WO2003078785A2 - Cone extensible repliable - Google Patents

Cone extensible repliable Download PDF

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Publication number
WO2003078785A2
WO2003078785A2 PCT/US2003/004837 US0304837W WO03078785A2 WO 2003078785 A2 WO2003078785 A2 WO 2003078785A2 US 0304837 W US0304837 W US 0304837W WO 03078785 A2 WO03078785 A2 WO 03078785A2
Authority
WO
WIPO (PCT)
Prior art keywords
expansion cone
support member
cam
tubular support
coupled
Prior art date
Application number
PCT/US2003/004837
Other languages
English (en)
Other versions
WO2003078785A3 (fr
WO2003078785B1 (fr
Inventor
Brock Wayne Watson
David Paul Brisco
Original Assignee
Eventure Global Technology
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Eventure Global Technology filed Critical Eventure Global Technology
Priority to US10/507,567 priority Critical patent/US20050103502A1/en
Priority to GB0422419A priority patent/GB2403756A/en
Priority to AU2003215290A priority patent/AU2003215290A1/en
Priority to CA002478868A priority patent/CA2478868A1/fr
Publication of WO2003078785A2 publication Critical patent/WO2003078785A2/fr
Publication of WO2003078785A3 publication Critical patent/WO2003078785A3/fr
Publication of WO2003078785B1 publication Critical patent/WO2003078785B1/fr
Priority to US11/552,703 priority patent/US7546881B2/en
Priority to US11/838,782 priority patent/US20080142213A1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E21B43/105—Expanding tools specially adapted therefor

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.
  • a wellbore typically traverses a number of zones within a subterranean formation.
  • Wellbore casings are then formed in the wellbore by radially expanding and plastically deforming tubular members that are coupled to one another by threaded connections.
  • Existing methods for radially expanding and plastically deforming tubular members coupled to one another by threaded connections are not always reliable or produce satisfactory results. In particular, the threaded connections can be damaged during the radial expansion process.
  • the present invention is directed to overcoming one or more of the limitations of the existing processes for radially expanding and plastically deforming tubular members coupled to one another by threaded connections.
  • an apparatus for radially expanding and plastically deforming an expandable tubular member includes an upper tubular support member defining a first passage, one or more cup seals coupled to the exterior surface of the upper tubular support member for sealing an interface between the upper tubular support member and the expandable tubular member, an upper cam assembly coupled to the upper tubular support member comprising: a tubular base coupled to the upper tubular support member, and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface, a plurality of upper expansion cone segments interleaved with the cam arms of the upper cam assembly and pivotally coupled to the tubular support member, a lower tubular support member defining a second passage fluidicly coupled to the first passage releasably coupled to the upper tubular support member, and a lower cam assembly coupled to the lower tubular support member comprising: a tubular base coupled to the lower tubular support member, and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam
  • a collapsible expansion cone assembly includes an upper tubular support member comprising an internal flange, an upper cam assembly coupled to the upper tubular support member comprising: a tubular base coupled to the upper support member, and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface, a plurality of upper expansion cone segments interleaved with the cam arms of the upper cam assembly and pivotally coupled to the internal flange of the upper tubular support member, a lower tubular support member comprising an internal flange, one or more frangible couplings for releasably coupling the upper and lower tubular support members, a lower cam assembly coupled to the lower tubular support member comprising: a tubular base coupled to the lower tubular support member, and a plurality of cam arms extending from the tubular base in an upward longitudinal direction, each cam arm defining an inclined surface that mates with the inclined surface of a corresponding one of
  • an apparatus for radially expanding and plastically deforming an expandable tubular member includes a tubular support member, a collapsible expansion cone coupled to the tubular support member, an expandable tubular member coupled to the collapsible expansion cone, means for displacing the collapsible expansion cone relative to the expandable tubular member, and means for collapsing the expansion cone.
  • a collapsible expansion cone that includes an upper cam assembly comprising: a tubular base, and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface, a plurality of upper expansion cone segments interleaved with the cam arms of the upper cam assembly, a lower cam assembly comprising: a tubular base, and a plurality of cam arms extending from the tubular base in an upward longitudinal direction, each cam arm defining an inclined surface that mates with the inclined surface of a corresponding one of the upper expansion cone segments, wherein the cams arms of the upper cam assembly are interleaved with and overlap the cam arms of the lower cam assembly, a plurality of lower expansion cone segments interleaved with cam arms of the lower cam assembly, each lower expansion cone segment mating with the inclined surface of a corresponding one of the cam arms of the upper cam assembly, means for moving the upper cam assembly away from the lower expansion cone segments, and means for moving
  • an apparatus for radially expanding and plastically deforming an expandable tubular member includes a tubular support member, a collapsible expansion cone coupled to the tubular support member, an expandable tubular member coupled to the collapsible expansion cone, means for displacing the collapsible expansion cone relative to the expandable tubular member, and means for collapsing the expansion cone.
  • a collapsible expansion cone that includes an upper cam assembly comprising: a tubular base, and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface, a plurality of upper expansion cone segments interleaved with the cam arms of the upper cam assembly, a lower cam assembly comprising: a tubular base, and a plurality of cam arms extending from the tubular base in an upward longitudinal direction, each cam arm defining an inclined surface that mates with the inclined surface of a corresponding one of the upper expansion cone segments, wherein the cams arms of the upper cam assembly are interleaved with and overlap the cam arms of the lower cam assembly, a plurality of lower expansion cone segments interleaved with cam arms of the lower cam assembly, each lower expansion cone segment mating with the inclined surface of a corresponding one of the cam arms of the upper cam assembly, means for moving the upper cam assembly away from the lower expansion cone segments, and means for moving the upper cam assembly away from the lower expansion cone segments, and means
  • a method of radially expanding and plastically deforming an expandable tubular member includes supporting the expandable tubular member using a tubular support member and a collapsible expansion cone, injecting a fluidic material into the tubular support member, sensing the operating pressure of the injected fluidic material within a first interior portion of the tubular support member, displacing the collapsible expansion cone relative to the expandable tubular member when the sensed operating pressure of the injected fluidic material exceeds a predetermined level within the first interior portion of the tubular support member, sensing the operating pressure of the injected fluidic material within a second interior portion of the tubular support member, and collapsing the collapsible expansion cone when the sensed operating pressure of the injected fluidic material exceeds a predetermined level within the second interior portion of the tubular support member.
  • Fig. la is a fragmentary cross-sectional illustration of the placement of a portion of an exemplary embodiment of an apparatus for radially expanding and plastically deforming a tubular member that includes a collapsible expansion cone within a preexisting structure.
  • Fig. lb is a fragmentary cross-sectional illustration of another portion of the apparatus of
  • FIGs. 2a and 2b are fragmentary cross-sectional illustration of a portion of the apparatus of
  • FIG. 3 is a fragmentary cross-sectional illustration of a portion of the apparatus of Figs, la and lb.
  • Fig. 3a is a fragmentary cross-sectional illustration of a portion of the apparatus of Fig 3.
  • Fig. 3b is a fragmentary cross-sectional illustration of a portion of the apparatus of Fig 3.
  • FIG. 4 is a fragmentary cross-sectional illustration of a portion of the apparatus of Figs, la and lb.
  • Fig. 4a is a fragmentary cross-sectional illustration of a portion of the apparatus of Fig 4.
  • FIG. 5 is a fragmentary cross-sectional illustration of a portion of the apparatus of Figs, la and lb.
  • FIG. 6 is a fragmentary cross-sectional illustration of a portion of the apparatus of Figs, la and lb.
  • FIGS. 7a-7e are fragmentary cross-sectional and perspective illustrations of the upper cam assembly of the apparatus of Figs, la and lb.
  • Fig. 7f is a fragmentary cross-sectional illustration of the lower cam assembly of the apparatus of Figs, la and lb.
  • FIGs. 8a-8d are fragmentary cross-sectional and perspective illustrations of one of the upper cone segments of the apparatus of Figs, la and lb.
  • Fig. 8e is a fragmentary cross-sectional illustration of one of the lower cone segments of the apparatus of Figs, la and lb.
  • Fig. 9 is a side view of a portion of the apparatus of Figs, la and lb.
  • Fig. 10a is a fragmentary cross sectional illustration of a portion of the apparatus of Figs. la and lb during the radial expansion of the expandable tubular member.
  • Fig. 10b is a fragmentary cross sectional illustration of another portion of the apparatus of
  • Fig. 11a is a fragmentary cross sectional illustration of a portion of the apparatus of Figs.
  • FIG. 1 lb is a fragmentary cross sectional illustration of another portion of the apparatus of
  • Fig. 12 is a fragmentary cross sectional illustration of a portion of the apparatus of Figs.
  • FIG. 13 is a fragmentary cross sectional illustration of a portion of the apparatus of Figs.
  • FIG. 14 is a fragmentary cross sectional illustration of a portion of the apparatus of Figs.
  • FIG. 15 is a fragmentary cross sectional illustration of a portion of the apparatus of Figs.
  • Fig. 16 is a side view of a portion of the apparatus of Figs. 10a and 10b.
  • Fig. 17a is a fragmentary cross sectional illustration of a portion of the apparatus of Figs.
  • FIG. 17b is a fragmentary cross sectional illustration of another portion of the apparatus of
  • an exemplary embodiment of an apparatus 10 for radially expanding and plastically deforming a tubular member includes a tubular support member 12 that defines a passage 12a.
  • An end of the tubular support member 12 is coupled to an end of a safety collar 14 that defines a passage 14a, a recess 14b at one end for receiving the end of the tubular support member, and recesses 14c and 14d at another end.
  • a torque plate 16 is received within and is coupled to the recess 14c of the safety collar
  • An end of an upper mandrel 22 is received within and is coupled to the upper mandrel collar 18 that defines a passage 22a, a plurality of meshing teeth 22b that mate with and transmit torque to and from the meshing teeth 16b of the torque plate 16, and an external flange 22c at another end.
  • An upper packer cup 24 mates with, receives and is coupled to the upper mandrel 22 proximate the end of the upper mandrel collar 18.
  • the upper packer cup 24 is a GuibersonTM packer cup.
  • An upper spacer sleeve 26 mates with, receives, and is coupled to the upper mandrel 22 proximate an end of the upper packer cup 24.
  • a lower packer cup 28 mates with, receives and is coupled to the upper mandrel 22 proximate an end of the upper spacer sleeve 26.
  • the lower packer cup 28 is a GuibersonTM packer cup.
  • a lower spacer sleeve 30 mates with, receives, and is coupled to the upper mandrel 22 proximate an end of the lower packer cup 28 and the external flange 22c of the upper mandrel.
  • a retaining sleeve 32 mates with, receives, and is coupled to an end of the lower spacer sleeve proximate the external flange 22c of the upper mandrel 22.
  • An end of a lower mandrel 34 defines a recess 34a that mates with, receives, and is coupled to the external flange 22c of the upper mandrel 22, a recess 34b that mates with, receives, and is coupled to the end of the upper mandrel, a passage 34c, and an external flange 34d including circumferentially spaced apart meshing teeth 34da on an end face of the external flange.
  • Torque pins 36a and 36b further couple the recess 34a of the end of the lower mandrel 34 to the external flange 22c of the upper mandrel 22.
  • the torque pins 36a and 36b transmit torque loads between the recess 34a of the end of the lower mandrel 34 and the external flange 22c of the upper mandrel 22.
  • An upper cam assembly 38 includes a tubular base 38a for receiving and mating with the lower mandrel 34 that includes an external flange 38aa, a plurality of circumferentially spaced apart meshing teeth 38b that extend from one end of the tubular base in the longitudinal and radial directions for engaging the meshing teeth 34da of the end face of the external flange 34d of the lower mandrel, and a plurality of circumferentially spaced apart cam arms 38c that extend from the other end of the tubular base in the opposite longitudinal direction and mate with and receive the lower mandrel.
  • the meshing teeth 34da of the end face of the external flange 34d of the lower mandrel 34 transmit torque loads to the meshing teeth 38b of the upper cam assembly 38.
  • Each of the cam arms 38c include an inner portion 38ca extending from the tubular base 38a that has arcuate cylindrical inner and outer surfaces, 38caa and 3 Scab, a tapered intermediate portion 38cb extending from the inner portion that has an arcuate cylindrical inner surface 38cba and an arcuate conical outer surface 38cbb, and an outer portion 38cc extending from the intermediate portion that has arcuate cylindrical inner and outer surfaces, 38cca and 38ccb.
  • the radius of curvatures of the arcuate outer cylindrical surfaces 38cab are greater than the radius of curvatures of the arcuate outer cylindrical surfaces 38ccb.
  • a lower cam assembly 40 includes a tubular base 40a for receiving and mating with the lower mandrel 34 that includes an external flange 40aa, a plurality of circumferentially spaced apart meshing teeth 40b that extend from one end of the tubular base in the longitudinal and radial directions, and a plurality of circumferentially spaced apart cam arms 40c that extend from the other end of the tubular base in the opposite longitudinal direction and mate with and receive the lower mandrel.
  • Each of the cam arms 40c include an inner portion 40ca extending from the tubular base 40a that has arcuate cylindrical inner and outer surfaces, 40caa and 40cab, a tapered intermediate portion 40cb extending from the inner portion 40ca that has an arcuate cylindrical inner surface 40cba and an arcuate conical outer surface 40cbb, and an outer portion 40cc extending from the intermediate portion that has arcuate cylindrical inner and outer surfaces, 40cca and 40ccb.
  • the radius of curvatures of the arcuate outer cylindrical surfaces 40cab are greater than the radius of curvatures the arcuate outer cylindrical surfaces 40ccb.
  • the radius of curvatures of the arcuate inner cylindrical surfaces, 40caa, 40cba, and 40cca are equal.
  • the upper and lower cam assemblies, 38 and 40 are substantially identical.
  • the cam arms 38c of the upper cam assembly 38 interleave the cam arms 40c of the lower cam assembly 40.
  • the cam arms 38c of the upper cam assembly also overlap with the cam arms 40c of the lower cam assembly 40 in the longitudinal direction thereby permitting torque loads to be transmitted between the upper and lower cam assemblies.
  • An end of an upper retaining sleeve 42 receives and is threadably coupled to the external flange 34d of the lower mandrel 34 that defines a passage 42a for receiving and mating with the outer circumferential surfaces of the external flange 38aa and the meshing teeth 38b of the upper cam assembly 38, and an inner annular recess 42b, and includes an internal flange 42c for retaining the external flange 38aa of the upper cam assembly, and an internal flange 42d at one end of the upper retaining sleeve that includes a rounded interior end face.
  • An o-ring seal 44 is received within the annular recess 42b for sealing the interface between the upper retaining sleeve 42 and the external flange 34d of the lower mandrel 34.
  • a disc shaped shim 43 is positioned within the upper retaining sleeve 42 between the opposing end faces of the internal flange 42c of the retaining sleeve and the meshing teeth 38b of the upper cam assembly 38.
  • a plurality of upper expansion cone segments 44 are interleaved among the cam arms 38c of the upper cam assembly 38.
  • Each of the upper expansion cone segments 44 include inner portions 44a having arcuate cylindrical inner surfaces, 44aaa and 44aab, and an arcuate cylindrical outer surface 44ab, intermediate portions 44b extending from the interior portions that have an arcuate conical inner surface 44ba and arcuate cylindrical and spherical outer surfaces, 44bba and 44bbb, and outer portions 44c having arcuate cylindrical inner and outer surfaces, 44ca and 44cb.
  • the outer surfaces 44ab of the inner portions 44a of the upper expansion cone segments define hinge grooves 44aba that receive and are pivotally mounted upon the internal flange 42d of the upper retaining sleeve 42.
  • arcuate inner cylindrical surfaces 44aaa mate with and receive the lower mandrel 34
  • the arcuate inner cylindrical surfaces 44aab mate with and receive the arcuate cylindrical outer surfaces 40ccb of the outer portions 40cc of the corresponding cam arms 40c of the lower cam assembly 40
  • the arcuate inner conical surfaces 44ba mate with and receive the arcuate conical outer surfaces 40cbb of the intermediate portions 40cb of the corresponding cam arms of the lower cam assembly.
  • the radius of curvature of the arcuate cylindrical inner surface 44aaa is less than the radius of curvature of the arcuate cylindrical inner surface 44aab. In an exemplary embodiment, the radius of curvature of the arcuate cylindrical inner surface 44ca is greater than the radius of curvature of the arcuate cylindrical surface 44aab. In an exemplary embodiment, the arcuate cylindrical inner surfaces, 44aaa and 44aab, are parallel. In an exemplary embodiment, the arcuate cylindrical outer surface 44ab is inclined relative to the arcuate cylindrical inner surface 44aaa. In an exemplary embodiment, the arcuate cylindrical outer surface 44bba is parallel to the arcuate cylindrical inner surfaces, 44aaa and 44aab.
  • the arcuate cylindrical outer surface 44cb is inclined relative to the arcuate cylindrical inner surface 44ca.
  • a plurality of lower expansion cone segments 46 are interleaved among, and overlap, the upper expansion cone segments 44 and the cam arms 38c of the lower cam assembly 38. In this manner, torque loads may be transmitted between the upper and lower expansion cone segments, 44 and 46.
  • Each of the lower expansion cone segments 46 include inner portions 46a having arcuate cylindrical inner surfaces, 46aaa and 46aab, and an arcuate cylindrical outer surface 46ab, intermediate portions 46b extending from the interior portions that have an arcuate conical inner surface 46ba and arcuate cylindrical and spherical outer surfaces, 46bba and 46bbb, and outer portions 46c having arcuate cylindrical inner and outer surfaces, 46ca and 46cb.
  • the outer surfaces 46ab of the inner portions 46a of the upper expansion cone segments 46 define hinge grooves 46aba.
  • the arcuate inner cylindrical surfaces 46aaa mate with and receive the lower mandrel 34
  • the arcuate inner cylindrical surfaces 46aab mate with and receive the arcuate cylindrical outer surfaces 38ccb of the outer portions 38cc of the corresponding cam arms 38c of the upper cam assembly 38
  • the arcuate inner conical surfaces 46ba mate with and receive the arcuate conical outer surfaces 38cbb of the intermediate portions 38cb of the corresponding cam arms of the lower cam assembly.
  • the radius of curvature of the arcuate cylindrical inner surface 46aaa is less than the radius of curvature of the arcuate cylindrical inner surface 46aab. In an exemplary embodiment, the radius of curvature of the arcuate cylindrical inner surface 46ca is greater than the radius of curvature of the arcuate cylindrical surface 46aab. In an exemplary embodiment, the arcuate cylindrical inner surfaces, 46aaa and 46aab, are parallel. In an exemplary embodiment, the arcuate cylindrical outer surface 46ab is inclined relative to the arcuate cylindrical inner surface 46aaa. In an exemplary embodiment, the arcuate cylindrical outer surface 46bba is parallel to the arcuate cylindrical inner surfaces, 46aaa and 46aab.
  • the arcuate cylindrical outer surface 46cb is inclined relative to the arcuate cylindrical inner surface 46ca.
  • the geometries of the upper and lower expansion cone segments 44 and 46 are substantially identical.
  • the upper expansion cone segments 44 are tapered in the longitudinal direction from the ends of the intermediate portions 44b to the ends of the outer portions 44c
  • the lower expansion cone segments 46 are tapered in the longitudinal direction from the ends of the intermediate portions 46b to the ends of the outer portions 46c.
  • the arcuate cylindrical outer surfaces, 44bba and 46cb, of the upper and lower expansion cone segments define a contiguous cylindrical surface
  • the arcuate spherical outer surfaces, 44bbb and 46bbb, of the upper and lower expansion cone segments define an contiguous arcuate spherical surface
  • the arcuate cylindrical outer surfaces, 44cb and 46bba, of the upper and lower expansion cone segments define a contiguous cylindrical surface.
  • An end of a lower retaining sleeve 48 defines a passage 48a for receiving and mating with the outer circumferential surfaces of the external flange 40aa and the meshing teeth 40b of the lower cam assembly 40, and an inner annular recess 48b, and includes an internal flange 48c for retaining the external flange of the lower cam assembly, and an internal flange 48d at one end of the lower retaining sleeve that includes a rounded interior end face for mating with the hinge grooves 46 aba of the lower expansion cone segments 46 thereby pivotally coupling the lower expansion cone segments to the lower retaining sleeve.
  • An o-ring seal 50 is received within the annular recess 48b.
  • a disc shaped shim 49 is positioned within the lower retaining sleeve 48 between the opposing end faces of the internal flange 48c of the retaining sleeve and the external flange 40aa of the lower cam assembly
  • the arcuate cylindrical outer surfaces 44bba of the upper expansion cone segments 44 and the arcuate cylindrical outer surfaces 46cb of the lower expansion cone segments 46 are aligned with the outer surface of the upper retaining sleeve 42.
  • the arcuate cylindrical outer surfaces 44cb of the upper expansion cone segments 44 and the arcuate cylindrical outer surfaces 46 bba of the lower expansion cone segments are aligned with the outer surface of the lower retaining sleeve 48.
  • An end of a float shoe adaptor 50 that includes a plurality of circumferentially spaced apart meshing teeth 50a for engaging the meshing teeth 40b of the lower cam assembly 40 is received within and threadably coupled to an end of the lower retaining sleeve 48 that defines a passage 50b at one end for receiving an end of the lower mandrel 34, a passage 50c having a reduced inside diameter at another end, a plurality of radial passages 50d at the other end, and includes an internal flange 50e, and a torsional coupling 5 Of at the other end that includes a plurality of torsional coupling members
  • the meshing teeth 40b of the lower cam assembly 40 transmit toque loads to and from the meshing teeth 50a of the float shoe adaptor.
  • An end of a retaining sleeve 52 abuts the end face of the tubular base 40a of the lower cam assembly 40 and is received within and mates with the passage 50b of the float shoe adaptor 50 that defines a passage 52a for receiving an end of the lower mandrel 34, a throat passage 52b including a ball valve seat 52c, and includes a flange 52d, and another end of the retaining sleeve, having a reduced outside diameter, is received within and mates with the passage 50c of the float shoe adaptor 50.
  • a stop nut 54 receives and is threadably coupled to the end of the lower mandrel 34 within the passage 52a of the retaining sleeve 52, and shear pins 56 releasably couple the stop nut 54 to the retaining sleeve 52.
  • Locking dogs 58 are positioned within an end of the retaining sleeve 52 that receive and are releasably coupled to the lower mandrel 34, and a disc shaped adjustment shim 60 receives the lower mandrel 34 and is positioned within an end of the retaining sleeve 52 between the opposing ends of the tubular base 40a of the upper cam assembly 40 and the locking dogs 58.
  • Burst discs 62 are releasably coupled to and positioned within the radial passages 50d of the float shoe adaptor 50.
  • An end of a float shoe 64 mates with and is releasably coupled to the torsional coupling members 50fa of the torsional coupling 50f of the float shoe adaptor 50 that defines a passage 64a and a valveable passage 64b. In this manner torsional loads may be transmitted between the float shoe adaptor 50 and the float shoe 64.
  • An end of an expandable tubular member 66 that surrounds the tubular support member 12, the safety collar 14, the upper mandrel collar 18, the upper packer cup 24, the lower packer cup 28, the lower mandrel 34, the upper expansion cone segments 44, the lower expansion cone segments 46, and the float shoe adaptor 50, is coupled to and receives an end of the float shoe 64 and is movably coupled to and supported by the arcuate spherical external surfaces,
  • the apparatus 10 is at least partially positioned within a preexisting structure such as, for example, a borehole 100 that traverses a subterranean formation that may include a preexisting wellbore casing 102.
  • the borehole 100 may be oriented in any position, for example, from vertical to horizontal.
  • a fluidic material 104 is then injected into the apparatus 10 through the passages 12a, 14a, 22a, 34c, 50c, 64a, and 64b into the annulus between the expandable tubular member 66 and the borehole 100.
  • the fluidic material 104 is a hardenable fluidic sealing material. In this manner, an annular sealing layer may be formed within the annulus between the expandable tubular member 66 and the borehole 100.
  • a ball 106 is then be positioned within and blocking the valveable passage 64b of the float shoe 64 by injecting a fluidic material 108 into the apparatus 10 through the passages 12a, 14a, 22a, 34c, and 50c.
  • a fluidic material 108 into the apparatus 10 through the passages 12a, 14a, 22a, 34c, and 50c.
  • the increased operating pressure within the passage 50c bursts open the burst discs 62 positioned within the radial passages 50d of the float shoe adaptor 50.
  • the continued injection of the fluidic material 108 thereby pressurizes the interior of the expandable tubular member 66 below the lower packer cup 28 thereby displacing the upper and lower expansion cone segments, 44 and 46, upwardly relative to the float shoe 64 and the expandable tubular member 66.
  • the expandable tubular member 66 is plastically deformed and radially expanded.
  • the burst discs 62 sense the operating pressure of the injected fluidic material 108 within the passage 50c and thereby control the initiation of the radial expansion and plastic deformation of the expandable tubular member 66.
  • any leakage of the pressurized fluidic material 108 past the lower packer cup 28 is captured and sealed against further leakage by the upper packer cup 24.
  • the lower packer cup 28 provides the primary fluidic seal against the interior surface of the expandable tubular member 66
  • the upper packer cup 24 provides a secondary, back-up, fluidic seal against the interior surface of the expandable tubular member.
  • the lower packer cup 28 and/or the upper packer cup 24 provide a fluid tight seal against the interior surface of the expandable tubular member 66, the upper and lower expansion cone segments, 44 and 46, are pulled upwardly through the expandable tubular member by the axial forces created by the packer cups.
  • the interface between the arcuate spherical external surfaces, 44bbb and 46bbb, of the upper and lower expansion cone segments, 44 and 46, and the interior surface of the expandable tubular member 66 is not fluid tight.
  • the fluidic material 108 may provide lubrication to the entire extent of the interface between the cylindrical external surfaces, 44bba and 46cb, and the arcuate spherical external surfaces,
  • the upper and lower expansion cone segments, 44 and 46 may then be adjusted to a collapsed position by placing a ball 110 within the ball valve seat 52c of the throat passage 52b of the retaining sleeve 52.
  • the shear pins 56 sense the operating pressure of the injected fluidic material 108 within the throat passage 52b and thereby controling the initiation of the collapsing of the upper and lower expansion cone segments, 44 and 46.
  • the downward longitudinal displacement of the float shoe adaptor 50 relative to the lower mandrel 34 causes the lower cam assembly 40, the lower expansion cone segments 46, and the lower retaining sleeve 48, which are rigidly attached to the float shoe adaptor, to also be displaced downwardly in the longitudinal direction relative to the lower mandrel 34, the upper cam assembly 38, and the upper expansion cone segments 44.
  • the downward longitudinal displacement of the lower cam assembly 40 relative to the upper expansion cone segments 44 causes the upper expansion cone segments to slide off of the conical external surfaces 40cbb of the lower cam assembly and thereby pivot inwardly in the radial direction about the internal flange 42d of the upper retaining sleeve 42.
  • the downward longitudinal displacement of the lower expansion cone segments 46 relative to the upper cam assembly 38 causes the lower expansion cone segments 46 to slide off of the external conical surfaces 38cbb of the upper cam assembly and thereby pivot inwardly in the radial direction about the internal flange 48d of the lower retaining sleeve.
  • the apparatus 10 may then be removed from the interior of the expandable tubular member 66.
  • the apparatus 10 may be removed from the expandable tubular member 66 prior to the complete radial expansion and plastic deformation of the expandable tubular member by controllably collapsing the upper and lower expansion cone segments, 44 and 46.
  • the apparatus 10 provides the following benefits: (1) the apparatus is removable when expansion problems are encountered; (2) lower expansion forces are required because the portion of the expandable tubular member 66 between the packer cups, 24 and 28, and the expansion cone segments is exposed to the expansion fluid pressure; and (3) the expansion cone segments can be run down through the expandable tubular member, prior to radial expansion, and then the expansion cone segments can be expanded.
  • resilient members such as, for example, spring elements are coupled to the upper and lower expansion cone segments, 44 and 46, for resiliently biasing the expansion cone segments towards the expanded or collapsed position.
  • the placement of the upper and lower expansion cone segments, 44 and 46, in an expanded or collapsed position is reversible.
  • a small gap is provided between the upper and lower expansion cone segments, 44 and 46, when positioned in the expanded condition that varies from about .005 to .030 inches.
  • An apparatus for radially expanding and plastically deforming an expandable tubular member has been described that includes an upper tubular support member defining a first passage, one or more cup seals coupled to the exterior surface of the upper tubular support member for sealing an interface between the upper tubular support member and the expandable tubular member, an upper cam assembly coupled to the upper tubular support member comprising: a tubular base coupled to the upper tubular support member, and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface, a plurality of upper expansion cone segments interleaved with the cam arms of the upper cam assembly and pivotally coupled to the tubular support member, a lower tubular support member defining a second passage fluidicly coupled to the first passage releasably coupled to the upper tubular
  • the upper tubular support member includes: a safety collar, a torque plate coupled to the safety collar including a plurality of circumferentially spaced apart meshing teeth at an end, an upper mandrel including a plurality of circumferentially spaced apart meshing teeth at one end for engaging the meshing teeth of the torque plate and an external flange at another end, and a lower mandrel coupled to the external flange of the upper mandrel including an external flange including a plurality of circumferentially spaced apart meshing teeth.
  • the tubular base of the upper cam assembly includes a plurality of circumferentially spaced apart meshing teeth for engaging the meshing teeth of the external flange of the lower mandrel.
  • the apparatus further includes a stop nut coupled to an end of the lower mandrel for limiting the movement of the lower tubular member relative to the lower mandrel.
  • the apparatus further includes locking dogs coupled to the lower mandrel.
  • the lower tubular support member includes: a float shoe adapter including a plurality of circumferentially spaced apart meshing teeth at one end, an internal flange, and a torsional coupling at another end, a lower retaining sleeve coupled to an end of the float shoe adapter including an internal flange for pivotally engaging the lower expansion cone segments, and a retaining sleeve received within the float shoe adapter releasably coupled to the upper tubular support member.
  • an end of the retaining sleeve abuts an end of the tubular base of the lower cam assembly.
  • the tubular base of the lower cam assembly includes a plurality of circumferentially spaced apart meshing teeth for engaging the meshing teeth of the float shoe adaptor.
  • the apparatus further includes a float shoe releasably coupled to the torsional coupling of the float shoe adaptor, and an expandable tubular member coupled to the float shoe and supported by and movably coupled to the upper and lower expansion cone segments.
  • the apparatus further includes: one or more shear pins coupled between the upper tubular support member and the lower tubular support member.
  • the apparatus further includes: a stop member coupled to the upper tubular support member for limiting movement of the upper tubular support member relative to the lower tubular support member.
  • the apparatus further includes: a float shoe releasably coupled to the lower tubular support member that defines a valveable passage, and an expandable tubular member coupled to the float shoe and supported by and movably coupled to the upper and lower expansion cone segments.
  • each upper expansion cone segment includes: an inner portion defining an arcuate cylindrical upper surface including a hinge groove for pivotally coupling the upper expansion cone segment to the upper tubular support member and arcuate cylindrical lower surfaces, an intermediate portion defining arcuate cylindrical and spherical upper surfaces and an arcuate conical lower surface, and an outer portion defining arcuate cylindrical upper and lower surfaces
  • each lower expansion cone segment includes: an inner portion defining an arcuate cylindrical upper surface including a hinge groove for pivotally coupling the lower expansion cone segment to the lower tubular support member and arcuate cylindrical lower surfaces, an intermediate portion defining arcuate cylindrical and spherical upper surfaces and an arcuate conical lower surface, and an outer portion defining arcuate cylindrical upper and lower surfaces.
  • each upper expansion cone segment is tapered in the longitudinal direction from the intermediate portion to the outer portion; and wherein each lower expansion cone segment is tapered in the longitudinal direction from the intermediate portion to the outer portion.
  • An apparatus for radially expanding and plastically deforming an expandable tubular member includes a safety collar, a torque plate coupled to the safety collar including a plurality of circumferentially spaced apart meshing teeth at an end, an upper mandrel including a plurality of circumferentially spaced apart meshing teeth at one end for engaging the meshing teeth of the torque plate and an external flange at another end, a lower mandrel coupled to the external flange of the upper mandrel including an external flange including a plurality of circumferentially spaced apart meshing teeth, a stop nut coupled to an end of the lower mandrel, an upper retaining sleeve coupled to the lower mandrel including an internal flange, one or more cup seals coupled to the upper mandrel for sealing an interface between the upper mandrel and the expandable tubular member, an upper cam assembly coupled to the lower mandrel including: a tubular base including a plurality of circumferentially space
  • a collapsible expansion cone assembly has also been described that includes an upper tubular support member including an internal flange, an upper cam assembly coupled to the upper tubular support member including: a tubular base coupled to the upper support member, and a plurality of cam arms extending from the tubular base in a.
  • each cam arm defining an inclined surface
  • a plurality of upper expansion cone segments interleaved with the cam arms of the upper cam assembly and pivotally coupled to the internal flange of the upper tubular support member
  • a lower tubular support member including an internal flange, one or more frangible couplings for releasably coupling the upper and lower tubular support members
  • a lower cam assembly coupled to the lower tubular support member including: a tubular base coupled to the lower tubular support member, and a plurality of cam arms extending from the tubular base in an upward longitudinal direction, each cam arm defining an inclined surface that mates with the inclined surface of a corresponding one of the upper expansion cone segments, wherein the cams arms of the upper cam assembly are interleaved with and overlap the cam arms of the lower cam assembly, and a plurality of lower expansion cone segments interleaved with cam arms of the lower cam assembly, each lower expansion cone segment pivotally coupled to the internal flange of the lower tubular support member and mating with the inclined surface of
  • each upper expansion cone segment includes: an inner portion defining an arcuate cylindrical upper surface including a hinge groove for pivotally coupling the upper expansion cone segment to the upper tubular support member and arcuate cylindrical lower surfaces, an intermediate portion defining arcuate cylindrical and spherical upper surfaces and an arcuate conical lower surface, and an outer portion defining arcuate cylindrical upper and lower surfaces
  • each lower expansion cone segment includes: an inner portion defining an arcuate cylindrical upper surface including a hinge groove for pivotally coupling the lower expansion cone segment to the lower tubular support member and arcuate cylindrical lower surfaces, an intermediate portion defining arcuate cylindrical and spherical upper surfaces and an arcuate conical lower surface, and an outer portion defining arcuate cylindrical upper and lower surfaces.
  • each upper expansion cone segment is tapered in the longitudinal direction from the intermediate portion to the outer portion
  • each lower expansion cone segment is tapered in the longitudinal direction from the intermediate portion to the outer portion.
  • a collapsible expansion cone assembly includes an upper tubular support member including an internal flange, an upper cam assembly coupled to the upper tubular support member including: a tubular base coupled to the upper support member, and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface, a plurality of upper expansion cone segments interleaved with the cam arms of the upper cam assembly and pivotally coupled to the internal flange of the upper tubular support member, a lower tubular support member including an internal flange, one or more frangible couplings for releasably coupling the upper and lower tubular support members, a lower cam assembly coupled to the lower tubular support member including: a tubular base coupled to the lower tubular support member, and a plurality of cam arms extending from the tubular base in an upward longitudinal direction, each cam arm defining an inclined surface that mates with the inclined surface of a corresponding one of the upper expansion cone segments, wherein the cams arms
  • An apparatus for radially expanding and plastically deforming an expandable tubular member includes a tubular support member, a collapsible expansion cone coupled to the tubular support member, an expandable tubular member coupled to the collapsible expansion cone, means for displacing the collapsible expansion cone relative to the expandable tubular member, and means for collapsing the expansion cone.
  • the tubular support member includes an upper tubular support member including an internal flange and a lower tubular support member including an internal flange
  • the expansion cone includes: an upper cam assembly coupled to the upper tubular support member including: a tubular base coupled to the upper support member, and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface, a plurality of upper expansion cone segments interleaved with the cam arms of the upper cam assembly and pivotally coupled to the internal flange of the upper tubular support member, a lower cam assembly coupled to the lower tubular support member including: a tubular base coupled to the lower tubular support member, and a plurality of cam arms extending from the tubular base in an upward longitudinal direction, each cam arm defining an inclined surface that mates with the inclined surface of a corresponding one of the upper expansion cone segments, wherein the cams arms of the upper cam assembly are interleaved with and overlap the cam arms of the lower cam assembly, and a plurality of cam arms extending
  • the apparatus further includes: means for pivoting the upper expansion cone segments, and means for pivoting the lower expansion cone segments. In an exemplary embodiment, the apparatus further includes: means for pulling the collapsible expansion cone through the expandable tubular member.
  • a collapsible expansion cone has also been described that includes an upper cam assembly including: a tubular base, and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface, a plurality of upper expansion cone segments interleaved with the cam arms of the upper cam assembly, a lower cam assembly including: a tubular base, and a plurality of cam arms extending from the tubular base in an upward longitudinal direction, each cam arm defining an inclined surface that mates with the inclined surface of a corresponding one of the upper expansion cone segments, wherein the cams arms of the upper cam assembly are interleaved with and overlap the cam arms of the lower cam assembly, a plurality of lower expansion cone segments interleaved with cam arms
  • each upper expansion cone segment includes: an inner portion defining an arcuate upper surface and arcuate cylindrical lower surfaces, an intermediate portion defining arcuate cylindrical and spherical upper surfaces and an arcuate conical lower surface, and an outer portion defining arcuate cylindrical upper and lower surfaces
  • each lower expansion cone segment includes: an inner portion defining an arcuate cylindrical upper surface and arcuate cylindrical lower surfaces, an intermediate portion defining arcuate cylindrical and spherical upper surfaces and an arcuate conical lower surface, and an outer portion defining arcuate cylindrical upper and lower surfaces.
  • each upper expansion cone segment is tapered in the longitudinal direction from the intermediate portion to the outer portion
  • each lower expansion cone segment is tapered in the longitudinal direction from the intermediate portion to the outer portion.
  • a method of radially expanding and plastically deforming an expandable tubular member includes supporting the expandable tubular member using a tubular support member and a collapsible expansion cone, injecting a fluidic material into the tubular support member, sensing the operating pressure of the injected fluidic material within a first interior portion of the tubular support member, displacing the collapsible expansion cone relative to the expandable tubular member when the sensed operating pressure of the injected fluidic material exceeds a predetermined level within the first interior portion of the tubular support member, sensing the operating pressure of the injected fluidic material within a second interior portion of the tubular support member, and collapsing the collapsible expansion cone when the sensed operating pressure of the injected fluidic material exceeds a predetermined level within the second interior portion of the tubular support member.
  • the method further includes: pulling the collapsible expansion cone through the expandable tubular member when the sensed operating pressure of the injected fluidic material exceeds a predetermined level within the first interior portion of the tubular support member.
  • pulling the collapsible expansion cone through the expandable tubular member includes: coupling one or more cup seals to the tubular support member above the collapsible expansion cone, pressuring the interior of the expandable tubular member below the cup seals, and pulling the collapsible expansion cone through the expandable tubular member using the cup seals.
  • the tubular support member includes an upper tubular support member and a lower tubular support member, and wherein collapsing the collapsible expansion cone includes displacing the upper tubular member relative to the lower tubular support member.
  • the collapsible expansion cone includes: an upper cam assembly including: a tubular base, and a plurality of cam arms extending from the tubular base in a downward longitudinal direction, each cam arm defining an inclined surface, a plurality of upper expansion cone segments interleaved with the cam arms of the upper cam assembly and pivotally coupled to the upper tubular support member, a lower cam assembly including: a tubular base, and a plurality of cam arms extending from the tubular base in an upward longitudinal direction, each cam arm defining an inclined surface that mates with the inclined surface of a corresponding one of the upper expansion cone segments, wherein the cams arms of the upper cam assembly are interleaved with and overlap the cam arms of the lower cam assembly, and a plurality of lower expansion

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  • Geology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mining & Mineral Resources (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • Physics & Mathematics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Prostheses (AREA)
  • Orthopedics, Nursing, And Contraception (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)

Abstract

L'invention concerne un dispositif servant à l'expansion radiale et à la déformation plastique d'un élément tubulaire extensible qui comprend un cône extensible repliable.
PCT/US2003/004837 2001-09-07 2003-02-19 Cone extensible repliable WO2003078785A2 (fr)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US10/507,567 US20050103502A1 (en) 2002-03-13 2003-02-19 Collapsible expansion cone
GB0422419A GB2403756A (en) 2002-03-13 2003-02-19 Collapsible expansion cone
AU2003215290A AU2003215290A1 (en) 2002-03-13 2003-02-19 Collapsible expansion cone
CA002478868A CA2478868A1 (fr) 2002-03-13 2003-02-19 Cone extensible repliable
US11/552,703 US7546881B2 (en) 2001-09-07 2006-10-25 Apparatus for radially expanding and plastically deforming a tubular member
US11/838,782 US20080142213A1 (en) 2002-11-12 2007-08-14 Radial expansion of a wellbore casing against a formation

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US36382902P 2002-03-13 2002-03-13
US60/363,829 2002-03-13

Related Parent Applications (7)

Application Number Title Priority Date Filing Date
US10495347 Continuation-In-Part 2002-11-12
PCT/US2002/036267 Continuation-In-Part WO2003042487A2 (fr) 2001-09-07 2002-11-12 Cuvelage a diametre unique
US10/495,344 Continuation-In-Part US7383889B2 (en) 2001-09-07 2002-11-12 Mono diameter wellbore casing
US10/495,347 Continuation-In-Part US7559365B2 (en) 2001-09-07 2002-11-12 Collapsible expansion cone
US10495344 Continuation-In-Part 2002-11-12
PCT/US2002/036157 Continuation-In-Part WO2003042486A2 (fr) 2001-09-07 2002-11-12 Cone de dilatation retractable
PCT/US2003/029859 Continuation-In-Part WO2004027205A2 (fr) 2002-09-20 2003-09-22 Tubage de puits de forage a diametre unique

Related Child Applications (6)

Application Number Title Priority Date Filing Date
PCT/US2002/036267 Continuation-In-Part WO2003042487A2 (fr) 2001-09-07 2002-11-12 Cuvelage a diametre unique
US10507567 A-371-Of-International 2003-02-19
US10/507,567 A-371-Of-International US20050103502A1 (en) 2001-09-07 2003-02-19 Collapsible expansion cone
US10513614 Continuation-In-Part 2003-05-06
US10/513,614 Continuation-In-Part US20050217866A1 (en) 2001-09-07 2003-05-06 Mono diameter wellbore casing
PCT/US2003/014153 Continuation-In-Part WO2003093623A2 (fr) 2001-09-07 2003-05-06 Tubage de puits de forage a mono-diametre

Publications (3)

Publication Number Publication Date
WO2003078785A2 true WO2003078785A2 (fr) 2003-09-25
WO2003078785A3 WO2003078785A3 (fr) 2004-07-15
WO2003078785B1 WO2003078785B1 (fr) 2004-09-23

Family

ID=28041818

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2003/004837 WO2003078785A2 (fr) 2001-09-07 2003-02-19 Cone extensible repliable

Country Status (5)

Country Link
US (1) US20050103502A1 (fr)
AU (1) AU2003215290A1 (fr)
CA (1) CA2478868A1 (fr)
GB (1) GB2403756A (fr)
WO (1) WO2003078785A2 (fr)

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US7665532B2 (en) 1998-12-07 2010-02-23 Shell Oil Company Pipeline
US7384981B2 (en) 2001-11-14 2008-06-10 N.V. Nutricia Preparation for improving the action of receptors
US7740076B2 (en) 2002-04-12 2010-06-22 Enventure Global Technology, L.L.C. Protective sleeve for threaded connections for expandable liner hanger
US7918284B2 (en) 2002-04-15 2011-04-05 Enventure Global Technology, L.L.C. Protective sleeve for threaded connections for expandable liner hanger
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US7886831B2 (en) 2003-01-22 2011-02-15 Enventure Global Technology, L.L.C. Apparatus for radially expanding and plastically deforming a tubular member
US7793721B2 (en) 2003-03-11 2010-09-14 Eventure Global Technology, Llc Apparatus for radially expanding and plastically deforming a tubular member
US7775290B2 (en) 2003-04-17 2010-08-17 Enventure Global Technology, Llc Apparatus for radially expanding and plastically deforming a tubular member
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

Also Published As

Publication number Publication date
AU2003215290A8 (en) 2003-09-29
WO2003078785A3 (fr) 2004-07-15
WO2003078785B1 (fr) 2004-09-23
AU2003215290A1 (en) 2003-09-29
CA2478868A1 (fr) 2003-09-25
GB0422419D0 (en) 2004-11-10
GB2403756A (en) 2005-01-12
US20050103502A1 (en) 2005-05-19

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