WO2010059535A2

WO2010059535A2 - Enhanced jack for drawing a mandrel

Info

Publication number: WO2010059535A2
Application number: PCT/US2009/064500
Authority: WO
Inventors: Mark Wilson Anderson; Donald Bruce Campo; Robert Lance Cook; Darrell Scott Costa; John Andrew Henley; Sam Sun Lloyd
Original assignee: Shell Oil Company; Shell Internationale Research Maatschappij B.V.
Priority date: 2008-11-18
Filing date: 2009-11-16
Publication date: 2010-05-27
Also published as: WO2010059535A3

Abstract

A system for expanding an expandable pipe in a wellbore comprises an expansion device, a support member supporting the expansion device, and a hydraulic jack system having a fixed first end and a second end engaging the expansion device, such that expansion of the jack moves the expansion device relative to the expandable pipe. A method for using the system comprises lowering the expandable pipe into the wellbore on the expansion device, expanding the claim so that it engages the inside of the expandable pipe, and expanding the jack so that the expansion device is pulled through a portion of the expandable pipe. The expandable pipe may be expanded such that the expanded portion engages the formation and the engagement of the expanded portion with the formation may be used to anchor the expandable pipe while an additional portion of the expandable pipe is expanded.

Description

ENHANCED JACK FOR DRAWING A MANDREL

RELATED APPLICATIONS

[0001] This application claims priority to application Serial No 61/115779 and is related to application Serial No 61/115787, filed concurrently herewith, entitled "Modifying Expansion Forces by Adding Compression."

TECHNICAL FIELD OF THE PRESENT DISCLOSURE

[0002] The present invention relates to wellbores, and more particularly to moving objects through a wellbore.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0003] The present disclosure is not subject to federally sponsored research or development. BACKGROUND OF THE INVENTION

[0004] Conventionally, when a wellbore is created, a number of casings are installed in the borehole to prevent collapse of the borehole wall and to prevent undesired outflow of drilling fluid into the formation or inflow of fluid from the formation into the borehole. The borehole is drilled in intervals whereby a casing which is to be installed in a lower borehole interval is lowered through a previously installed casing of an upper borehole interval. As a consequence of this procedure the casing of the lower interval typically has a smaller diameter than the casing of the upper interval. Thus, the casings are in a nested arrangement with casing diameters decreasing in downward direction. Cements is typically provided between the outer surfaces of the casings and the borehole wall to seal the casings from the borehole wall.

[0005] As a consequence of this nested arrangement, a relatively large borehole diameter is required at the upper part of the wellbore. Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings. In addition, the small diameter casing that is required at the bottom of the hole may not allow desired flow rates of drilling fluid. For these reasons, it may be desirable to expand the diameter of one or more strings of casing so as to reduce the diameter reduction(s) that would otherwise be necessary. Expandable casings are known in the art.

[0006] Expansion of a length of pipe is typically accomplished by pushing or pulling an expansion device, such as a cone or mandrel, through the pipe. Moving the expansion device through the pipe is difficult, due to the magnitude of the forces involved. Forces in excess of half a million pounds are sometimes used. The required expansion force is even greater if two ends of adjacent lengths of pipe overlap and must be expanded simultaneously. Therefore, it is desirable to provide a practical device for applying the require force to the expansion device.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The following figures form part of the present specification and are included to further demonstrate certain aspects of the present claimed subject matter, and should not be used to limit or define the present claimed subject matter. Consequently, a more complete understanding of the present embodiments and further features and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which the leftmost significant digit(s) in the reference numerals denote(s) the first figure in which the respective reference numerals appear, wherein:

[0008] FIG. 1 is a schematic diagram depicting a system for drawing a expanding a liner in accordance with one embodiment of the invention;

[0010] FIG. 2 is a schematic diagram showing the system of FIG. 1 in operation;

[0011] FIG. 3 is a schematic diagram illustrating operation of an alternative embodiment of the of the invention; and

[0012] FIG. 4 is a schematic diagram depicting a system for pressing a expansion device down through an expandable liner, in accordance with another alternative embodiment of the present invention.

[0013] The figures form part of the present specification and are included to demonstrate certain aspects of the present claimed subject matter, and should not be used to limit or define the claims, as the claimed subject matter may admit to other equally effective embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Referring initially to FIG. 1, one embodiment of the present invention includes a jack system 114 for drawing an expansion device 102 up through an expandable liner 140 located within a wellbore 126 that has been drilled into a formation 128. An upper section of casing or liner 124 is already in place in the well. Typically, upper liner 124 will have a diameter that is larger than the unexpanded diameter of liner 140. Before the expansion process begins, liner 140 is typically lowered into the borehole on expansion device 102, which is in turn supported on drill string 154.

[0015] The present jack system is preferably used to facilitate the expansion of liner 140 to an inside diameter that is the same as, or nearly the same as, the inside diameter of upper liner 124, although it may alternatively be used to expand liner 140 to an inside diameter that is greater than the inside diameter of upper liner 124. As discussed in more detail below, jack system 114 preferably includes a hydraulic jack 116, a clamp 115, and a hydraulic line 117. A pump 190 is connected to the other end of hydraulic line 117. In preferred embodiments, before the expansion process begins, jack system 114, expansion device 102, and expandable liner 140 may be lowered into the well by drill string 154. As these components are lowered into the well, liner 140 may rest on expansion device 102, which in turn is supported by jack 116, which in turn is supported by drill string 154.

[0016] In some wells, drill string 154 is coupled to expansion device 102 and draws expansion device 102 upward through liner 140 when upward force is applied to drill string 154. In some instances, however, it may be undesirable or impractical to apply the level of upward force on drill string 154 that would be required to deform (expand) liner 140. For example, wellbore 126 may dogleg, bend slightly, or otherwise prevent or restrict the ability of drill string 154 to apply an upward force to expansion device 102. In addition, as expansion device 102 nears the upper end 110 of expandable liner 140, the overlapping lower end 123 of upper liner 124 will resist full expansion of the upper end of expandable liner 140. In other instances, features of formation 128 may also obstruct expansion of expandable liner 140. Finally, expandable liner 140 may shift axially as expansion device 102 begins to move through it, unless it is anchored to the formation or to upper liner 124.

[0017] In all of these instances, jack system 114 can advantageously be used to apply expansion forces to expandable liner 140.

[0018] Referring now to FIG. 2, operation of one embodiment begins with expansion of clamp 115 until it engages the inside wall of expandable liner 140. Once jack system 114 has engaged liner 140, jack system 114 can be activated by pumping a fluid, which may be liquid or gas but is preferably liquid, through hydraulic line 117 and into jack 116. Fluid pressure within jack 116 will tend to cause jack 116 to expand axially, i.e. in the direction indicated by arrows 118. When sufficient pressure is applied to overcome the resistance of liner 140 to expansion, expansion device 102 will begin to move in an upward direction relative to liner 140. Because jack system 114 engages liner 140, the force applied to expansion device 102 by jack 116 will cause expansion device 102 to move relative to liner regardless of whether liner 140 is supported on expansion device 102 or resting on the borehole bottom. An added advantage is that all or part of the expansion force can be applied by jack system 114, thereby eliminating or reducing the amount of force that has to be applied by the drill string.

[0019] Fluid pressure may be supplied to jack 116 through line 117 by means of pump 190. Pump 190 may be located at the surface and may comprise any suitable pumping device.

[0020] In the embodiment illustrated in FIG. 2, expansion device 102 is shown expanded to a diameter that is larger than the inside diameter of upper liner 124. In some embodiments, expansion device 102 may be configured to expand the inside diameter of liner 140 to the same or substantially the same diameter as the inside diameter of upper liner 124. It will further be understood that expansion device 102 may comprise a cone, mandrel, or other suitable device, and may be expandable or collapsible, or have a fixed configuration. In FIG. 2, expansion device 102 is radially expanded as indicated by arrows 122 using any suitable means such as known to those skilled in the art.

[0021] In instances where expansion device 102 is capable of expanding liner 140 against the borehole wall, it is contemplated that the engagement of liner 140 with the borehole wall may be used to fix or mount liner 140 so that, once a lower portion of liner 140 has been expanded by the action of jack system 114, clamp 115 may be disengaged from the inside of liner 140. With the lower end of liner 140 fixed by engagement with the formation, there is no tendency for liner 140 to move upward and the expansion device 102 can be pulled the rest of the way through liner 140 by drill string 154, if desired.

[0022] It will be understood that clamp 115 could alternatively be affixed to the inside of upper liner 124, provided there is a mechanism for preventing liner 140 from moving upward as expansion device 102 is pulled up through it. Liner 140 can be prevented from moving upward by the application of a downward force, such as by a weight applied to its upper end, or by the provision of retaining means to resist its upward movement.

[0023] In some embodiments, jack system 114 may be used to expand only a lower portion of liner 140. In that case, clamp 115 may be disengaged and an alternative mechanism for applying upward force to expansion device 102, such as the drill string 154, can be used to complete the expansion once the lower end of liner 140 has been expanded. In other embodiments, jack 116 may be contracted following expansion of a portion of liner 140, clamp 115 may be released, and jack system 114 may be repositioned higher in liner 140, so that jack system 114 can be used to incrementally expand a larger portion of the length of liner 140. At the bottom of liner 140, jack system 114 may be adapted to engage the lower edge rather than the inside wall of liner 140, so as to complete the expansion of liner 140, or it may be necessary to provide alternative expansion means.

[0024] FIG. 3 depicts an alternative system for driving expansion device 102 up through liner 140. In the system of FIG. 3, jack 116 is situated below, rather than above, expansion device 102. The lower end of jack 116 is suspended from clamp 115 and hydraulic fluid is transmitted from line 117 to jack 116, as shown in phantom in FIG. 3. Upon expansion, jack 116 applies an upward force on expandable liner 140. Like the system of FIG. 1, the jack system of FIG. 3 eliminates or reduces the amount of force that must be applied by the drill string in order to accomplish an expansion.

[0025] FIG. 4 depicts still another alternative system, in which a expansion device 102 is driven downwardly through liner 140, in contrast to the systems depicted in FIGs. 1 and 2. In the system of FIG. 4, jack system 114 is situated in expandable liner 140 with expansion device 102 above it. Once clamp 115 has engaged the inside wall of liner 140, expansion of jack 116 applies a downward force on expansion device 102. Again, this allows an increased expansion force to be applied without requiring greater pulling force from drill string 154.

[0026] In some embodiments, jack system 114 may be used to expand just an upper portion of liner 140. In that case, an alternative mechanism for applying downward force to expansion device 102 can be used to complete the expansion once the upper end of liner 140 has engaged the lower end of upper liner 124 as shown, or the borehole wall in other instances. In other embodiments, jack 116 may be contracted following expansion of a portion of liner 140, clamp 115 may be released, and jack system 114 may be repositioned lower in liner 140, so that jack system 114 can be used to incrementally expand a larger portion of the length of liner 140. [0027] It will be appreciated that multiple expandable jacks may be used together in accordance with the present invention, with each jack contributing a part of the force required to pull the mandrel upward through the liner.

[0028] Thus, although the invention has been described with reference to several exemplary embodiments, it is understood that the words that have been used are words of description and illustration, rather than words of limitation. Changes may be made within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the invention in its aspects. Although the invention has been described with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed; rather, the invention extends to all functionally equivalent structures, methods, and uses such as are within the scope of the appended claims.

Claims

C L A I M S

1. A method for expanding an expandable pipe, comprising the steps of: a) providing an expansion system comprising: i) an expansion device disposed in the expandable pipe; ii) a support member extending to the surface and supporting the expansion device; and iii) a hydraulic jack system having a first end engaging one of the expandable pipe, the wellbore, and another pipe in the wellbore and a second end engaging the expansion device, such that expansion of the jack moves the expansion device relative to the expandable pipe; b) lowering the expandable pipe into the wellbore on the expansion device; c) expanding the expansion device so that it engages the inside of the expandable pipe; and d) expanding the jack so that the expansion device is pulled through a portion of the expandable pipe.

2. The method according to claim 1 wherein the method is carried out in a borehole having borehole wall, wherein the expandable pipe is expanded such that the portion expanded in step d) engages the borehole wall.

3. The method according to claim 2 further including the steps of releasing the first end of the hydraulic jack system from engagement and using the engagement of the expanded portion with the formation to anchor the expandable pipe while an additional portion of the expandable pipe is expanded.

5. The method according to claim 1 wherein the first end of the hydraulic jack system engages the expandable pipe.

6. The method according to claim 1 wherein the expansion device supports the expandable pipe prior to expansion.

7. The system according to claim 1 wherein the hydraulic jack system comprises: a radially expandable clamp; an expansion cone; and a hydraulic jack.

8. The system according to claim 7 wherein the expansion cone is reversibly radially expandable.

9. A method for expanding an expandable pipe in a borehole having a borehole wall, comprising the steps of: a) providing an expansion system comprising: i) an expansion device disposed in the expandable pipe; ii) a support member extending to the surface and supporting the expansion device; and iii) a hydraulic jack system having a first end engaging the expandable pipe and a second end engaging the expansion device, such that expansion of the jack moves the expansion device relative to the expandable pipe; b) lowering the expandable pipe into the wellbore on the expansion device; c) expanding the expansion device so that it engages the inside of the expandable pipe; d) expanding the jack so that the expansion device is pulled through a portion of the expandable pipe, causing said portion to engage the borehole wall; and e) releasing the first end of the hydraulic jack system from engagement and using the engagement of the expanded portion with the formation to anchor the expandable pipe while an additional portion of the expandable pipe is expanded.

10. The method according to claim 9 wherein the expansion device supports the expandable pipe prior to expansion.