage 3646 b of the tubularlower mandrel 3646. In an exemplary embodiment, the tubular slidingsleeve valve 3650 is fabricated from aluminum. Aset screw 3652 is mounted within and coupled to the mountinghole 3646 g of the tubularlower mandrel 3646 that is received within the externalannular recess 3650 e of thetubular sliding sleeve 3650. Sealing elements, 3654 and 3656, are mounted within the external annular recesses, 3650 f and 3650 g, respectively, of the tubular slidingsleeve valve 3650 for sealing an interface between the tubular sliding sleeve valve and the tubularlower mandrel 3646. - An end of a tubular
outer sleeve 3658 that defines alongitudinal passage 3658 a, radial passages, 3658 b and 3658 c, upper flow ports, 3658 d and 3658 e, lower flow ports, 3658 f and 3658 g, and radial passages, 3658 h and 3658 i, receives, mates with, and is coupled to the other end of the tubularupper mandrel 3604 and an end face of the end of the tubular outer sleeve is positioned proximate and end face of the lowertubular spacer ring 3610. The other end of the tubularouter sleeve 3658 receives, mates with, and is coupled to the other end of the tubularlower mandrel 3646. - An external threaded
connection 3660 a of an end of atubular bypass mandrel 3660 that defines alongitudinal passage 3660 b, upper flow ports, 3660 c and 3660 d, lower flow ports, 3660 e and 3660 f, and a mountinghole 3660 g and includes an internalannular recess 3660 h and an external threadedconnection 3660 i at another end is received within and coupled to the internal threadedconnection 3646 k of the tubularlower mandrel 3646. Asealing element 3662 is received within the internalannular recess 3646 j of the tubularlower mandrel 3646 for sealing an interface between the tubular lower mandrel and thetubular bypass mandrel 3660. - A
tubular plug seat 3664 that defines alongitudinal passage 3664 a having a taperedopening 3664 b at one end, and flow ports, 3664 c and 3664 d, and includes an externalannular recess 3664 e, an externalannular recess 3664 f, an externalannular recess 3664 g, an externalannular recess 3664 h, and an external annular recess 3664 i having an external threaded connection at another end is received within and is movably coupled to thelongitudinal passage 3660 b of thetubular bypass mandrel 3660. Atubular nose 3666 is, threadably coupled to and mounted upon the external annular recess 3664 i of thetubular plug seat 3664. In an exemplary embodiment, thetubular plug seat 3664 is fabricated from aluminum. Sealing elements, 3668, 3670, and 3672, are received within the external annular recesses, 3664 e, 3664 g, and 3664 h, respectively, of thetubular plug seat 3664 for sealing an interface between the tubular plug seat and thetubular bypass mandrel 3660. Aset screw 3674 is mounted within and coupled to the mountinghole 3660 g of thetubular bypass mandrel 3660 that is received within the externalannular recess 3664 f of thetubular plug seat 3664. - An end of a
tubular bypass sleeve 3676 that defines alongitudinal passage 3676 a and includes an internalannular recess 3676 b at one end and an internal threadedconnection 3676 c at another end is coupled to the other end of the tubularouter sleeve 3658 and mates with and receives thetubular bypass mandrel 3660. In an exemplary embodiment, thetubular bypass sleeve 3676 is fabricated from aluminum. - An external threaded
connection 3678 a of atubular valve seat 3678 that defines alongitudinal passage 3678 b including avalve seat 3678 c and up-jet flow ports, 3678 d and 3678 e, and includes aspring retainer 3678 f and an externalannular recess 3678 g is received within and is coupled to the internal threadedconnection 3676 c of thetubular bypass sleeve 3676. In an exemplary embodiment, thetubular valve seat 3678 is fabricated from aluminum. Asealing element 3680 is received within the externalannular recess 3678 g of thetubular valve seat 3678 for fluidicly sealing an interface between the tubular valve seat and thetubular bypass sleeve 3676. - A
poppet valve 3682 mates with and is positioned within thevalve seat 3678 c of thetubular valve seat 3678. An end of thepoppet valve 3682 is coupled to an end of astem bolt 3684 that is slidingly supported for longitudinal displacement by thespring retainer 3678 fA valve spring 3686 that surrounds a portion of thestem bolt 3684 is positioned in opposing relation to the head of the stem bolt and asupport 3678 fa of thespring retainer 3678 f for biasing thepoppet valve 3682 into engagement with thevalve seat 3678 c of thetubular valve seat 3678. - An end of a composite nose 3688 that defines a
longitudinal passage 3688 a and mounting holes, 3688 b and 3688 c, and includes an internal threadedconnection 3688 d at another end receives, mates with, and is coupled to the other end of thetubular valve seat 3678. Atubular nose sleeve 3690 that defines mounting holes, 3690 a and 3690 b, is coupled to the composite nose 3688 by shear pins, 3692 a and 3692 b, that are mounted in and coupled to the mounting holes, 3688 b and 3690 a, and, 3688 c and 3690 b, respectively, of the composite nose and tubular nose sleeve, respectively. - An external threaded
connection 3694 a of abaffle nose 3694 that defines longitudinal passages, 3694 b and 3694 c, is received within and is coupled to the internal threaded connection internal threadedconnection 3688 d of the composite nose 3688. - In an exemplary embodiment, as illustrated in FIGS. 19A1 to 19A5, during the operation of the packer
setting tool assembly 32 andpacker assembly 36, the packer setting tool and packer assembly are coupled to one another by inserting the end of the tubularupper adaptor 3602 into the other end of thetubular coupling ring 3244, bringing the circumferentially spacedteeth 3216 g of the other end of thetubular bushing 3216 into engagement with the circumferentially spacedteeth 3602 e of the end of the tubular upper adaptor, and mounting shear pins, 36100 a and 36100 b, within the mounting holes, 3244 c and 3602 c, and, 3244 d and 3602 d, respectively, of the tubular coupling ring and tubular upper adaptor, respectively. As a result, thetubular mandrel 3206 andtubular stinger 3208 of the packersetting tool assembly 32 are thereby positioned within thelongitudinal passage 3604 a of the tubularupper mandrel 3604 with the 3208 e of the tubular stinger positioned within thelongitudinal passage 3646 b of the tubularlower mandrel 3646 proximate thecollet fingers 3650 d of the tubular slidingsleeve valve 3650. - Furthermore, in an exemplary embodiment, during the operation of the
packer setting tool 32 andpacker assembly 36, as illustrated in FIGS. 19A1 to 19A5, the packer setting tool and packer assembly are positioned within theexpandable wellbore casing 100 and an internal threadedconnection 30 a of an end of the adjustable casingexpansion cone assembly 30 receives and is coupled to the external threadedconnection 3202 f of the end of thetubular adaptor 3202 of the packer setting tool assembly. Furthermore, shear pins, 36102 a and 36102 b, mounted within the mounting holes, 3658 b and 3658 c, of the tubularouter sleeve 3658 couple the tubular outer sleeve to the expandable wellbore casing. As a result, torsion loads may transferred between the tubularouter sleeve 3658 and theexpandable wellbore casing 100. - In an exemplary embodiment, as illustrated in FIGS. 19B1 to 19B5, a
conventional plug 36104 is then injected into thesetting tool assembly 32 andpacker assembly 36 by injecting afluidic material 36106 into the setting tool assembly and packer assembly through the longitudinal passages, 3202 a, 3204 b, 3206 b, 3208 b, 3650 a, 3646 a, 3660 b, and 3664 a of thetubular adaptor 3202, tubularupper mandrel 3204,tubular mandrel 3206,tubular stinger 3208, tubular slidingsleeve valve 3650, tubularlower mandrel 3646,tubular bypass mandrel 3660, andtubular plug seat 3664, respectively. Theplug 36104 is thereby positioned within thelongitudinal passage 3664 a of thetubular plug seat 3664. Continued injection of thefluidic material 36106 following the seating of theplug 1606 within thelongitudinal passage 3664 a of thetubular plug seat 3664 causes the plug and the tubular plug seat to be displaced downwardly in adirection 36108 until further movement of the tubular plug seat is prevented by interaction of theset screw 3674 with the externalannular recess 3664 f of the tubular plug seat. As a result, the flow ports, 3664 c and 3664 d, of thetubular plug seat 3664 are moved out of alignment with the upper flow ports, 3660 c and 3660 d, of thetubular bypass mandrel 3660. - In an exemplary embodiment, as illustrated in FIGS. 19C1 to 19C5, after the
expandable wellbore casing 100 has been radially expanded and plastically deformed to form at least thebell section 112 of theexpandable wellbore casing 100 thereby shearing the shear pins, 36102 a and 36102 b, thesetting tool assembly 32 andpacker assembly 36 are then moved upwardly to a position within theexpandable wellbore casing 100 above the bell section. Thetubular adaptor 3202 is then rotated, by rotating the tool string of thesystem 10 above thesetting tool assembly 32, to displace and position the drag blocks, 3228 and 3230, into engagement with the interior surface of theexpandable wellbore casing 100. - As a result of the engagement of the drag blocks, 3228 and 3230, with the interior surface of the
expandable wellbore casing 100, further rotation of the drag blocks relative to the wellbore casing is prevented. Consequently, due to the operation and interaction of the threaded connections, 3216 d and 3218 a, of thetubular bushing 3216 and tubulardrag block body 3218, respectively, further rotation of thetubular adaptor 3202 causes the tubular drag block body and settingsleeve 3242 to be displaced downwardly in adirection 36112 relative to the remaining elements of thesetting tool assembly 32 andpacker assembly 36. As a result, thesetting sleeve 3242 engages and displaces the uppertubular spacer ring 3606 thereby shearing the shear pins, 3622 a and 3622 b, and driving theupper tubular slip 3612 onto and up theangled end face 3620 d of theupper tubular wedge 3620 and into engagement with the interior surface of theexpandable wellbore casing 100. As a result, longitudinal displacement of theupper tubular slip 3612 relative to theexpandable wellbore casing 100 is prevented. Furthermore, as a result, the 3246 b collet fingers of thetubular retaining collet 3246 are disengaged from the tubularupper adaptor 3602. - In an alternative embodiment, after the drag blocks, 3228 and 3230, engage the interior surface of the
expandable wellbore casing 100, an upward tensile force is applied to thetubular support member 12, and theball gripper assembly 16 is then operate to engage the interior surface of the expandable wellbore casing. Thetension actuator assembly 18 is then operated to apply an upward tensile force to thetubular adaptor 3202 thereby pulling the uppertubular spacer ring 3606, lowertubular spacer ring 3610,upper tubular slip 3612, lowertubular slip 3616,upper tubular wedge 3620, lowertubular wedge 3624, uppertubular extrusion limiter 3628, lowertubular extrusion limiter 3634, and central tubularelastomeric element 3644 upwardly into contact with the 3242 thereby compressing the upper tubular spacer ring, lower tubular spacer ring, upper tubular slip, lower tubular slip, upper tubular wedge, lower tubular wedge, upper tubular extrusion limiter, lower tubular extrusion limiter, and central tubular elastomeric element. As a result, theupper tubular slip 3612, lowertubular slip 3616, and central tubularelastomeric element 3644 engage the interior surface of theexpandable wellbore casing 100. - In an exemplary embodiment, as illustrated in FIGS. 19D1 to 19D5, an upward tensile force is then applied to the
tubular adaptor 3202 thereby compressing thelower tubular slip 3616, lowertubular wedge 3624, centralelastomeric packer element 3644, uppertubular extrusion limiter 3628, and uppertubular wedge 3620 between the lowertubular spacer ring 3610 and the stationary uppertubular slip 3612. As a result, thelower tubular slip 3616 is driven onto and up theangled end face 3624 d of the lowertubular wedge 3624 and into engagement with the interior surface of theexpandable wellbore casing 100, and the centralelastomeric packer element 3644 is compressed radially outwardly into engagement with the interior surface of the expandable tubular member. As a result, further longitudinal displacement of theupper tubular slip 3612, lowertubular slip 3616, and centralelastomeric packer element 3644 relative to theexpandable wellbore casing 100 is prevented. - In an exemplary embodiment, as illustrated in FIGS. 19E1 to 19E6, continued application of the upward tensile force to
tubular adaptor 3202 will then shear the shear pins, 1602 a and 1602 b, thereby disengaging thesetting tool assembly 32 from thepacker assembly 36. - In an exemplary embodiment, as illustrated in FIGS. 19F1 to 19F6, with the drag blocks, 3228 and 3230, in engagement with the interior surface of the
expandable wellbore casing 100, thetubular adaptor 102 is further rotated thereby causing the tubulardrag block body 3218 and settingsleeve 3242 to be displaced further downwardly in thedirection 36113 until the tubular drag block body and setting sleeve are disengaged from thetubular stinger 3208. As a result, thetubular stinger 3208 of thesetting tool assembly 32 may then be displaced downwardly into complete engagement with the tubular slidingsleeve valve 3650. - In an exemplary embodiment, as illustrated in FIGS. 19G1 to 19G6, a
fluidic material 36114 is then injected into thesetting tool assembly 32 and thepacker assembly 36 through thelongitudinal passages tubular adaptor 3202, tubularupper mandrel 3204,tubular mandrel 3206,tubular stinger 3208, tubularupper mandrel 3604, tubular slidingsleeve valve 3650, and tubularlower mandrel 3646, respectively. Because, theplug 36104 is seated within and blocks thelongitudinal passage 3664 a of thetubular plug seat 3664, thelongitudinal passages upper mandrel 3604, tubular slidingsleeve valve 3650, and tubularlower mandrel 3646 are pressurized thereby displacing the tubularupper adaptor 3602 and tubularupper mandrel 3604 downwardly until the end face of the tubular upper mandrel impacts the end face of the uppertubular spacer ring 3606. - In an exemplary embodiment, as illustrated in FIGS. 19H1 to 19H5, the
setting tool assembly 32 is brought back into engagement with thepacker assembly 36 until theengagement shoulder 3208 e of the other end of thetubular stinger 3208 engages thecollet fingers 3650 d of the end of the tubular slidingsleeve valve 3650. As a result, further downward displacement of thetubular stinger 3208 displaces the tubular slidingsleeve valve 3650 downwardly until the radial flow ports, 3650 b and 3650 c, of the tubular sliding sleeve valve are aligned with the flow ports, 3646 e and 3646 f, of the tubularlower mandrel 3646. A hardenablefluidic sealing material 36116 may then be injected into thesetting tool assembly 32 and thepacker assembly 36 through thelongitudinal passages tubular adaptor 3202, tubularupper mandrel 3204,tubular mandrel 3206,tubular stinger 3208, and tubular slidingsleeve valve 3650, respectively. The hardenable fluidic sealing material may then flow out of thepacker assembly 36 through the upper flow ports, 3658 d and 3658 e, into the annulus between theexpandable wellbore casing 100 and thewellbore 102. - The tubular sliding
sleeve valve 3650 may then be returned to its original position, with the radial flow ports, 3650 b and 3650 c, of the tubular sliding sleeve valve out of alignment with the flow ports, 3646 e and 3646 f, of the tubularlower mandrel 3646. The hardenablefluidic sealing material 36116 may then be allowed to cure before, during, or after the continued operation of thesystem 10 to further radially expand and plastically deform the expandable wellbore casing. - In an alternative embodiment, as illustrated in
FIGS. 20 and 20 A to 20AX, thepacker assembly 36 includes an uppertubular spacer ring 36200 receives and mates with the end of the tubularupper mandrel 3604 and includes anangled end face 36200 a that includes a plurality of spaced apartradial grooves 36200 b and another end face that is positioned proximate to an end face of the tubularupper adaptor 3602 is coupled to the tubular upper mandrel by shear pins, 36202 a, 36202 b, 36202 c, and 36202 d. A lowertubular spacer ring 36204 that includes anangled end face 36204 a that includes a plurality of spaced apartradial grooves 36204 b receives, mates, and is coupled to the other end of the tubularupper mandrel 3604 and includes another end face that is positioned proximate to an end face of theexternal flange 3604 i of the tubularupper mandrel 3604. In an exemplary embodiment, the upper and tubular spacer rings, 3606 and 3610, are fabricated from a composite material. - An upper
tubular slip assembly 36206 that receives and is movably mounted upon the tubularupper mandrel 3604 includes a plurality of substantiallyidentical slip elements 36206 a that each include an exterior arcuatecylindrical surface 36206 aa including mounting holes, 36206 ab, 36206 ac, 36206 ad, 36206 ae, 36206 af, 36206 ag, 36206 ah, 36206 ai, and 36206 aj, and grooves, 36206 aj and 36206 ak, afront end face 36206 al, a rear end face 36206 am including a mountinghole 36206 an, side faces, 36206 ao and 36206 ap, an interior arcuatecylindrical surface 36206 aq that mates with the exterior surface of the tubularupper mandrel 3604, and an interiortapered surface 36206 ar including a mountinghole 36206 as. Mountingpins 36206 at are received within and coupled to the mountingholes 36206 an and are received within correspondingradial grooves 36200 b of theangled end face 36200 a of the uppertubular spacer ring 36200. Retainingpins 36206 au are mounted within and coupled to the mountingholes 36206 as that includeheads 36206 av. Slip retaining bands, 36206 aw and 36206 ax, are received within and coupled to grooves, 36206 aj and 36206 ak, respectively, of theslip elements 36206 a. Slip gripping elements, 36206 ay, 36206 az, 36206 aaa, 36206 aab, 36206 aac, 36206 aad, 36206 aae, 36206 aaf, and 36206 aag, are mounted within, coupled to, and extend out of the mounting holes, 36206 ab, 36206 ac, 36206 ad, 36206 ae, 36206 af, 36206 ag, 36206 ah, 36206 ai, and 36206 aj, respectively. In an exemplary embodiment, the adjacent exterior arcuatecylindrical surfaces 36206 aa of theidentical slip elements 36206 a of the uppertubular slip assembly 36206 together define a substantially contiguous cylindrical surface. - A lower
tubular slip assembly 36208 that receives and is movably mounted upon the tubularupper mandrel 3604 includes a plurality of substantiallyidentical slip elements 36208 a that each include an exterior arcuatecylindrical surface 36208 aa including mounting holes, 36208 ab, 36208 ac, 36208 ad, 36208 ae, 36208 af, 36208 ag, 36208 ah, 36208 ai, and 36208 aj, and grooves, 36208 aj and 36208 ak, afront end face 36208 al, a rear end face 36208 am including a mountinghole 36208 an, side faces, 36208 ao and 36208 ap, an interior arcuatecylindrical surface 36208 aq that mates with the exterior surface of the tubularupper mandrel 3604, and an interiortapered surface 36208 ar including a mountinghole 36208 as. Mountingpins 36208 at are received within and coupled to the mountingholes 36208 an and are received within correspondingradial grooves 36204 b of theangled end face 36204 a of the lowertubular spacer ring 36204. Retainingpins 36208 au are mounted within and coupled to the mountingholes 36208 as that includeheads 36208 av. Slip retaining bands, 36208 aw and 36208 ax, are received within and coupled to grooves, 36208 aj and 36208 ak, respectively, of theslip elements 36208 a. Slip gripping elements, 36208 ay, 36208 az, 36208 aaa, 36208 aab, 36208 aac, 36208 aad, 36208 aae, 36208 aaf, and 36208 aag, are mounted within, coupled to, and extend out of the mounting holes, 36208 ab, 36208 ac, 36208 ad, 36208 ae, 36208 af, 36208 ag, 36208 ah, 36208 ai, and 36208 aj, respectively. In an exemplary embodiment, the adjacent exterior arcuatecylindrical surfaces 36208 aa of theidentical slip elements 36208 a of the uppertubular slip assembly 36208 together define a substantially contiguous cylindrical surface. - An upper
tubular wedge 36210 that receives the tubularupper mandrel 3604 includes an angledfront end face 36210 a including spaced apartradial grooves 36210 b, arear end face 36210 c, an exteriorcylindrical surface 36210 d, a plurality of spaced apart faceted taperedexterior surface segments 36210 e that mate with corresponding taperedinternal surfaces 36206 ar ofcorresponding slip elements 36206 a of the uppertubular slip assembly 36206, and T-shapedexterior grooves 36210 f aligned with the midline of corresponding faceted tapered exterior surface segments that extend from the angled end face to the rear end face that receive and mate with corresponding retainingpins 36206 au of corresponding slip elements of the upper tubular slip assembly. The uppertubular wedge 36210 is releasably coupled to the tubularupper mandrel 3604 by shear pins 36211. - A lower
tubular wedge 36212 that receives the tubularupper mandrel 3604 includes an angledfront end face 36212 a including spaced apartradial grooves 36212 b, arear end face 36212 c, an exteriorcylindrical surface 36212 d, a plurality of spaced apart faceted taperedexterior surface segments 36212 e that mate with corresponding taperedinternal surfaces 36208 ar ofcorresponding slip elements 36208 a of the uppertubular slip assembly 36208, and T-shapedexterior grooves 36212 f aligned with the midline of corresponding faceted tapered exterior surface segments that extend from the angled end face to the rear end face that receive and mate with corresponding retainingpins 36208 au of corresponding slip elements of the lower tubular slip assembly. The lowertubular wedge 36212 is releasably coupled to the tubularupper mandrel 3604 by shear pins 36213. - An upper tubular
extrusion limiter assembly 36214 that receives and is movably mounted upon the tubularupper mandrel 3604 includes a plurality of substantially identicalextrusion limiter elements 36214 a that each include an angledfront end face 36214 aa having a recessedportion 36214 ab, an angledrear end face 36214 ac that defines a mountinghole 36214 ad, an interior arcuatecylindrical surface 36214 ae that mates with the tubular upper mandrel, and an exterior arcuatecylindrical surface 36214 af including grooves, 36214 ag, 36214 ah, and 36214 ai.Disk extrusion preventers 36214 aj are mounted within and coupled to the recessedportions 36214 ab of adjacentextrusion limiter elements 36214 a, and mountingpins 36214 ak are mounted within and coupled to mountingholes 36214 ad of correspondingextrusion limiter elements 36214 a that are received within correspondingradial grooves 36210 b of thefront end face 36210 a of the uppertubular wedge 36210. Retaining bands, 36214 al, 36214 am, and 36214 an, are positioned within and coupled to the grooves, 36214 ai, 36214 ah, and 36214 ag, respectively, of theextrusion limiter elements 36214 a. - A lower tubular
extrusion limiter assembly 36216 that receives and is movably mounted upon the tubularupper mandrel 3604 includes a plurality of substantially identicalextrusion limiter elements 36216 a that each include an angledfront end face 36216 aa having a recessedportion 36216 ab, an angledrear end face 36216 ac that defines a mountinghole 36216 ad, an interior arcuatecylindrical surface 36216 ae that mates with the tubular upper mandrel, and an exterior arcuatecylindrical surface 36216 af including grooves, 36216 ag, 36216 ah, and 36216 ai.Disk extrusion preventers 36216 aj are mounted within and coupled to the recessedportions 36216 ab of adjacentextrusion limiter elements 36216 a, and mountingpins 36216 ak are mounted within and coupled to mountingholes 36216 ad of correspondingextrusion limiter elements 36216 a that are received within correspondingradial grooves 36212 b of thefront end face 36212 a of the lowertubular wedge 36212. Retaining bands, 36216 al, 36216 am, and 36216 an, are positioned within and coupled to the grooves, 36216 ag, 36216 ah, and 36216 ai, of theextrusion limiter elements 36216 a. - The
angled end face 3640 b of the upper tubularelastomeric packer element 3640 mates with and is positioned proximate the angled end faces 36214 aa anddisk extrusion preventers 36214 aj of theextrusion limiter elements 36214 a of the upper tubularextrusion limiter assembly 36214, and theangled end face 3642 b of the lower tubularelastomeric packer element 3642 mates with and is positioned proximate the angled end faces 36216 aa anddisk extrusion preventers 36216 aj of theextrusion limiter elements 36216 a of the lower tubularextrusion limiter assembly 36216. - During operation of the alternative embodiment of the
packer assembly 36 described above with reference toFIGS. 20 and 20 A to 20AX, the first step in setting thepacker assembly 36 includes pushing the slip elements, 36206 a and 36208 a, of the upper and lower slip assemblies, 36206 and 36208, respectively, up the upper and lower tubular wedges, 36210 and 36212, respectively, which breaks the retaining rings, 36206 aw and 36206 ax, and 36208 aw and 36208 ax, respectively, and moves the slip elements outwardly against the interior surface of theexpandable wellbore casing 100. In an exemplary embodiment, during the radial displacement of the slip elements, 36206 a and 36208 a, the retaining pins, 36206 au and 36208 au, respectively, and the mounting pins, 36206 at and 36208 at, respectively, maintain the slip elements in an evenly spaced apart configuration. In an exemplary embodiment, during the operation of thepacker assembly 36, the mounting pins, 36214 ak and 36216 ak, maintain the extrusion limiter elements, 36214 a and 36216 a, of the upper and lower tubular extrusion limiter assemblies, 36214 and 36216, respectively, in an evenly spaced apart configuration. The operation of the alternative embodiment of thepacker assembly 36 described above with reference toFIGS. 20 and 20 A to 20AX is otherwise substantially identical to the operation of the packer assembly described above with reference to FIGS. 19A1 to 19A5, 19B1 to 19B5, 19C1 to 19C5, 19D1 to 19D5, 19E1 to 19E6, 19F1 to 19F6, 19G1 to 19G6, and 19H1 to 19H5. - An apparatus for radially expanding and plastically deforming an expandable tubular member has been described that includes a support member, a cutting device for cutting the tubular member coupled to the support member, and an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member. In an exemplary embodiment, the apparatus further includes a gripping device for gripping the tubular member coupled to the support member. In an exemplary embodiment, the gripping device comprises a plurality of movable gripping elements. In an exemplary embodiment, the gripping elements are moveable in a radial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable in an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable in a radial and an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction relative to the support member. In an exemplary embodiment, if the tubular member is displaced in a first axial direction, the gripping device grips the tubular member; and, if the tubular member is displaced in a second axial direction, the gripping device does not grip the tubular member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, the gripping elements are biased to remain in the first position. In an exemplary embodiment, the gripping device further includes an actuator for moving the gripping elements from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein the actuator is a fluid powered actuator. In an exemplary embodiment, the apparatus further includes a sealing device for sealing an interface with the tubular member coupled to the support member. In an exemplary embodiment, the sealing device seals an annulus defines between the support member and the tubular member. In an exemplary embodiment, the apparatus further includes a locking device for locking the position of the tubular member relative to the support member. In an exemplary embodiment, the apparatus further includes a packer assembly coupled to the support member. In an exemplary embodiment, the packer assembly includes a packer; and a packer control device for controlling the operation of the packer coupled to the support member. In an exemplary embodiment, the packer includes: a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve movably positioned within the passage of the support member. In an exemplary embodiment, the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the packer. In an exemplary embodiment, the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve positioned within the passage of the support member; and wherein the packer control device includes: a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the sliding sleeve valve. In an exemplary embodiment, the apparatus further includes an actuator for displacing the expansion device relative to the support member. In an exemplary embodiment, the actuator includes a first actuator for pulling the expansion device; and a second actuator for pushing the expansion device. In an exemplary embodiment, the actuator includes means for transferring torsional loads between the support member and the expansion device. In an exemplary embodiment, the first and second actuators include means for transferring torsional loads between the support member and the expansion device. In an exemplary embodiment, the actuator includes a plurality of pistons positioned within corresponding piston chambers. In an exemplary embodiment, the cutting device includes a support member; and a plurality of movable cutting elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the cutting elements includes a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements. In an exemplary embodiment, in the first position, the first set of cutting elements are not axially aligned with the second set of cutting elements. In an exemplary embodiment, in the second position, the first set of cutting elements are axially aligned with the second set of cutting elements. In an exemplary embodiment, the expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements. In an exemplary embodiment, in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements. In an exemplary embodiment, the expansion device includes an adjustable expansion device. In an exemplary embodiment, the expansion device includes a plurality of expansion devices. In an exemplary embodiment, at least one of the expansion devices includes an adjustable expansion device. In an exemplary embodiment, the adjustable expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements. In an exemplary embodiment, in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
- An apparatus for radially expanding and plastically deforming an expandable tubular member has been described that includes a support member, an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member, and an actuator coupled to the support member for displacing the expansion device relative to the support member. In an exemplary embodiment, the apparatus further includes a cutting device coupled to the support member for cutting the tubular member. In an exemplary embodiment, the cutting device includes a support member; and a plurality of movable cutting elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the cutting elements include a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements. In an exemplary embodiment, in the first position, the first set of cutting elements are not axially aligned with the second set of cutting elements. In an exemplary embodiment, in the second position, the first set of cutting elements are axially aligned with the second set of cutting elements. In an exemplary embodiment, the apparatus further includes a gripping device for gripping the tubular member coupled to the support member. In an exemplary embodiment, the gripping device includes a plurality of movable gripping elements. In an exemplary embodiment, the gripping elements are moveable in a radial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable in an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable in a radial and an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction relative to the support member. In an exemplary embodiment, if the tubular member is displaced in a first axial direction, the gripping device grips the tubular member; and wherein, if the tubular member is displaced in a second axial direction, the gripping device does not grip the tubular member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, the gripping elements are biased to remain in the first position. In an exemplary embodiment, the gripping device further includes an actuator for moving the gripping elements from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein the actuator is a fluid powered actuator. In an exemplary embodiment, the apparatus further includes a sealing device for sealing an interface with the tubular member coupled to the support member. In an exemplary embodiment, the sealing device seals an annulus defines between the support member and the tubular member. In an exemplary embodiment, the apparatus further includes a locking device for locking the position of the tubular member relative to the support member. In an exemplary embodiment, the apparatus further includes a packer assembly coupled to the support member. In an exemplary embodiment, the packer assembly includes a packer; and a packer control device for controlling the operation of the packer coupled to the support member. In an exemplary embodiment, the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member, and a sliding sleeve valve movably positioned within the passage of the support member. In an exemplary embodiment, the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the packer. In an exemplary embodiment, the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve positioned within the passage of the support member; and wherein the packer control device comprises: a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the sliding sleeve valve. In an exemplary embodiment, the expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements. In an exemplary embodiment, the in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements. In an exemplary embodiment, the expansion device includes an adjustable expansion device. In an exemplary embodiment, the expansion device includes a plurality of expansion devices. In an exemplary embodiment, at least one of the expansion devices includes an adjustable expansion device. In an exemplary embodiment, the adjustable expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements. In an exemplary embodiment, in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
- An apparatus for radially expanding and plastically deforming an expandable tubular member has been described that includes a support member; an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a sealing assembly for sealing an annulus defined between the support member and the tubular member. In an exemplary embodiment, the apparatus further includes a gripping device for gripping the tubular member coupled to the support member. In an exemplary embodiment, the gripping device includes a plurality of movable gripping elements. In an exemplary embodiment, the gripping elements are moveable in a radial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable in an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable in a radial and an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction relative to the support member. In an exemplary embodiment, the if the tubular member is displaced in a first axial direction, the gripping device grips the tubular member; and wherein, if the tubular member is displaced in a second axial direction, the gripping device does not grip the tubular member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, the gripping elements are biased to remain in the first position. In an exemplary embodiment, the gripping device further includes an actuator for moving the gripping elements from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein the actuator is a fluid powered actuator. In an exemplary embodiment, the apparatus further includes a locking device for locking the position of the tubular member relative to the support member. In an exemplary embodiment, the apparatus further includes a packer assembly coupled to the support member. In an exemplary embodiment, the packer assembly includes a packer; and a packer control device for controlling the operation of the packer coupled to the support member. In an exemplary embodiment, the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member, and a sliding sleeve valve movably positioned within the passage of the support member. In an exemplary embodiment, the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the packer. In an exemplary embodiment, the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve positioned within the passage of the support member; and wherein the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the sliding sleeve valve. In an exemplary embodiment, the apparatus further includes an actuator for displacing the expansion device relative to the support member. In an exemplary embodiment, the actuator includes a first actuator for pulling the expansion device; and a second actuator for pushing the expansion device. In an exemplary embodiment, the actuator includes means for transferring torsional loads between the support member and the expansion device. In an exemplary embodiment, the first and second actuators comprise means for transferring torsional loads between the support member and the expansion device. In an exemplary embodiment, the actuator includes a plurality of pistons positioned within corresponding piston chambers. In an exemplary embodiment, the cutting device includes a support member; and a plurality of movable cutting elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the cutting elements include a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements. In an exemplary embodiment, in the first position, the first set of cutting elements are not axially aligned with the second set of cutting elements. In an exemplary embodiment, in the second position, the first set of cutting elements are axially aligned with the second set of cutting elements. In an exemplary embodiment, the expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the expansion elements includes a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements. In an exemplary embodiment, in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements. In an exemplary embodiment, the expansion device includes an adjustable expansion device. In an exemplary embodiment, the expansion device includes a plurality of expansion devices. In an exemplary embodiment, at least one of the expansion devices includes an adjustable expansion device. In an exemplary embodiment, the adjustable expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements. In an exemplary embodiment, in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
- An apparatus for radially expanding and plastically deforming an expandable tubular member has been described that includes a support member; a first expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a second expansion device for radially expanding and plastically deforming the tubular member coupled to the support member. In an exemplary embodiment, the apparatus further includes a gripping device for gripping the tubular member coupled to the support member. In an exemplary embodiment, the gripping device includes a plurality of movable gripping elements. In an exemplary embodiment, the gripping elements are moveable in a radial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable in an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable in a radial and an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction relative to the support member. In an exemplary embodiment, if the tubular member is displaced in a first axial direction, the gripping device grips the tubular member; and wherein, if the tubular member is displaced in a second axial direction, the gripping device does not grip the tubular member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, the gripping elements are biased to remain in the first position. In an exemplary embodiment, the gripping device further includes an actuator for moving the gripping elements from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein the actuator is a fluid powered actuator. In an exemplary embodiment, the apparatus further includes a sealing device for sealing an interface with the tubular member coupled to the support member. In an exemplary embodiment, the sealing device seals an annulus defines between the support member and the tubular member. In an exemplary embodiment, the apparatus further includes a locking device for locking the position of the tubular member relative to the support member. In an exemplary embodiment, the apparatus further includes a packer assembly coupled to the support member. In an exemplary embodiment, the packer assembly includes a packer; and a packer control device for controlling the operation of the packer coupled to the support member. In an exemplary embodiment, the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve movably positioned within the passage of the support member. In an exemplary embodiment, the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the packer. In an exemplary embodiment, the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve positioned within the passage of the support member; and wherein the packer control device comprises: a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the sliding sleeve valve. In an exemplary embodiment, the apparatus further includes an actuator for displacing the expansion device relative to the support member. In an exemplary embodiment, the actuator includes a first actuator for pulling the expansion device; and a second actuator for pushing the expansion device. In an exemplary embodiment, the actuator includes means for transferring torsional loads between the support member and the expansion device. In an exemplary embodiment, the first and second actuators include means for transferring torsional loads between the support member and the expansion device. In an exemplary embodiment, the actuator includes a plurality of pistons positioned within corresponding piston chambers. In an exemplary embodiment, the apparatus further includes a cutting device for cutting the tubular member coupled to the support member. In an exemplary embodiment, the cutting device includes a support member; and a plurality of movable cutting elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the cutting elements include a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements. In an exemplary embodiment, in the first position, the first set of cutting elements are not axially aligned with the second set of cutting elements. In an exemplary embodiment, in the second position, the first set of cutting elements are axially aligned with the second set of cutting elements. In an exemplary embodiment, at least one of the first second expansion devices include a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements. In an exemplary embodiment, in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements. In an exemplary embodiment, at least one of the first and second expansion devices comprise a plurality of expansion devices. In an exemplary embodiment, at least one of the first and second expansion device comprise an adjustable expansion device. In an exemplary embodiment, the adjustable expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements. In an exemplary embodiment, in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
- An apparatus for radially expanding and plastically deforming an expandable tubular member has been described that includes a support member; an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a packer coupled to the support member. In an exemplary embodiment, the apparatus further includes a gripping device for gripping the tubular member coupled to the support member. In an exemplary embodiment, the gripping device comprises a plurality of movable gripping elements. In an exemplary embodiment, the gripping elements are moveable in a radial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable in an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable in a radial and an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction relative to the support member. In an exemplary embodiment, if the tubular member is displaced in a first axial direction, the gripping device grips the tubular member; and wherein, if the tubular member is displaced in a second axial direction, the gripping device does not grip the tubular member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, the gripping elements are biased to remain in the first position. In an exemplary embodiment, the gripping device further includes an actuator for moving the gripping elements from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein the actuator is a fluid powered actuator. In an exemplary embodiment, the apparatus further includes a sealing device for sealing an interface with the tubular member coupled to the support member. In an exemplary embodiment, the sealing device seals an annulus defines between the support member and the tubular member. In an exemplary embodiment, the apparatus further includes a locking device for locking the position of the tubular member relative to the support member. In an exemplary embodiment, the packer assembly includes a packer; and a packer control device for controlling the operation of the packer coupled to the support member. In an exemplary embodiment, the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve movably positioned within the passage of the support member. In an exemplary embodiment, the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the packer. In an exemplary embodiment, the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve positioned within the passage of the support member; and wherein the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the sliding sleeve valve. In an exemplary embodiment, the apparatus further includes an actuator for displacing the expansion device relative to the support member. In an exemplary embodiment, the actuator includes a first actuator for pulling the expansion device; and a second actuator for pushing the expansion device. In an exemplary embodiment, the actuator includes means for transferring torsional loads between the support member and the expansion device. In an exemplary embodiment, the first and second actuators include means for transferring torsional loads between the support member and the expansion device. In an exemplary embodiment, the actuator includes a plurality of pistons positioned within corresponding piston chambers. In an exemplary embodiment, the apparatus further includes a cutting device coupled to the support member for cutting the tubular member. In an exemplary embodiment, the cutting device includes a support member; and a plurality of movable cutting elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the cutting elements include a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements. In an exemplary embodiment, in the first position, the first set of cutting elements are not axially aligned with the second set of cutting elements. In an exemplary embodiment, in the second position, the first set of cutting elements are axially aligned with the second set of cutting elements. In an exemplary embodiment, the expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements. In an exemplary embodiment, in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements. In an exemplary embodiment, the expansion device includes an adjustable expansion device. In an exemplary embodiment, the expansion device includes a plurality of expansion devices. In an exemplary embodiment, at least one of the expansion devices comprises an adjustable expansion device. In an exemplary embodiment, the adjustable expansion device includes a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements. In an exemplary embodiment, in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
- An apparatus for radially expanding and plastically deforming an expandable tubular member has been described that includes a support member; a cutting device for cutting the tubular member coupled to the support member; a gripping device for gripping the tubular member coupled to the support member; a sealing device for sealing an interface with the tubular member coupled to the support member; a locking device for locking the position of the tubular member relative to the support member; a first adjustable expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; a second adjustable expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; a packer coupled to the support member; and an actuator for displacing one or more of the sealing assembly, first and second adjustable expansion devices, and packer relative to the support member. In an exemplary embodiment, the gripping device includes a plurality of movable gripping elements. In an exemplary embodiment, the gripping elements are moveable in a radial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable in an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable in a radial and an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction relative to the support member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction relative to the support member. In an exemplary embodiment, if the tubular member is displaced in a first axial direction, the gripping device grips the tubular member; and wherein, if the tubular member is displaced in a second axial direction, the gripping device does not grip the tubular member. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, the gripping elements are biased to remain in the first position. In an exemplary embodiment, the gripping device further includes an actuator for moving the gripping elements from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein the actuator is a fluid powered actuator. In an exemplary embodiment, the sealing device seals an annulus defines between the support member and the tubular member. In an exemplary embodiment, the packer assembly includes a packer; and a packer control device for controlling the operation of the packer coupled to the support member. In an exemplary embodiment, the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve movably positioned within the passage of the support member. In an exemplary embodiment, the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the packer. In an exemplary embodiment, the packer includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve positioned within the passage of the support member; and wherein the packer control device includes a support member; one or more drag blocks releasably coupled to the support member; and a stinger coupled to the support member for engaging the sliding sleeve valve. In an exemplary embodiment, the actuator includes a first actuator for pulling the expansion device; and a second actuator for pushing the expansion device. In an exemplary embodiment, the actuator includes means for transferring torsional loads between the support member and the expansion device. In an exemplary embodiment, the first and second actuators include means for transferring torsional loads between the support member and the expansion device. In an exemplary embodiment, the actuator includes a plurality of pistons positioned within corresponding piston chambers. In an exemplary embodiment, the cutting device includes a support member; and a plurality of movable cutting elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the cutting elements include a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements. In an exemplary embodiment, in the first position, the first set of cutting elements are not axially aligned with the second set of cutting elements. In an exemplary embodiment, in the second position, the first set of cutting elements are axially aligned with the second set of cutting elements. In an exemplary embodiment, at least one of the adjustable expansion devices include a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements. In an exemplary embodiment, in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements. In an exemplary embodiment, at least one of the adjustable expansion devices comprise a plurality of expansion devices. In an exemplary embodiment, at least one of the adjustable expansion devices include a support member; and a plurality of movable expansion elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the expansion elements between a first position and a second position, wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the expansion elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the expansion elements include a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements. In an exemplary embodiment, in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements. In an exemplary embodiment, in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
- An apparatus for cutting a tubular member has been described that includes a support member; and a plurality of movable cutting elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the cutting elements between a first position and a second position; wherein in the first position, the cutting elements do not engage the tubular member; and wherein in the second position, the cutting elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the cutting elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the cutting elements include a first set of cutting elements; and a second set of cutting elements; wherein the first set of cutting elements are interleaved with the second set of cutting elements. In an exemplary embodiment, in the first position, the first set of cutting elements are not axially aligned with the second set of cutting elements. In an exemplary embodiment, in the second position, the first set of cutting elements are axially aligned with the second set of cutting elements.
- An apparatus for engaging a tubular member has been described that includes a support member; and a plurality of movable elements coupled to the support member. In an exemplary embodiment, the apparatus further includes an actuator coupled to the support member for moving the elements between a first position and a second position; wherein in the first position, the elements do not engage the tubular member; and wherein in the second position, the elements engage the tubular member. In an exemplary embodiment, the apparatus further includes a sensor coupled to the support member for sensing the internal diameter of the tubular member. In an exemplary embodiment, the sensor prevents the elements from being moved to the second position if the internal diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, the elements include a first set of elements; and a second set of elements; wherein the first set of elements are interleaved with the second set of elements. In an exemplary embodiment, in the first position, the first set of elements are not axially aligned with the second set of elements. In an exemplary embodiment, in the second position, the first set of elements are axially aligned with the second set of elements.
- An apparatus for gripping a tubular member has been described that includes a plurality of movable gripping elements. In an exemplary embodiment, the gripping elements are moveable in a radial direction. In an exemplary embodiment, the gripping elements are moveable in an axial direction. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial and an axial direction. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in a radial direction. In an exemplary embodiment, the gripping elements are moveable from a first position to a second position; wherein in the first position, the gripping elements do not engage the tubular member; wherein in the second position, the gripping elements do engage the tubular member; and wherein, during the movement from the first position to the second position, the gripping elements move in an axial direction. In an exemplary embodiment, in a first axial direction, the gripping device grips the tubular member; and wherein, in a second axial direction, the gripping device does not grip the tubular member. In an exemplary embodiment, the apparatus further includes an actuator for moving the gripping elements. In an exemplary embodiment, the gripping elements include a plurality of separate and distinct gripping elements.
- An actuator has been described that includes a tubular housing; a tubular piston rod movably coupled to and at least partially positioned within the housing; a plurality of annular piston chambers defined by the tubular housing and the tubular piston rod; and a plurality of tubular pistons coupled to the tubular piston rod, each tubular piston movably positioned within a corresponding annular piston chamber. In an exemplary embodiment, the actuator further includes means for transmitting torsional loads between the tubular housing and the tubular piston rod.
- An apparatus for controlling a packer has been described that includes a tubular support member; one or more drag blocks releasably coupled to the tubular support member; and a tubular stinger coupled to the tubular support member for engaging the packer. In an exemplary embodiment, the apparatus further includes a tubular sleeve coupled to the drag blocks. In an exemplary embodiment, the tubular support member includes one or more axially aligned teeth for engaging the packer.
- A packer has been described that includes a support member defining a passage; a shoe comprising a float valve coupled to an end of the support member; one or more compressible packer elements movably coupled to the support member; and a sliding sleeve valve movably positioned within the passage of the support member.
- A method of radially expanding and plastically deforming an expandable tubular member within a borehole having a preexisting wellbore casing has been described that includes positioning the tubular member within the borehole in overlapping relation to the wellbore casing; radially expanding and plastically deforming a portion of the tubular member to form a bell section; and radially expanding and plastically deforming a portion of the tubular member above the bell section comprising a portion of the tubular member that overlaps with the wellbore casing; wherein the inside diameter of the bell section is greater than the inside diameter of the radially expanded and plastically deformed portion of the tubular member above the bell section. In an exemplary embodiment, radially expanding and plastically deforming a portion of the tubular member to form a bell section includes positioning an adjustable expansion device within the expandable tubular member; supporting the expandable tubular member and the adjustable expansion device within the borehole; lowering the adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the adjustable expansion device; and displacing the adjustable expansion device upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member, wherein n is greater than or equal to 1.
- A method for forming a mono diameter wellbore casing has been described that includes positioning an adjustable expansion device within a first expandable tubular member; supporting the first expandable tubular member and the adjustable expansion device within a borehole; lowering the adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; positioning the adjustable expansion device within a second expandable tubular member; supporting the second expandable tubular member and the adjustable expansion device within the borehole in overlapping relation to the first expandable tubular member; lowering the adjustable expansion device out of the second expandable tubular member; increasing the outside dimension of the adjustable expansion device; and displacing the adjustable expansion device upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole.
- A method for radially expanding and plastically deforming an expandable tubular member within a borehole has been described that includes positioning an adjustable expansion device within the expandable tubular member; supporting the expandable tubular member and the adjustable expansion device within the borehole; lowering the adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the adjustable expansion device; displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the borehole; and pressurizing an interior region of the expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the expandable tubular member within the borehole.
- A method for forming a mono diameter wellbore casing has been described that includes positioning an adjustable expansion device within a first expandable tubular member; supporting the first expandable tubular member and the adjustable expansion device within a borehole; lowering the adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; pressurizing an interior region of the first expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the first expandable tubular member within the borehole; positioning the adjustable expansion mandrel within a second expandable tubular member; supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member; lowering the adjustable expansion mandrel out of the second expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole; and pressurizing an interior region of the second expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the second expandable tubular member within the borehole.
- A method for radially expanding and plastically deforming an expandable tubular member within a borehole has been described that includes positioning first and second adjustable expansion devices within the expandable tubular member; supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; lowering the first adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- A method for forming a mono diameter wellbore casing has been described that includes positioning first and second adjustable expansion devices within a first expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; lowering the first adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; positioning first and second adjustable expansion devices within a second expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion devices within the borehole in overlapping relation to the first expandable tubular member; lowering the first adjustable expansion device out of the second expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform a lower portion of the second expandable tubular member; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the second expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; and displacing the second adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform portions of the second expandable tubular member above the lower portion of the second expandable tubular member; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- A method for radially expanding and plastically deforming an expandable tubular member within a borehole has been described that includes positioning first and second adjustable expansion devices within the expandable tubular member; supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; lowering the first adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; pressurizing an interior region of the expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the expandable tubular member by the first adjustable expansion device; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; and pressurizing an interior region of the expandable tubular member above the second adjustable expansion device during the radial expansion of the portions of the expandable tubular member above the lower portion of the expandable tubular member by the second adjustable expansion device; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- A method for forming a mono diameter wellbore casing has been described that includes positioning first and second adjustable expansion devices within a first expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; lowering the first adjustable expansion device out of the first expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; pressurizing an interior region of the first expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the first expandable tubular member by the first adjustable expansion device; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; pressurizing an interior region of the first expandable tubular member above the second adjustable expansion device during the radial expansion of the portions of the first expandable tubular member above the lower portion of the first expandable tubular member by the second adjustable expansion device; positioning first and second adjustable expansion devices within a second expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion devices within the borehole in overlapping relation to the first expandable tubular member; lowering the first adjustable expansion device out of the second expandable tubular member; increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform a lower portion of the second expandable tubular member; pressurizing an interior region of the second expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the second expandable tubular member by the first adjustable expansion device; displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the second expandable tubular member; decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; displacing the second adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform portions of the second expandable tubular member above the lower portion of the second expandable tubular member; and pressurizing an interior region of the second expandable tubular member above the second adjustable expansion device during the radial expansion of the portions of the second expandable tubular member above the lower portion of the second expandable tubular member by the second adjustable expansion device; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- A method for radially expanding and plastically deforming an expandable tubular member within a borehole has been described that includes supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; increasing the size of the adjustable expansion device; and displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member. In an exemplary embodiment, the method further includes reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed. In an exemplary embodiment, the method further includes fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device. In an exemplary embodiment, the method further includes permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member. In an exemplary embodiment, the method further includes injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and a preexisting structure after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator. In an exemplary embodiment, the method further includes increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator. In an exemplary embodiment, the method further includes displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member. In an exemplary embodiment, the method further includes if the end of the other portion of the expandable tubular member overlaps with a preexisting structure, then not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the other portion of the expandable tubular member that overlaps with the preexisting structure.
- A method for forming a mono diameter wellbore casing within a borehole that includes a preexisting wellbore casing has been described that includes supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; increasing the size of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting wellbore casing that overlaps with an end of the remaining portion of the expandable tubular member. In an exemplary embodiment, the method further includes reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed. In an exemplary embodiment, the method further includes fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device. In an exemplary embodiment, the method further includes permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member. In an exemplary embodiment, the method further includes injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the borehole after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator. In an exemplary embodiment, the method further includes increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator. In an exemplary embodiment, the method further includes displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member. In an exemplary embodiment, the method further includes not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the remaining portion of the expandable tubular member that overlaps with the preexisting wellbore casing after not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
- A method of radially expanding and plastically deforming a tubular member has been described that includes positioning the tubular member within a preexisting structure; radially expanding and plastically deforming a lower portion of the tubular member to form a bell section; and radially expanding and plastically deforming a portion of the tubular member above the bell section. In an exemplary embodiment, positioning the tubular member within a preexisting structure includes locking the tubular member to an expansion device. In an exemplary embodiment, the outside diameter of the expansion device is less than the inside diameter of the tubular member. In an exemplary embodiment, the expansion device is positioned within the tubular member. In an exemplary embodiment, the expansion device includes an adjustable expansion device. In an exemplary embodiment, the adjustable expansion device is adjustable to a plurality of sizes. In an exemplary embodiment, the expansion device includes a plurality of expansion devices. In an exemplary embodiment, at least one of the expansion devices includes an adjustable expansion device. In an exemplary embodiment, at least one of the adjustable expansion device is adjustable to a plurality of sizes. In an exemplary embodiment, radially expanding and plastically deforming a lower portion of the tubular member to form a bell section includes lowering an expansion device out of an end of the tubular member; and pulling the expansion device through the end of the tubular member. In an exemplary embodiment, lowering an expansion device out of an end of the tubular member includes lowering the expansion device out of the end of the tubular member; and adjusting the size of the expansion device. In an exemplary embodiment, the adjustable expansion device is adjustable to a plurality of sizes. In an exemplary embodiment, the expansion device includes a plurality of adjustable expansion devices. In an exemplary embodiment, at least one of the adjustable expansion devices is adjustable to a plurality of sizes. In an exemplary embodiment, pulling the expansion device through the end of the tubular member includes gripping the tubular member; and pulling an expansion device through an end of the tubular member. In an exemplary embodiment, gripping the tubular member includes permitting axial displacement of the tubular member in a first direction; and not permitting axial displacement of the tubular member in a second direction. In an exemplary embodiment, pulling the expansion device through the end of the tubular member includes pulling the expansion device through the end of the tubular member using an actuator. In an exemplary embodiment, radially expanding and plastically deforming a portion of the tubular member above the bell section includes lowering an expansion device out of an end of the tubular member; and pulling the expansion device through the end of the tubular member. In an exemplary embodiment, lowering an expansion device out of an end of the tubular member includes lowering the expansion device out of the end of the tubular member; and adjusting the size of the expansion device. In an exemplary embodiment, the adjustable expansion device is adjustable to a plurality of sizes. In an exemplary embodiment, the expansion device includes a plurality of adjustable expansion devices. In an exemplary embodiment, at least one of the adjustable expansion devices is adjustable to a plurality of sizes. In an exemplary embodiment, pulling the expansion device through the end of the tubular member includes gripping the tubular member; and pulling an expansion device through an end of the tubular member. In an exemplary embodiment, gripping the tubular member includes permitting axial displacement of the tubular member in a first direction; and not permitting axial displacement of the tubular member in a second direction. In an exemplary embodiment, pulling the expansion device through the end of the tubular member includes pulling the expansion device through the end of the tubular member using an actuator. In an exemplary embodiment, pulling the expansion device through the end of the tubular member includes pulling the expansion device through the end of the tubular member using fluid pressure. In an exemplary embodiment, pulling the expansion device through the end of the tubular member using fluid pressure includes pressurizing an annulus within the tubular member above the expansion device. In an exemplary embodiment, radially expanding and plastically deforming a portion of the tubular member above the bell section includes fluidicly sealing an end of the tubular member; and pulling the expansion device through the tubular member. In an exemplary embodiment, the expansion device is adjustable. In an exemplary embodiment, the expansion device is adjustable to a plurality of sizes. In an exemplary embodiment, the expansion device comprises a plurality of adjustable expansion devices. In an exemplary embodiment, at least one of the adjustable expansion devices is adjustable to a plurality of sizes. In an exemplary embodiment, pulling the expansion device through the end of the tubular member includes gripping the tubular member; and pulling an expansion device through an end of the tubular member. In an exemplary embodiment, gripping the tubular member includes permitting axial displacement of the tubular member in a first direction; and not permitting axial displacement of the tubular member in a second direction. In an exemplary embodiment, pulling the expansion device through the end of the tubular member includes pulling the expansion device through the end of the tubular member using an actuator. In an exemplary embodiment, pulling the expansion device through the end of the tubular member includes pulling the expansion device through the end of the tubular member using fluid pressure. In an exemplary embodiment, pulling the expansion device through the end of the tubular member using fluid pressure includes pressurizing an annulus within the tubular member above the expansion device. In an exemplary embodiment, radially expanding and plastically deforming a portion of the tubular member above the bell section includes overlapping the portion of the tubular member above the bell section with an end of a preexisting tubular member; and pulling an expansion device through the overlapping portions of the tubular member and the preexisting tubular member. In an exemplary embodiment, the expansion device is adjustable. In an exemplary embodiment, the expansion device is adjustable to a plurality of sizes. In an exemplary embodiment, the expansion device includes a plurality of adjustable expansion devices. In an exemplary embodiment, at least one of the adjustable expansion devices is adjustable to a plurality of sizes. In an exemplary embodiment, pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member includes gripping the tubular member; and pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member. In an exemplary embodiment, gripping the tubular member includes permitting axial displacement of the tubular member in a first direction; and not permitting axial displacement of the tubular member in a second direction. In an exemplary embodiment, pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member includes pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using an actuator. In an exemplary embodiment, pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member includes pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure. In an exemplary embodiment, pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure includes pressurizing an annulus within the tubular member above the expansion device. In an exemplary embodiment, the method further includes cutting an end of the portion of the tubular member that overlaps with the preexisting tubular member. In an exemplary embodiment, the method further includes removing the cut off end of the expandable tubular member from the preexisting structure. In an exemplary embodiment, the method further includes injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the preexisting structure. In an exemplary embodiment, the method further includes cutting off an end of the expandable tubular member. In an exemplary embodiment, the method further includes removing the cut off end of the expandable tubular member from the preexisting structure.
- A method of radially expanding and plastically deforming a tubular member has been described that includes applying internal pressure to the inside surface of the tubular member at a plurality of discrete location separated from one another.
- A system for radially expanding and plastically deforming an expandable tubular member within a borehole having a preexisting wellbore casing has been described that includes means for positioning the tubular member within the borehole in overlapping relation to the wellbore casing; means for radially expanding and plastically deforming a portion of the tubular member to form a bell section; and means for radially expanding and plastically deforming a portion of the tubular member above the bell section comprising a portion of the tubular member that overlaps with the wellbore casing; wherein the inside diameter of the bell section is greater than the inside diameter of the radially expanded and plastically deformed portion of the tubular member above the bell section. In an exemplary embodiment, means for radially expanding and plastically deforming a portion of the tubular member to form a bell section includes means for positioning an adjustable expansion device within the expandable tubular member; means for supporting the expandable tubular member and the adjustable expansion device within the borehole; means for lowering the adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member, wherein n is greater than or equal to 1.
- A system for forming a mono diameter wellbore casing has been described that includes means for positioning an adjustable expansion device within a first expandable tubular member; means for supporting the first expandable tubular member and the adjustable expansion device within a borehole; means for lowering the adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; means for positioning the adjustable expansion device within a second expandable tubular member; means for supporting the second expandable tubular member and the adjustable expansion device within the borehole in overlapping relation to the first expandable tubular member; means for lowering the adjustable expansion device out of the second expandable tubular member, means for increasing the outside dimension of the adjustable expansion device; and means for displacing the adjustable expansion device upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole.
- A system for radially expanding and plastically deforming an expandable tubular member within a borehole has been described that includes means for positioning an adjustable expansion device within the expandable tubular member; means for supporting the expandable tubular member and the adjustable expansion device within the borehole; means for lowering the adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; means for displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the borehole; and means for pressurizing an interior region of the expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the expandable tubular member within the borehole.
- A system for forming a mono diameter wellbore casing has been described that includes means for positioning an adjustable expansion device within a first expandable tubular member, means for supporting the first expandable tubular member and the adjustable expansion device within a borehole; means for lowering the adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; means for pressurizing an interior region of the first expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the first expandable tubular member within the borehole; means for positioning the adjustable expansion mandrel within a second expandable tubular member; means for supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member; means for lowering the adjustable expansion mandrel out of the second expandable tubular member; means for increasing the outside dimension of the adjustable expansion mandrel; means for displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole; and means for pressurizing an interior region of the second expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the second expandable tubular member within the borehole.
- A system for radially expanding and plastically deforming an expandable tubular member within a borehole has been described that includes means for positioning first and second adjustable expansion devices within the expandable tubular member; means for supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; means for lowering the first adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- A system for forming a mono diameter wellbore casing has been described that includes means for positioning first and second adjustable expansion devices within a first expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; means for lowering the first adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; means for positioning first and second adjustable expansion devices within a second expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion devices within the borehole in overlapping relation to the first expandable tubular member; means for lowering the first adjustable expansion device out of the second expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform a lower portion of the second expandable tubular member; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the second expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; and means for displacing the second adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform portions of the second expandable tubular member above the lower portion of the second expandable tubular member; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- A system for radially expanding and plastically deforming an expandable tubular member within a borehole has been described that includes means for positioning first and second adjustable expansion devices within the expandable tubular member; means for supporting the expandable tubular member and the first and second adjustable expansion devices within the borehole; means for lowering the first adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; means for pressurizing an interior region of the expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the expandable tubular member by the first adjustable expansion device; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member, and means for pressurizing an interior region of the expandable tubular member above the second adjustable expansion device during the radial expansion of the portions of the expandable tubular member above the lower portion of the expandable tubular member by the second adjustable expansion device; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- A system for forming a mono diameter wellbore casing has been described that includes means for positioning first and second adjustable expansion devices within a first expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion devices within a borehole; means for lowering the first adjustable expansion device out of the first expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; means for pressurizing an interior region of the first expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the first expandable tubular member by the first adjustable expansion device; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the first expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; means for pressurizing an interior region of the first expandable tubular member above the second adjustable expansion device during the radial expansion of the portions of the first expandable tubular member above the lower portion of the first expandable tubular member by the second adjustable expansion device; means for positioning first and second adjustable expansion devices within a second expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion devices within the borehole in overlapping relation to the first expandable tubular member; means for lowering the first adjustable expansion device out of the second expandable tubular member; means for increasing the outside dimension of the first adjustable expansion device; means for displacing the first adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform a lower portion of the second expandable tubular member; means for pressurizing an interior region of the second expandable tubular member above the first adjustable expansion device during the radial expansion of the lower portion of the second expandable tubular member by the first adjustable expansion device; means for displacing the first adjustable expansion device and the second adjustable expansion device downwardly relative to the second expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion device and increasing the outside dimension of the second adjustable expansion device; means for displacing the second adjustable expansion device upwardly relative to the second expandable tubular member to radially expand and plastically deform portions of the second expandable tubular member above the lower portion of the second expandable tubular member; and means for pressurizing an interior region of the second expandable tubular member above the second adjustable expansion device during the radial expansion of the portions of the second expandable tubular member above the lower portion of the second expandable tubular member by the second adjustable expansion device; wherein the outside dimension of the first adjustable expansion device is greater than the outside dimension of the second adjustable expansion device.
- A system for radially expanding and plastically deforming an expandable tubular member within a borehole has been described that includes means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; means for increasing the size of the adjustable expansion device; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member. In an exemplary embodiment, the system further includes means for reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed. In an exemplary embodiment, the system further includes means for fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device. In an exemplary embodiment, the system further includes means for permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member. In an exemplary embodiment, the system further includes means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and a preexisting structure after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator. In an exemplary embodiment, the system further includes means for increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator. In an exemplary embodiment, system further includes means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member. In an exemplary embodiment, the system further includes if the end of the other portion of the expandable tubular member overlaps with a preexisting structure, then means for not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the other portion of the expandable tubular member that overlaps with the preexisting structure.
- A system for forming a mono diameter wellbore casing within a borehole that includes a preexisting wellbore casing has been described that includes means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; means for increasing the size of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting wellbore casing that overlaps with an end of the remaining portion of the expandable tubular member. In an exemplary embodiment, the system further includes means for reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed. In an exemplary embodiment, the system further includes means for fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device. In an exemplary embodiment, the system further includes means for permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member. In an exemplary embodiment, the system further includes means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the borehole after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator. In an exemplary embodiment, the system further includes means for increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator. In an exemplary embodiment, the system further includes means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member. In an exemplary embodiment, the system further includes means for not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the remaining portion of the expandable tubular member that overlaps with the preexisting wellbore casing after not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
- A system for radially expanding and plastically deforming a tubular member has been described that includes means for positioning the tubular member within a preexisting structure; means for radially expanding and plastically deforming a lower portion of the tubular member to form a bell section; and means for radially expanding and plastically deforming a portion of the tubular member above the bell section. In an exemplary embodiment, positioning the tubular member within a preexisting structure includes means for locking the tubular member to an expansion device. In an exemplary embodiment, the outside diameter of the expansion device is less than the inside diameter of the tubular member. In an exemplary embodiment, the expansion device is positioned within the tubular member. In an exemplary embodiment, the expansion device includes an adjustable expansion device. In an exemplary embodiment, the adjustable expansion device is adjustable to a plurality of sizes. In an exemplary embodiment, the expansion device includes a plurality of expansion devices. In an exemplary embodiment, at least one of the expansion devices includes an adjustable expansion device. In an exemplary embodiment, at least one of the adjustable expansion device is adjustable to a plurality of sizes. In an exemplary embodiment, means for radially expanding and plastically deforming a lower portion of the tubular member to form a bell section includes means for lowering an expansion device out of an end of the tubular member; and means for pulling the expansion device through the end of the tubular member. In an exemplary embodiment, means for lowering an expansion device out of an end of the tubular member includes means for lowering the expansion device out of the end of the tubular member; and means for adjusting the size of the expansion device. In an exemplary embodiment, the adjustable expansion device is adjustable to a plurality of sizes. In an exemplary embodiment, the expansion device includes a plurality of adjustable expansion devices. In an exemplary embodiment, at least one of the adjustable expansion devices is adjustable to a plurality of sizes. In an exemplary embodiment, means for pulling the expansion device through the end of the tubular member includes means for gripping the tubular member; and means for pulling an expansion device through an end of the tubular member. In an exemplary embodiment, means for gripping the tubular member includes means for permitting axial displacement of the tubular member in a first direction; and means for not permitting axial displacement of the tubular member in a second direction. In an exemplary embodiment, means for pulling the expansion device through the end of the tubular member includes means for pulling the expansion device through the end of the tubular member using an actuator. In an exemplary embodiment, means for radially expanding and plastically deforming a portion of the tubular member above the bell section includes means for lowering an expansion device out of an end of the tubular member; and means for pulling the expansion device through the end of the tubular member. In an exemplary embodiment, means for lowering an expansion device out of an end of the tubular member includes means for lowering the expansion device out of the end of the tubular member; and means for adjusting the size of the expansion device. In an exemplary embodiment, the adjustable expansion device is adjustable to a plurality of sizes. In an exemplary embodiment, the expansion device comprises a plurality of adjustable expansion devices. In an exemplary embodiment, at least one of the adjustable expansion devices is adjustable to a plurality of sizes. In an exemplary embodiment, means for pulling the expansion device through the end of the tubular member includes means for gripping the tubular member; and means for pulling an expansion device through an end of the tubular member. In an exemplary embodiment, means for gripping the tubular member includes means for permitting axial displacement of the tubular member in a first direction; and means for not permitting axial displacement of the tubular member in a second direction. In an exemplary embodiment, means for pulling the expansion device through the end of the tubular member includes means for pulling the expansion device through the end of the tubular member using an actuator. In an exemplary embodiment, means for pulling the expansion device through the end of the tubular member includes means for pulling the expansion device through the end of the tubular member using fluid pressure. In an exemplary embodiment, means for pulling the expansion device through the end of the tubular member using fluid pressure includes means for pressurizing an annulus within the tubular member above the expansion device. In an exemplary embodiment, means for radially expanding and plastically deforming a portion of the tubular member above the bell section includes means for fluidicly sealing an end of the tubular member; and means for pulling the expansion device through the tubular member. In an exemplary embodiment, the expansion device is adjustable. In an exemplary embodiment, the expansion device is adjustable to a plurality of sizes. In an exemplary embodiment, the expansion device includes a plurality of adjustable expansion devices. In an exemplary embodiment, at least one of the adjustable expansion devices is adjustable to a plurality of sizes. In an exemplary embodiment, means for pulling the expansion device through the end of the tubular member includes means for gripping the tubular member; and means for pulling an expansion device through an end of the tubular member. In an exemplary embodiment, means for gripping the tubular member includes means for permitting axial displacement of the tubular member in a first direction; and means for not permitting axial displacement of the tubular member in a second direction. In an exemplary embodiment, means for pulling the expansion device through the end of the tubular member includes means for pulling the expansion device through the end of the tubular member using an actuator. In an exemplary embodiment, means for pulling the expansion device through the end of the tubular member includes means for pulling the expansion device through the end of the tubular member using fluid pressure. In an exemplary embodiment, means for pulling the expansion device through the end of the tubular member using fluid pressure includes means for pressurizing an annulus within the tubular member above the expansion device. In an exemplary embodiment, means for radially expanding and plastically deforming a portion of the tubular member above the bell section includes means for overlapping the portion of the tubular member above the bell section with an end of a preexisting tubular member; and means for pulling an expansion device through the overlapping portions of the tubular member and the preexisting tubular member. In an exemplary embodiment, the expansion device is adjustable. In an exemplary embodiment, the expansion device is adjustable to a plurality of sizes. In an exemplary embodiment, the expansion device includes a plurality of adjustable expansion devices. In an exemplary embodiment, at least one of the adjustable expansion devices is adjustable to a plurality of sizes. In an exemplary embodiment, means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member includes means for gripping the tubular member; and means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member. In an exemplary embodiment, means for gripping the tubular member includes means for permitting axial displacement of the tubular member in a first direction; and means for not permitting axial displacement of the tubular member in a second direction. In an exemplary embodiment, means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member includes means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using an actuator. In an exemplary embodiment, means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member includes means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure. In an exemplary embodiment, means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure includes means for pressurizing an annulus within the tubular member above the expansion device. In an exemplary embodiment, the system further includes means for cutting an end of the portion of the tubular member that overlaps with the preexisting tubular member. In an exemplary embodiment, the system further includes means for removing the cut off end of the expandable tubular member from the preexisting structure. In an exemplary embodiment, the system further includes means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the preexisting structure. In an exemplary embodiment, the system further includes means for cutting off an end of the expandable tubular member. In an exemplary embodiment, the system further includes means for removing the cut off end of the expandable tubular member from the preexisting structure.
- A system of radially expanding and plastically deforming a tubular member has been described that includes a support member; and means for applying internal pressure to the inside surface of the tubular member at a plurality of discrete location separated from one another coupled to the support member.
- A method of cutting a tubular member has been described that includes positioning a plurality of cutting elements within the tubular member; and bringing the cutting elements into engagement with the tubular member. In an exemplary embodiment, the cutting elements include a first group of cutting elements; and a second group of cutting elements; wherein the first group of cutting elements are interleaved with the second group of cutting elements. In an exemplary embodiment, bringing the cutting elements into engagement with the tubular member includes bringing the cutting elements into axial alignment. In an exemplary embodiment, bringing the cutting elements into engagement with the tubular member further includes pivoting the cutting elements. In an exemplary embodiment, bringing the cutting elements into engagement with the tubular member further includes translating the cutting elements. In an exemplary embodiment, bringing the cutting elements into engagement with the tubular member further includes pivoting the cutting elements; and translating the cutting elements. In an exemplary embodiment, bringing the cutting elements into engagement with the tubular member includes rotating the cutting elements about a common axis. In an exemplary embodiment, bringing the cutting elements into engagement with the tubular member includes pivoting the cutting elements about corresponding axes; translating the cutting elements; and rotating the cutting elements about a common axis. In an exemplary embodiment, the method further includes preventing the cutting elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, preventing the cutting elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value includes sensing the inside diameter of the tubular member.
- A method of gripping a tubular member has been described that includes positioning a plurality of gripping elements within the tubular member; bringing the gripping elements into engagement with the tubular member. In an exemplary embodiment, bringing the gripping elements into engagement with the tubular member includes displacing the gripping elements in an axial direction; and displacing the gripping elements in a radial direction. In an exemplary embodiment, the method further includes biasing the gripping elements against engagement with the tubular member.
- A method of operating an actuator has been described that includes pressurizing a plurality of pressure chamber. In an exemplary embodiment, the method further includes transmitting torsional loads.
- A method of injecting a hardenable fluidic sealing material into an annulus between a tubular member and a preexisting structure has been described that includes positioning the tubular member into the preexisting structure; sealing off an end of the tubular member; operating a valve within the end of the tubular member; and injecting a hardenable fluidic sealing material through the valve into the annulus between the tubular member and the preexisting structure.
- A system for cutting a tubular member has been described that includes means for positioning a plurality of cutting elements within the tubular member; and means for bringing the cutting elements into engagement with the tubular member. In an exemplary embodiment, the cutting elements include a first group of cutting elements; and a second group of cutting elements; wherein the first group of cutting elements are interleaved with the second group of cutting elements. In an exemplary embodiment, means for bringing the cutting elements into engagement with the tubular member includes means for bringing the cutting elements into axial alignment. In an exemplary embodiment, means for bringing the cutting elements into engagement with the tubular member further includes means for pivoting the cutting elements. In an exemplary embodiment, means for bringing the cutting elements into engagement with the tubular member further includes means for translating the cutting elements. In an exemplary embodiment, means for bringing the cutting elements into engagement with the tubular member further includes means for pivoting the cutting elements; and means for translating the cutting elements. In an exemplary embodiment, means for bringing the cutting elements into engagement with the tubular member includes means for rotating the cutting elements about a common axis. In an exemplary embodiment, means for bringing the cutting elements into engagement with the tubular member includes means for pivoting the cutting elements about corresponding axes; means for translating the cutting elements; and means for rotating the cutting elements about a common axis. In an exemplary embodiment, the system further includes means for preventing the cutting elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, means for preventing the cutting elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value includes means for sensing the inside diameter of the tubular member.
- A system for gripping a tubular member has been described that includes means for positioning a plurality of gripping elements within the tubular member; and means for bringing the gripping elements into engagement with the tubular member. In an exemplary embodiment, means for bringing the gripping elements into engagement with the tubular member includes means for displacing the gripping elements in an axial direction; and means for displacing the gripping elements in a radial direction. In an exemplary embodiment, the system further includes means for biasing the gripping elements against engagement with the tubular member.
- An actuator system has been described that includes a support member; and means for pressurizing a plurality of pressure chambers coupled to the support member. In an exemplary embodiment, the system further includes means for transmitting torsional loads.
- A system for injecting a hardenable fluidic sealing material into an annulus between a tubular member and a preexisting structure has been described that includes means for positioning the tubular member into the preexisting structure; means for sealing off an end of the tubular member; means for operating a valve within the end of the tubular member; and means for injecting a hardenable fluidic sealing material through the valve into the annulus between the tubular member and the preexisting structure.
- A method of engaging a tubular member has been described that includes positioning a plurality of elements within the tubular member; and bringing the elements into engagement with the tubular member. In an exemplary embodiment, the elements include a first group of elements; and a second group of elements; wherein the first group of elements are interleaved with the second group of elements. In an exemplary embodiment, bringing the elements into engagement with the tubular member includes bringing the elements into axial alignment. In an exemplary embodiment, bringing the elements into engagement with the tubular member further includes pivoting the elements. In an exemplary embodiment, bringing the elements into engagement with the tubular member further includes translating the elements. In an exemplary embodiment, bringing the elements into engagement with the tubular member further includes pivoting the elements; and translating the elements. In an exemplary embodiment, bringing the elements into engagement with the tubular member includes rotating the elements about a common axis. In an exemplary embodiment, bringing the elements into engagement with the tubular member includes pivoting the elements about corresponding axes; translating the elements; and rotating the elements about a common axis. In an exemplary embodiment, the method further includes preventing the elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, preventing the elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value includes sensing the inside diameter of the tubular member.
- A system for engaging a tubular member has been described that includes means for positioning a plurality of elements within the tubular member; and means for bringing the elements into engagement with the tubular member. In an exemplary embodiment, the elements include a first group of elements; and a second group of elements; wherein the first group of elements are interleaved with the second group of elements. In an exemplary embodiment, means for bringing the elements into engagement with the tubular member includes means for bringing the elements into axial alignment. In an exemplary embodiment, means for bringing the elements into engagement with the tubular member further includes means for pivoting the elements. In an exemplary embodiment, means for bringing the elements into engagement with the tubular member further includes means for translating the elements. In an exemplary embodiment, means for bringing the elements into engagement with the tubular member further includes means for pivoting the elements; and means for translating the elements. In an exemplary embodiment, means for bringing the elements into engagement with the tubular member includes means for rotating the elements about a common axis. In an exemplary embodiment, means for bringing the elements into engagement with the tubular member includes means for pivoting the elements about corresponding axes; means for translating the elements; and means for rotating the elements about a common axis. In an exemplary embodiment, the system further includes means for preventing the elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value. In an exemplary embodiment, means for preventing the elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value includes means for sensing the inside diameter of the tubular member.
- It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, the teachings of the present illustrative embodiments may be used to provide a wellbore casing, a pipeline, or a structural support. Furthermore, the elements and teachings of the various illustrative embodiments may be combined in whole or in part in some or all of the illustrative embodiments. In addition, one or more of the elements and teachings of the various illustrative embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.
- 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. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
Claims (98)
1. A system for forming a mono diameter wellbore casing within a borehole that includes a preexisting wellbore casing, comprising:
means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole;
means for increasing the size of the adjustable expansion device;
means for displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and
means for displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable member and a portion of the preexisting wellbore casing that overlaps with an end of the remaining portion of the expandable tubular member.
2. The system of claim 1 , further comprising:
means for reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed.
3. The system of claim 2 , further comprising:
means for fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device.
4. The system of claim 3 , further comprising:
means for permitting the position of the expandable tubular to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end expandable tubular member.
5. The system of claim 4 , further comprising:
means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the borehole after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
6. The system of claim 4 , further comprising:
means for increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative the position of the hydraulic actuator.
7. The system of claim 6 , further comprising:
means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastic deform the remaining portion of the expandable tubular member.
8. The system of claim 7 , further comprising:
means for not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and
means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expandable and plastically deform the end of the remaining portion of the expandable tubular member that overlaps with the preexisting wellbore casing after not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
9. A system for radially expanding and plastically deforming a tubular member, comprising:
means for positioning the tubular member within a preexisting structure;
means for radially expanding and plastically deforming a lower portion of the tubular member to form a bell section; and
means for radially expanding and plastically deforming a portion of the tubular member above the bell section.
10. The system of claim 9 , wherein positioning the tubular member within a preexisting structure comprises:
means for locking the tubular member to an expansion device.
11. The system of claim 10 , wherein the outside diameter of the expansion device is less than the inside diameter of the tubular member.
12. The system of claim 10 , wherein the expansion device is positioned within the tubular member.
13. The system of claim 10 , wherein the expansion device comprises an adjustable expansion device.
14. The system of claim 13 , wherein the adjustable expansion device is adjustable to a plurality of sizes.
15. The system of claim 10 , wherein the expansion device comprises a plurality of expansion devices.
16. The system of claim 15 , wherein at least one of the expansion devices comprises an adjustable expansion device.
17. The system of claim 16 , wherein at least one of the adjustable expansion device is adjustable to a plurality of sizes.
18. The system of claim 9 , wherein means for radially expanding and plastically deforming a lower portion of the tubular member to form a bell section comprises:
means for lowering an expansion device out of an end of the tubular member; and
means for pulling the expansion device through the end of the tubular member.
19. The system of claim 18 , wherein means for lowering an expression device out of an end of the tubular member comprises:
means for lowering the expansion device out of the end of the tubular member; and
means for adjusting the size of the expansion device.
20. The system of claim 19 , wherein the adjustable expansion device is adjustable to a plurality of sizes.
21. The system of claim 19 , wherein the expansion device comprises a plurality of adjustable expansion devices.
22. The system of claim 21 , wherein at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
23. The system of claim 18 , wherein means for pulling the expansion device through the end of the tubular member comprises:
means for gripping the tubular member; and
means for pulling an expansion device through an end of the tubular member.
24. The system of claim 23 , wherein means for gripping the tubular member comprises:
means for permitting axial displacement of the tubular member in a first direction; and
means for not permitting axial displacement of the tubular member in a second direction.
25. The system of claim 23 , wherein means for pulling the expansion device through the end of the tubular member comprises:
means for pulling the expansion device through the end of the member using an actuator.
26. The system of claim 9 , wherein means for radially expanding and plastically deforming a portion of the tubular member above the bell section comprises:
means for lowering an expansion device out of an end of the tubular member; and
means for pulling the expansion device through the end of the tubular member.
27. The system of claim 26 , wherein means for lowering an expansion device out of an end of the tubular member comprises:
means for lowering the expansion device out of the end of the tubular member; and
means for adjusting the size of the expansion device.
28. The system of claim 27 , wherein the adjustable expansion device is adjustable to a plurality of sizes.
29. The system of claim 27 , wherein the expansion device comprises a plurality of adjustable expansion devices.
30. The system of claim 29 , wherein at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
31. The system of claim 26 , wherein means for pulling the expansion device through the end of the tubular member comprises:
means for gripping the tubular member; and
means for pulling an expansion device through an end of the tubular member.
32. The system of claim 31, wherein means for gripping the tubular member comprises:
means or permitting axial displacement of the tubular member in a first direction; and
means for not permitting axial displacement of the tubular member in a second direction.
33. The system of claim 31 , wherein means for pulling the expansion device through the end of the tubular member comprises:
means for pulling the expansion device through the end of the tubular member using an actuator.
34. The system of claim 26 , wherein means for pulling the expansion device through the end of the tubular member comprises:
means for pulling the expansion device through the end of the tubular member using fluid pressure.
35. The system of claim 34 , wherein means for pulling the expansion device through the end of the tubular member using fluid pressure comprises:
means for pressurizing an annulus within the tubular member above the expansion device.
36. The system of claim 9 , wherein means for radially expanding and plastically deforming a portion of the tubular member above the bell section comprises:
means for fluidicly sealing an end of the tubular member; and
means for pulling the expansion device through the tubular member.
37. The system of claim 36 , wherein the expansion device is adjustable.
38. The system of claim 37 , wherein the expansion device is adjustable to a plurality of sizes.
39. The system of claim 36 , wherein the expansion device comprises a plurality of adjustable expansion devices.
40. The system of claim 39 , wherein at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
41. The system of claim 36 , wherein means for pulling the expansion device through the end of the tubular member comprises:
means for gripping the tubular member; and
means for pulling an expansion device through an end of the tubular member.
42. The system of claim 42 , wherein means for gripping the tubular member comprises:
means for permitting axial displacement of the tubular member in a first direction; and
means for not permitting axial displacement of the tubular member in a second direction.
43. The system of claim 42 , wherein means for pulling the expansion device though the end of the tubular member comprises:
means for pulling the expansion device through the end of the tubular member using an actuator.
44. The system of claim 36 , wherein means for pulling the expansion device through the end of the tubular member comprises:
means for pulling the expansion device through the end of the tubular member using fluid pressure.
45. The system of claim 44 , wherein means for pulling the expansion device through the end of the tubular member using fluid pressure comprises:
means for pressurizing an annulus within the tubular member above the expansion device.
46. The system of claim 9 , wherein means for radially expansion and plastically deforming a portion of the tubular member above the bell section comprises:
means for overlapping the portion of the tubular member above the bell section with an end of a preexisting tubular means; and
means for pulling an expansion device through the overlapping portions of the tubular member and the preexisting tubular member.
47. The system of claim 46 , wherein the expansion device is adjustable.
48. The system of claim 47 , wherein the expansion device is adjustable to a plurality of sizes.
49. The system of claim 46 , wherein the expansion device comprises a plurality of adjustable expansion devices.
50. The system of claim 49 , wherein at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
51. The system of claim 46 , wherein means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member comprises:
means for gripping the tubular member; and
means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member.
52. The system of claim 51 , wherein means for gripping the tubular member comprises:
means for permitting axial displacement of the tubular member in a first direction; and
means for not permitting axial displacement of the tubular member in a second direction.
53. The system of claim 51 , wherein means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member comprises:
means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using an actuator.
54. The system of claim 51 , wherein means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member comprises:
means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure.
55. The system of claim 54 , wherein means for pulling the expansion device through the overlapping portion of the tubular member and the preexisting tubular member using fluid pressure comprises:
means for pressurizing an annulus within the tubular member above the expansion device.
56. The system of claim 51 , further comprising:
means for cutting an end of the portion of the tubular member that overlaps with the preexisting tubular member.
57. The system of claim 56 , further comprising:
means for removing the cut off end of the expandable tubular member from the preexisting structure.
58. The system of claim 9 , further comprising:
means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the preexisting structure.
59. The system of claim 9 , further comprising:
means for cutting off an end of the expandable tubular member.
60. The system of claim 59 , further comprising:
means for removing the cut off end of the expandable tubular member from the preexisting structure.
61. A system for cutting a tubular member, comprising:
means for positioning a plurality of cutting elements within the tubular member, and
means for bringing the cutting elements into engagement with the tubular member.
62. The system of claim 61 , wherein the cutting elements comprise:
a first group of cutting elements; and
a second group of cutting elements;
wherein the first group of cutting elements are interleaved with the second group of cutting elements.
63. The system of claim 61 , wherein means for bringing the cutting elements into engagement with the tubular member comprises:
means for bringing the cutting elements into axial alignment.
64. The system of claim 61 , wherein means for bringing the cutting into engagement with the tubular member further comprise:
means for pivoting the cutting elements.
65. The system of claim 61 , wherein means for bringing the cutting elements into engagement with the tubular member further comprises:
means for translating the cutting element.
66. The system of claim 61 , wherein means for bringing the cutting elements into engagement with the tubular member further comprises:
means for pivoting the cutting elements; and
means for translating the cutting elements.
67. The method of claim 61 , wherein means for bringing the cutting elements into engagement with the tubular member comprises:
means for rotating the cutting elements about a common axis.
68. The system of claim 61 , wherein means for bringing the cutting elements into engagement with the tubular member comprises:
means for pivoting the cutting elements about corresponding axes;
means for translating the cutting elements; and
means for rotating the cutting elements about a common axis.
69. The system of claim 61 , further comprising:
means for preventing the cutting elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value.
70. The system of claim 70 , wherein means for preventing the cutting elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value comprises:
means for sensing the inside diameter of the tubular member.
71. A system for gripping a tubular member, comprising:
means for positioning a plurality of gripping elements within the tubular member; and
means for bringing gripping elements into engagement with the tubular member.
72. The system of claim 71 , wherein means for bringing the gripping elements into engagement with the tubular member comprises:
means for displacing the gripping elements in an axial direction; and
means for displacing the gripping elements in a radial direction.
73. The system of claim 71 , further comprising:
means for biasing the gripping elements against engagement with the tubular member.
74. A system for injecting a hardenable fluidic sealing material into an annulus between a tubular member and a preexisting structure, comprising:
means for positioning the tubular member into the preexisting structure;
means for sealing off an end of the tubular member;
means for operating a valve within the end of the tubular member; and
means for injecting a hardenable fluidic sealing material through the valve into the annulus between the tubular member and the preexisting structure.
75. An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising:
a support member;
a cutting device for cutting the tubular member coupled to the support member;
a gripping device for gripping the tubular member coupled to the support member;
a sealing device for sealing an interface with the tubular member coupled to the support member;
a locking device for locking the position of the tubular member relative to the support member;
a first adjustable expansion device for radially expanding and plastically deforming the tubular member coupled to the support member;
a second adjustable expansion device for radially expanding and plastically deforming the tubular member coupled to the support member;
a packer coupled to the support member; and
an actuator for displacing one or more of the sealing assembly, first and second adjustable expansion devices, and packer relative to the support member.
76. An apparatus for cutting a tubular member, comprising:
a support member; and
a plurality of movable cutting elements coupled to the support member.
77. An actuator, comprising:
a tubular housing;
a tubular piston rod movably coupled to and at least partially positioned within the housing;
a plurality of annular piston chambers defined by the tubular housing and the tubular piston rod; and
a plurality of tubular pistons coupled to the tubular piston rod, each tubular piston movably positioned within a corresponding annular piston chamber.
78. A packer comprising:
a support member defining a passage;
a shoe comprising a float valve coupled to an end of the support member;
one or more compressible packer elements movably coupled to the support member; and
a sliding sleeve valve movably positioned within the passage of the support member.
79. A method of radially expanding and plastically deforming an expandable tubular member within a borehole having a preexisting wellbore casing, comprising:
positioning the tubular member within the borehole in overlapping relation to the wellbore casing;
radially expanding and plastically deforming a portion of the tubular member to form a bell section; and
radially expanding and plastically deforming a portion of the tubular member above the bell section comprising a portion of the tubular member that overlaps with the wellbore casing;
wherein the inside diameter of the bell section is greater than the inside diameter of the radially expanded and plastically deformed portion of the tubular member above the bell section.
80. A method for forming a mono diameter wellbore casing, comprising:
positioning an adjustable expansion device within a first expandable tubular member;
supporting the first expandable tubular member and the adjustable expansion device within a borehole;
lowering the adjustable expansion device out of the first expandable tubular member;
increasing the outside dimension of the adjustable expansion device;
displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole;
positioning the adjustable expansion device within a second expandable tubular member;
supporting the second expandable tubular member and the adjustable expansion device within the borehole in overlapping relation to the first expandable tubular member;
lowering the adjustable expansion device out of the second expandable tubular member;
increasing the outside dimension of the adjustable expansion device; and
displacing the adjustable expansion device upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole.
81. A method for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising:
positioning an adjustable expansion device within the expandable tubular member;
supporting the expandable tubular member and the adjustable expansion device within the borehole;
lowering the adjustable expansion device out of the expandable tubular member;
increasing the outside dimension of the adjustable expansion device;
displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the borehole; and
pressurizing an interior region of the expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the expandable tubular member within the borehole.
82. A method for forming a mono diameter wellbore casing, comprising:
positioning an adjustable expansion device within a first expandable tubular member;
supporting the first expandable tubular member and the adjustable expansion device within a borehole;
lowering the adjustable expansion device out of the first expandable tubular member;
increasing the outside dimension of the adjustable expansion device;
displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole;
pressurizing an interior region of the first expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the first expandable tubular member within the borehole;
positioning the adjustable expansion mandrel within a second expandable tubular member;
supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member;
lowering the adjustable expansion mandrel out of the second expandable tubular member;
increasing the outside dimension of the adjustable expansion mandrel;
displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole; and
pressurizing an interior region of the second expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the second expandable tubular member within the borehole.
83. A method for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising:
supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole;
increasing the size of the adjustable expansion device; and
displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member.
84. A method for forming a mono diameter wellbore casing within a borehole that includes a preexisting wellbore casing, comprising:
supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole;
increasing the size of the adjustable expansion device;
displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and
displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting wellbore casing that overlaps with an end of the remaining portion of the expandable tubular member.
85. A method of radially expanding and plastically deforming a tubular member, comprising;
positioning the tubular member within a preexisting structure;
radially expanding and plastically deforming a lower portion of the tubular member to form a bell section; and
radially expanding and plastically deforming a portion of the tubular member above the bell section.
86. A method of radially expanding and plastically deforming a tubular member, comprising:
applying internal pressure simultaneously to the inside surface of the tubular member at a plurality of discrete spaced apart locations separated from one another.
87. A system for radially expanding and plastically deforming an expandable tubular member within a borehole having a preexisting wellbore casing, comprising:
means for positioning the tubular member within the borehole in overlapping relation to the wellbore casing;
means for radially expanding and plastically deforming a portion of the tubular member to form a bell section; and
means for radially expanding and plastically deforming a portion of the tubular member above the bell section comprising a portion of the tubular member that overlaps with the wellbore casing;
wherein the inside diameter of the bell section is greater than the inside diameter of the radially expanded and plastically deformed portion of the tubular member above the bell section.
88. A system for forming a mono diameter wellbore casing, comprising:
means for positioning an adjustable expansion device within a first expandable tubular member;
means for supporting the first expandable tubular member and the adjustable expansion device within a borehole;
means for lowering the adjustable expansion device out of the first expandable tubular member;
means for increasing the outside dimension of the adjustable expansion device;
means for displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole;
means for positioning the adjustable expansion device within a second expandable tubular member;
means for supporting the second expandable tubular member and the adjustable expansion device within the borehole in overlapping relation to the first expandable tubular member;
means for lowering the adjustable expansion device out of the second expandable tubular member;
means for increasing the outside dimension of the adjustable expansion device; and
means for displacing the adjustable expansion device upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole.
89. A system for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising:
means for positioning an adjustable expansion device within the expandable tubular member;
means for supporting the expandable tubular member and the adjustable expansion device within the borehole;
means for lowering the adjustable expansion device out of the expandable tubular member;
means for increasing the outside dimension of the adjustable expansion device;
means for displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the borehole; and
means for pressurizing an interior region of the expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the expandable tubular member within the borehole.
90. A system for forming a mono diameter wellbore casing, comprising:
means for positioning an adjustable expansion device within a first expandable tubular member;
means for supporting the first expandable tubular member and the adjustable expansion device within a borehole;
means for lowering the adjustable expansion device out of the first expandable tubular member;
means for increasing the outside dimension of the adjustable expansion device;
means for displacing the adjustable expansion device upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole;
means for pressurizing an interior region of the first expandable tubular member above the adjustable expansion device during the radial expansion and plastic deformation of the first expandable tubular member within the borehole;
means for positioning the adjustable expansion mandrel within a second expandable tubular member;
means for supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member;
means for lowering the adjustable expansion mandrel out of the second expandable tubular member;
means for increasing the outside dimension of the adjustable expansion mandrel;
means for displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole; and
means for pressurizing an interior region of the second expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the second expandable tubular member within the borehole.
91. A system for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising;
means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole;
means for increasing the size of the adjustable expansion device; and
means for displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member.
92. A system of radially expanding and plastically deforming a tubular member, comprising:
a support member; and
means for applying internal pressure to the inside surface of the tubular member at a plurality of discrete location separated from one another coupled to the support member.
93. A method of cutting a tubular member, comprising:
positioning a plurality of cutting elements within the tubular member; and
bringing the cutting elements into engagement with the tubular member.
94. The method of claim 469, wherein the cutting elements comprise:
a first group of cutting elements; and
a second group of cutting elements;
wherein the first group of cutting elements are interleaved with the second group of cutting elements.
95. A method of injecting a hardenable fluidic sealing material into an annulus between a tubular member and a preexisting structure, comprising:
positioning the tubular member into the preexisting structure;
sealing off an end of the tubular member;
operating a valve within the end of the tubular member; and
injecting a hardenable fluidic sealing material through the valve into the annulus between the tubular member and the preexisting structure.
96. An actuator system, comprising:
a support member; and
means for pressurizing a plurality of pressure chambers coupled to the support member.
97. A method of engaging a tubular member, comprising:
positioning a plurality of elements within the tubular member; and
bringing the elements into engagement with the tubular member.
98. A packer module for a packer assembly, comprising:
a support member;
one or more compressible packer sealing elements coupled to the support member;
one or more packer compressing elements movably coupled to the support member for compressing the compressible packer sealing elements; and
one or more engagement elements movably coupled to the support member for engaging the interior surface of a tubular member;
wherein each of the packer compressing elements comprise a plurality of circumferentially spaced apart packer compressing elements; and
wherein each of the engagement elements comprise a plurality of circumferentially spaced apart packer compressing elements.
Priority Applications (2)
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US10/552,253 US20060266527A1 (en) | 2003-04-07 | 2004-04-06 | Apparatus for radially expanding and plastically deforming a tubular member |
US11/552,703 US7546881B2 (en) | 2001-09-07 | 2006-10-25 | Apparatus for radially expanding and plastically deforming a tubular member |
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US46103803P | 2003-04-07 | 2003-04-07 | |
US10/552,253 US20060266527A1 (en) | 2003-04-07 | 2004-04-06 | Apparatus for radially expanding and plastically deforming a tubular member |
PCT/US2004/010762 WO2004092528A2 (en) | 2003-04-07 | 2004-04-06 | Apparatus for radially expanding and plastically deforming a tubular member |
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US10/550,906 Continuation-In-Part US20080190616A1 (en) | 2001-09-07 | 2004-03-26 | Apparatus for Radially Expanding and Plastically Deforming a Tubular Member |
PCT/US2004/009434 Continuation-In-Part WO2004085790A2 (en) | 2001-09-07 | 2004-03-26 | Apparatus for radially expanding and plastically deforming a tubular member |
US10/551,880 Continuation-In-Part US20060243444A1 (en) | 2001-09-07 | 2004-04-02 | apparatus for radially expanding and plastically deforming a tubular member |
US10551880 Continuation-In-Part | 2004-04-02 | ||
PCT/US2004/010317 Continuation-In-Part WO2004089608A2 (en) | 2001-09-07 | 2004-04-02 | Apparatus for radially expanding and plastically deforming a tubular member |
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US10/552,790 Continuation-In-Part US20060196679A1 (en) | 2001-09-07 | 2004-04-06 | Apparatus for radially expanding and plastically deforming a tubular member |
PCT/US2004/010712 Continuation-In-Part WO2004092527A2 (en) | 2001-09-07 | 2004-04-06 | Apparatus for radially expanding and plastically deforming a tubular member |
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US (1) | US20060266527A1 (en) |
CA (1) | CA2523654A1 (en) |
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AU2003265452A1 (en) | 2002-09-20 | 2004-04-08 | Enventure Global Technology | Pipe formability evaluation for expandable tubulars |
CA2523862C (en) * | 2003-04-17 | 2009-06-23 | Enventure Global Technology | Apparatus for radially expanding and plastically deforming a tubular member |
GB0412131D0 (en) | 2004-05-29 | 2004-06-30 | Weatherford Lamb | Coupling and seating tubulars in a bore |
AU2008333796B2 (en) | 2007-12-04 | 2013-08-22 | Arconic Inc. | Improved aluminum-copper-lithium alloys |
CN116658116B (en) * | 2023-07-31 | 2024-01-30 | 成都若克石油技术开发有限公司 | Packer for positioning perforation and use method |
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US20050056433A1 (en) * | 2001-11-12 | 2005-03-17 | Lev Ring | Mono diameter wellbore casing |
-
2004
- 2004-04-06 US US10/552,253 patent/US20060266527A1/en not_active Abandoned
- 2004-04-06 CA CA002523654A patent/CA2523654A1/en not_active Abandoned
- 2004-04-06 GB GB0522050A patent/GB2416795A/en not_active Withdrawn
- 2004-04-06 WO PCT/US2004/010762 patent/WO2004092528A2/en active Application Filing
-
2005
- 2005-11-04 NO NO20055200A patent/NO20055200L/en not_active Application Discontinuation
Patent Citations (1)
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US20050056433A1 (en) * | 2001-11-12 | 2005-03-17 | Lev Ring | Mono diameter wellbore casing |
Cited By (17)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7886831B2 (en) | 2003-01-22 | 2011-02-15 | Enventure Global Technology, L.L.C. | Apparatus for radially expanding and plastically deforming a tubular member |
US7367389B2 (en) * | 2003-06-16 | 2008-05-06 | Weatherford/Lamb, Inc. | Tubing expansion |
US20060052936A1 (en) * | 2003-06-16 | 2006-03-09 | Duggan Andrew M | Tubing expansion |
US7712522B2 (en) | 2003-09-05 | 2010-05-11 | Enventure Global Technology, Llc | Expansion cone and system |
US7819185B2 (en) | 2004-08-13 | 2010-10-26 | Enventure Global Technology, Llc | Expandable tubular |
US20100147535A1 (en) * | 2006-04-18 | 2010-06-17 | Read Well Services Limited | Expandable Liner Hanger |
US8291986B2 (en) * | 2006-04-18 | 2012-10-23 | Meta Downhole Limited | Expandable liner hanger |
US20090200041A1 (en) * | 2008-02-07 | 2009-08-13 | Halliburton Energy Services, Inc. | Expansion Cone for Expandable Liner Hanger |
US7779910B2 (en) | 2008-02-07 | 2010-08-24 | Halliburton Energy Services, Inc. | Expansion cone for expandable liner hanger |
US8261842B2 (en) | 2009-12-08 | 2012-09-11 | Halliburton Energy Services, Inc. | Expandable wellbore liner system |
US20110220356A1 (en) * | 2010-03-11 | 2011-09-15 | Halliburton Energy Services, Inc. | Multiple stage cementing tool with expandable sealing element |
US8230926B2 (en) | 2010-03-11 | 2012-07-31 | Halliburton Energy Services Inc. | Multiple stage cementing tool with expandable sealing element |
US20180119527A1 (en) * | 2015-07-01 | 2018-05-03 | Shell Oil Company | Hybrid push and pull method and system for expanding well tubulars |
US10450846B2 (en) * | 2015-07-01 | 2019-10-22 | Shell Oil Company | Hybrid push and pull method and system for expanding well tubulars |
US20190078416A1 (en) * | 2016-03-14 | 2019-03-14 | Halliburton Energy Services, Inc. | 3d printed tool with integral stress concentration zone |
US10954743B2 (en) * | 2016-03-14 | 2021-03-23 | Halliburton Energy Services, Inc. | 3D printed tool with integral stress concentration zone |
US11708739B2 (en) | 2016-03-14 | 2023-07-25 | Halliburton Energy Services, Inc. | 3D printed tool with integral stress concentration zone |
Also Published As
Publication number | Publication date |
---|---|
WO2004092528A2 (en) | 2004-10-28 |
GB2416795A (en) | 2006-02-08 |
NO20055200D0 (en) | 2005-11-04 |
CA2523654A1 (en) | 2004-10-28 |
GB0522050D0 (en) | 2005-12-07 |
NO20055200L (en) | 2005-12-12 |
WO2004092528A3 (en) | 2005-11-10 |
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AS | Assignment |
Owner name: ENVENTURE GLOBAL TECHNOLOGY, TEXAS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:BRISCO, DAVID PAUL;WATSON, BROCK WAYNE;TREECE, HAROLD OTIS;REEL/FRAME:017471/0625;SIGNING DATES FROM 20060303 TO 20060316 |
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STCB | Information on status: application discontinuation |
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