US20050217866A1 - Mono diameter wellbore casing - Google Patents

Abstract

An apparatus and system is disclosed for radially expanding and plastically deforming an expandable tubular member.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
• The present application is the National Stage application corresponding to PCT application serial number PCT/US2003/014153, attorney docket number 25791.104.02, filed on May 6, 2003, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/380,147, attorney docket no 25791.104, filed on May 6, 2002, the disclosures of which are incorporated herein by reference.
• The present application is a continuation-in-part of U.S. utility patent application Ser. No. 10/507,567, attorney docket number 25791.95.03, filed on Sep. 13, 2004, which was the National Stage application for PCT application serial number PCT/US2003/004837, attorney docket number 25791.95.02, filed on Feb. 19, 2003, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/363829, attorney docket number 25791.95, filed on Mar. 13, 2002, which was a continuation-in-part of both of: (1) U.S. utility patent application Ser. No. 10/495,347, attorney docket number 25791.87.05, filed on May 12, 2004, which was filed as the National Stage application for PCT application serial number PCT/US2002/036157, attorney docket number 25791.87.02, filed on Nov. 12, 2002, which claimed the benefit of the filing date of U.S. provisional application Ser. No. 60/338996, attorney docket number 25791.87, filed on Nov. 12, 2001; and (2) U.S. utility patent application Ser. No. 10/495,344, attorney docket number 25791.88.05, filed on May 12, 2004, which was filed as the National Stage application for PCT application serial number PCT/US2002/036267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, which claimed the benefit of the filing date of U.S. provisional application Ser. No. 60/339013, attorney docket number 25791.88, filed on Nov. 12, 2001, the disclosures of which are incorporated herein by reference.
• The present application is related to the following: (1) U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, attorney docket no. 25791.25.02, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, attorney docket no. 25791.45, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000, (20) U.S. provisional patent application Ser. No. 60/233,638, attorney docket no. 25791.47, filed on Sep. 18, 2000, (21) U.S. provisional patent application Ser. No. 60/237,334, attorney docket no. 25791.48, filed on Oct. 2, 2000, (22) U.S. provisional patent application Ser. No. 60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001, (23) U.S. provisional patent application Ser. No. 60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001, (24) U.S. provisional patent application Ser. No. 60/259,486, attorney docket no. 25791.52, filed on Jan. 3, 2001, (25) U.S. provisional patent application Ser. No. 60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001, (26) U.S. provisional patent application Ser. No. 60/313,453, attorney docket no. 25791.59, filed on Aug. 20, 2001, (27) U.S. provisional patent application Ser. No. 60/317,985, attorney docket no. 25791.67, filed on Sep. 6, 2001, (28) U.S. provisional patent application Ser. No. 60/3318,386, attorney docket no. 25791.67.02, filed on Sep. 10, 2001, (29) U.S. utility patent application Ser. No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, (30) U.S. utility patent application Ser. No. 10/016,467, attorney docket no. 25791.70, filed on Dec. 10, 2001; (31) U.S. provisional patent application Ser. No. 60/343,674, attorney docket no. 25791.68, filed on Dec. 27, 2001; (32) U.S. provisional patent application Ser. No. 60/346,309, attorney docket no 25791.92, filed on Jan. 7, 2002; (33) U.S. provisional patent application Ser. No. 60/372,048, attorney docket no. 25791.93, filed on Apr. 12, 2002; and (34) U.S. provisional patent application Ser. No. 60/372,632, attorney docket no. 25791.101, filed on Apr. 15, 2002, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
• This invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration and production.
• 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 is of smaller diameter than the casing of the upper interval. Thus, the casings are in a nested arrangement with casing diameters decreasing in downward direction. Cement annuli are provided between the outer surfaces of the casings and the borehole wall to seal the casings from the borehole wall. 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. Moreover, increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.
• The present invention is directed to overcoming one or more of the limitations of the existing processes for forming and repairing wellbore casings.
SUMMARY OF THE INVENTION
• According to one aspect of the present invention, an apparatus and method for forming a mono diameter wellbore casing is provided.
BRIEF DESCRIPTION OF THE DRAWINGS
• FIGS. 1a-1fare conceptual illustrations of one aspect of the present invention.
• FIGS. 2a-2fare fragmentary cross-sectional illustrations of the placement of an exemplary embodiment of an apparatus for forming a mono diameter wellbore casing within a wellbore that traverses a subterranean formation.
• FIGS. 3a-3fare fragmentary cross-sectional illustrations of the apparatus ofFIGS. 2a-2fafter placement on the bottom of the wellbore.
• FIGS. 4a-4fare fragmentary cross-sectional illustrations of the apparatus ofFIGS. 3a-3fafter placing a ball or dart within the ball or dart seat to initiate the radial expansion and plastic deformation of the expandable tubular member.
• FIGS. 5a-5fare fragmentary cross-sectional illustrations of the apparatus ofFIGS. 4a-4fafter the initiation of the radial expansion and plastic deformation of the aluminum sleeve within the shoe.
• FIG. 6a-6fare fragmentary cross sectional illustrations of the apparatus ofFIGS. 5a-5fafter the completion of the radial expansion and plastic deformation of the aluminum sleeve within the shoe.
• FIGS. 7a-7fare fragmentary cross-sectional illustrations of the apparatus ofFIGS. 6a-6fafter displacing the sliding sleeve valve within the shoe to permit circulation around the ball or dart.
• FIGS. 8a-8fare fragmentary cross-sectional illustrations of an alternative embodiment of a bottom anchoring apparatus.
• FIGS. 9a-9gare fragmentary cross sectional illustrations of certain aspects of the operation of the apparatus ofFIGS. 8a-8f.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
• Referring initially toFIG. 1a, an embodiment of an apparatus and method for radially expanding a tubular member will now be described. As illustrated inFIG. 1a, awellbore100 is positioned in asubterranean formation105. In an exemplary embodiment, thewellbore100 may include acasing110. Thewellbore100 may be positioned in any orientation from vertical to horizontal. Thus, in this application the direction “up”, “upper” or “upward” refers to the direction towards the surface termination of the wellbore and the direction “down”, “lower” or “downward” refers to the direction towards the bottom or end of the wellbore.
• In order to extend thewellbore100 into thesubterranean formation105, a drill string (not shown) is used in a well known manner to drill out material from thesubterranean formation105 to form thewellbore100. The inside diameter of thewellbore100 is greater than or equal to the outside diameter of thecasing110.
• In an exemplary embodiment, atubular apparatus120 having anopening122 may then be positioned within thewellbore100 with anupper end124aof theapparatus120 initially coupled to awell string125. Theapparatus120 is adapted to allow fluidic materials to enter theupper end124aof the tool and exit through theopening122 positioned at thelower end124bof the tool, thereby creating a passage (not shown) orfluid flow path126. Theapparatus120 may include, among other components, acasing lock130, agripping device132, atension actuator134, asealing mechanism136, anexpansion cone140, acementing probe144, and acasing anchor148.
• Theapparatus120 as illustrated inFIG. 1ais in a “running” or positioning configuration. In other words, the tool is running or traveling down the wellbore. In several exemplary embodiments, in the running configuration, thelower end124bof theapparatus120 extends past thecasing110 into the wellbore. Thecasing lock130 may be used to support or couple theapparatus120 to thecasing110 which may keep thecasing110 positioned above thelower end124bof the tool when theapparatus120 is in the running configuration. Alternatively, theexpansion cone140 may be used to support thecasing110 during the running or positioning of theapparatus120.
• In one embodiment, thegripping device132 may be positioned close to theupper end124aof theapparatus120. In the illustrative embodiment, thegripping device132 is positioned above thecasing lock130. As will be explained in detail below, thegripping device132 may be used to keep thecasing110 stationary during the operation of theapparatus120. A force multiplier ortension actuator134 may be positioned below thecasing lock130. Thetension actuator134 may be used to “pull” theexpansion cone140 and thelower end124bof theapparatus120 inside thecasing110. In the illustrative embodiment, analternative sealing mechanism136 may be positioned below thetension actuator134.
• As illustrated inFIG. 1a, an apparatus for radially expanding a tubular member, such as anexpansion cone140 may then be positioned outside of thecasing110. A tubular member, such as acementing probe144, may be positioned below theexpansion cone140. Acasing anchor148, such as a packer or drillable shoe, may be positioned at thelower end124bof theapparatus120.
• Turning now toFIG. 1b, there is illustrated theapparatus120 positioned at the bottom of thewellbore100. As will be explained in detail below, when theapparatus120 contacts with the bottom of thewellbore100, anexpansion mechanism150, coupled to thecasing anchor148, expands radially outward such that thecasing110 cannot move past the expansion mechanism. In one embodiment, theexpansion cone140 may also expand upon impact with the bottom of the well. The expansion cone may expand to a diameter that is greater than the interior diameter of thecasing110.
• In an exemplary embodiment, as illustrated inFIG. 1c, an actuating event may occur to cause thegripping device132 to grip thecasing110. Such an actuating event may be placing a plug, such as a ball or dart into theapparatus120 to block theflow path126 and prevent fluids from exiting throughopening122. Injecting a fluidic material into the apparatus when theflow path126 is blocked causes an increase in pressure within the tool. The increase pressure may actuate gripping elements of thegripping device132 thereby locking the top end of theapparatus120 to the expandable tubular member. In some alternative embodiments, the continued injection of the fluidic material furthermore increases the operating pressure within the tool which causes the expansion cone to expand. The increase operating pressure may also cause thetension actuator134 to pull theexpansion cone140 into the expandable tubular member. As a result, the casing orexpandable casing110 is radially expanded as theexpansion cone140 travels up thecasing110.
• Turning now toFIG. 1d, the continued upward movement of theexpansion cone140 pulls thecasing anchor148 into the end of the radially expandedcasing110. As a result, the end of the radially expanded casing110 will impact theexpansion mechanism150, thereby preventing thecasing anchor148 from moving further in the upward direction. In some embodiments, the continued upward force on thecasing anchor148 may cause the casing anchor to radially expand within the casing to firmly couple the end of the tubular member to thecasing anchor148. In alternative embodiments, this anchoring may also hydraulically seal theanchor148 to thecasing110.
• The continued upward force on theapparatus120 may cause thecementing probe144 to separate from thecasing anchor148, as illustrated inFIG. 1e. At the top of the stroke, the casing lock130 (not shown) may be released. After separation, theapparatus120 is free to continue to advance up causing thecasing110 to expand as necessary. If a hydraulic seal is created between theanchor148 and thecasing110, the region between the anchor and thesealing mechanism136 may be pressurized. This pressurized region forces the expansion cone upwardly, thereby causing a radial expansion and plastic deformation of theexpandable casing110. In this manner, in the alternative embodiment, the fluid pressure below thesealing mechanism136 pulls theexpansion cone140 upwardly through theexpandable casing110. Thus, the use of thetension actuator134 to pull the expansion cone upwards is no longer necessary.
• At some point (e.g., at the top of the liner), it may become desirable to stop expanding and to inject a hardenable fluidic sealing material such as, for example, cement into the well annulus. To begin the cementing operation, theapparatus120 may be lowered into thewellbore100 until thecementing probe144 couples to thecasing anchor148 as illustrated inFIG. 1f. This coupling opens abypass flowpath154 to permit fluidic materials to bypass around the blockage inflow path126. As a result, thebypass flow path154 allows for cement or other fluidic materials to flow around the blockage offlow path126.
• Thus, the cement flows through the interior of theapparatus120, through thebypass flow path154, and out through a one-way valve (not shown) into the annulus between the radially expanded tubular member and the wellbore. After the cement has been injected into the annulus, the one way valve may prevent the cement from flowing backwards into theapparatus120.
• After completing the injection of the cement into the annulus, the drilling pipe may then pulled upwardly out of the wellbore. The radial expansion and plastic deformation of the expandable tubular member may then be continued by the resumed injection of fluidic material into the apparatus. After the cement has cured, theanchor148 may be drilled out and another expandable tubular member may then be radially expanded and plastically deformed within the wellbore with the upper end of the other tubular member overlapping with the lower end of the earlier expanded tubular member. In this manner, a mono diameter wellbore casing may be formed that includes a plurality of radially expanded tubular members.
• Turning now toFIGS. 2a-2f, there is illustrated an exemplary embodiment of anapparatus200, which illustrates certain aspects of theapparatus120 discussed above. At the upper end of theapparatus200, there is thegripping device132. In several exemplary embodiments, thegripping device132 may be any device capable of engaging the inside surface of the tubular member or casing110 in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: (1) PCT application no. serial no. PCT/US02/36267, attorney docket no. 25791.88, filed on Nov. 12, 2002, (2) U.S. provisional patent application Ser. No. 60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001, (3) U.S. provisional patent application Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13, 2002, and (4) U.S. provisional patent application Ser. No. 60/339,013, attorney number attorney docket no. 25791.88, filed on Nov. 12, 2001, the disclosures of which are incorporated herein by reference. In the embodiment as illustrated inFIGS. 2a-2f, thegripping device132 comprises a tubularcentral mandrel202 which defines acentral passage203. Thecentral mandrel202 has anupper end204aadapted to threadably couple to and receive within an end of thewell string125 in a conventional manner. Atubular retaining sleeve206 slidingly engages thecentral mandrel202, such that the retainingsleeve206 may move longitudinally relative to thecentral mandrel202 between an external annular upper flange205aand an external annularlower flange205bprojecting from thecentral mandrel202. A pair of concentric annular recesses in the upper flange205aform anannular guide flange209 which fits within the retainingsleeve206. The retainingsleeve206 has an internalupper flange207aand an internallower flange207b. Theupper flange207a, theguide flange209, the external surface of thecentral mandrel202 and the internal surface of the retainingsleeve206 defines an annularupper spring chamber208a. Similarly, thelower flange205b, thelower flange207b, the external surface of thecentral mandrel202 and the internal surface of the retainingsleeve206 defines an annularlower spring chamber208b. Helical springs210aand210bmay be disposed within the upper andlower retaining chambers208aand208b, respectively to longitudinally position the retainingsleeve206 relative to thecentral mandrel202.
• A plurality of tapered recesses, for example recesses212a-212dare defined in the external surface of thecentral mandrel202. Corresponding to each recess212a-212d, there is a tapered circular opening, for instance circular openings214a-214d, through the wall of the retainingsleeve206. The tapered recesses212a-212d, the interior surface of the retainingsleeve206, and the circular openings214a-214ddefine retaining chambers216a-216d, respectively. Hardened gripping elements, such as balls218a-218dor sprag clutch elements, made from stainless steel or another hardened material, may be positioned with the retaining chambers216a-216d. In the running configuration illustrated inFIGS. 2a-2e, thesprings210aand210bbias thesleeve206 such that the balls218a-218dremain in the widest portion of the tapered retaining chambers216a-216d. In this configuration, the balls do not engage the interior surface of the casing orcasing110.
• Anannular pressure chamber222 may be defined between the bottom of theinternal flange207aof the retainingsleeve206 and the top of an externalannular flange224. A sealing means, such as an O-ring or sealingcartridge211 may provide a seal between theinternal flange207aand the exterior surface of thecentral mandrel202. Additionally, a sealing means, such as an O-ring or sealingcartridge213 may provide a seal between the side of theflange224 and the exterior of thecentral mandrel202. A plurality of radial passages, forinstance passages220aand220bmay be defined with thecentral mandrel202 which provides fluid communication between thecentral passage203 and thepressure chamber222. Thus, the pressure of thepressure chamber222 remains approximately the same as the pressure within thecentral passage203. When the pressure of thecentral passage203 is large enough to overcome the biasing of the springs208anand208b, thepressure chamber222 expands by driving the upper flange207 away from theexternal flange224. Thus, the upper flange207 acts like a piston pushing the retainingsleeve206 in an upperwardly direction with respect to thecentral mandrel202.
• When the retaining sleeve moves up, the steel balls218a-218dare forced up into thinner regions of the retaining chambers216a-216d. A portion of the steels balls218a-218d, therefore, projects radially through the circular openings214a-214d. As the steel balls218a-218dproject through the circular openings214a-214d, they engage the interior surface of thecasing110. The balls218a-218dgrip the interior surface in proportion to the pressure applied to thecentral passage203. The balls may create small concave indents that imparts a benign compressive stress into thecasing110.
• Alower end204bof thecentral mandrel202 may be adapted to threadably couple to other components or tools, such as thecasing lock130 or thetension actuator134. In the illustrative embodiment, the lower end204 is coupled to thetension actuator134.
• In several exemplary embodiments, thetension actuator134 may be any device capable of pulling theexpansion cone140 into thecasing110 in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: (1) PCT application no. serial no. PCT/US02/36267, attorney docket no. 25791.88, filed on Nov. 12, 2002, (2) U.S. provisional patent application Ser. No. 60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001, (3) U.S. provisional patent application Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13, 2002, and (4) U.S. provisional patent application Ser. No. 60/339,013, attorney number attorney docket no. 25791.88, filed on Nov. 12, 2001, the disclosures of which are incorporated herein by reference.
• In the illustrative embodiment, theactuator134 comprisesactuator barrel250 having atop end252 adapted to threadably couple to thelower end204bof thegripping device132. Theactuator barrel250 defines alongitudinal passage250ahaving an internalannular flange250bat the lower end of thelongitudinal passage250. The lower end of theactuator barrel250 couples to aconnector barrel254. Theconnector barrel254 defines alongitudinal passage254ahaving an internalannular flange254bat the lower end of thelongitudinal passage254a. The lower end of theconnector barrel254 couples to aconnector barrel256. Theconnector barrel256 defines alongitudinal passage256ahaving an internalannular flange256bat the lower end of thelongitudinal passage256a.
• Apiston tube260 runs through thepassages250a,254a, and256aof theactuator barrel250 and the connector barrels254 and256, respectively. Thepiston tube260 may define alongitudinal passage261. An externalannular flange262ais defined at the top end of thepiston tube260. The outside diameter of theannular flange262ais slightly smaller than the inside diameter of thelongitudinal passage250asuch that theannular flange262acan slide longitudinally within thelongitudinal passage250a. A sealing means, such as a sealingcartridge264acreates a seal between theannular flange262aand the interior surface of thelongitudinal passage250. Similarly a sealing means, such as a sealingcartridge266acreates a seal between the exterior surface of thepiston tube260 and theflange254b. Anannular pressure chamber268amay be defined between the bottom of the external flange262 of thepiston tube260 and the top of theannular flange250b.Radial tubes270aand270bmay connect thepressure chamber268ato thelongitudinal passage261 of thepiston tube260.
• An externalannular flange262bmay be defined on the exterior of thepiston tube260. The outside diameter of theannular flange262bis slightly smaller than the inside diameter of thelongitudinal passage254asuch that theannular flange262bcan slide longitudinally within thelongitudinal passage254a. A sealing means, such as a sealingcartridge264bcreates a seal between theannular flange262band the interior surface of thelongitudinal passage254a. Similarly a sealing means, such as a sealingcartridge266bcreates a seal between the exterior surface of thepiston tube260 and theflange254b. Anannular pressure chamber268bmay be defined between the bottom of theexternal flange262bof thepiston tube260 and the top of theannular flange254b.Radial tubes270cand270dmay connect thepressure chamber268bto thelongitudinal passage261 of thepiston tube260.
• Similarly, an externalannular flange262cmay be defined on the exterior of thepiston tube260. The outside diameter of theannular flange262cis slightly smaller than the inside diameter of thelongitudinal passage256asuch that theannular flange262ccan slide longitudinally within thelongitudinal passage256a. Optionally, a sealing means, such as a sealingcartridge264ccreates a seal between theannular flange262cand the interior surface of thelongitudinal passage256a. Similarly a sealing means, such as a sealingcartridge266ccreates a seal between the exterior surface of thepiston tube260 and theflange256b. Anannular pressure chamber268cmay be defined between the bottom of theexternal flange262cof thepiston tube260 and the top of theannular flange256b.Radial tubes270eand270fmay connect thepressure chamber268bto thelongitudinal passage261 of thepiston tube260.
• Alower end272 of the piston tube may be adapted to be coupled to another component, such as thecasing lock130. Optionally, thecasing lock130 may be positioned above theactuator130. In several exemplary embodiments, thecasing lock134 may be any device capable of coupling the apparatus to the casing while the apparatus is being positioned within the wellbore in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: (1) PCT application no. serial no. PCT/US02/36267, attorney docket no. 25791.88, filed on Nov. 12, 2002, (2) U.S. provisional patent application Ser. No. 60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001, (3) U.S. provisional patent application Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13, 2002, and (4) U.S. provisional patent application Ser. No. 60/339,013, attorney number attorney docket no. 25791.88, filed on Nov. 12, 2001, the disclosures of which are incorporated herein by reference.
• FIG. 2dillustrates an alternative embodiment where a sealing means136, such as a packer cup assembly may provide a way to create a pressurized zone within thecasing110. In several exemplary embodiments, the sealing means136 may be any device capable of sealing between differential zones of pressure in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: (1) PCT application no. serial no. PCT/US02/36267, attorney docket no. 25791.88, filed on Nov. 12, 2002, (2) U.S. provisional patent application Ser. No. 60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001, (3) U.S. provisional patent application Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13, 2002, and (4) U.S. provisional patent application Ser. No. 60/339,013, attorney number attorney docket no. 25791.88, filed on Nov. 12, 2001, the disclosures of which are incorporated herein by reference.
• For instance, an upperpacker cup assembly280 may be coupled to amandrel282 proximate the upper end of themandrel282. Themandrel282 may define anlongitudinal passage283. In an exemplary embodiment, apacker cup284 may be a Guiberson™ packer cup. Optionally, a spacer sleeve (not shown) may mate with, receives, and may be coupled to themandrel282 proximate an end of the upperpacker cup assembly280. A lowerpacker cup assembly286 may be coupled to themandrel282. In an exemplary embodiment, alower packer cup286 is a Guiberson™ packer cup. Optionally, a lower spacer sleeve may be coupled to themandrel282 to longitudinally position thelower packer assembly286.
• Anexpansion cone140 may be positioned below the sealing means136. In several exemplary embodiments, theexpansion cone140 may be any device capable of expanding the casing ortubing member110 within thewellbore105 in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: (1) PCT application no. serial no. PCT/US02/36267, attorney docket no. 25791.88, filed on Nov. 12, 2002, (2) U.S. provisional patent application Ser. No. 60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001, (3) U.S. provisional patent application Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13, 2002, and (4) U.S. provisional patent application Ser. No. 60/339,013, attorney number attorney docket no. 25791.88, filed on Nov. 12, 2001, the disclosures of which are incorporated herein by reference.
• In an exemplary embodiment, an adjustable expansion cone may be similar to a conventional adjustable expansion mandrel in that may be expanded to a larger outside dimension or collapsed to a smaller outside dimension and includes external surfaces for engaging thecasing110 to thereby radially expand and plastically deform the tubular member when the adjustable expansion mandrel is expanded to the larger outside dimension. In an alternative embodiment, theexpansion cone140 may include a rotary adjustable expansion device such as, for example, the commercially available rotary expansion devices of Weatherford International, Inc. In several alternative embodiments, the cross sectional profile of theexpansion cone140 for radial expansion operations may, for example, be an n-sided shape, where n may vary from 2 to infinity, and the side shapes may include straight line segments, arcuate segments, parabolic segments, and/or hyperbolic segments. In several alternative embodiments, the cross sectional profile of theadjustable expansion cone140 may, for example, be circular, oval, elliptical, and/or multifaceted.
• Alternatively, theexpansion cone140 may be comprised of a plurality of circumferentially spaced apart upper cone segments interleaved among the cam arms of an upper cam spaced around a mandrel291 defininglongitudinal passage293. In an exemplary embodiment, each upper cone segment includes a first outer surface that defines a hinge groove, a plurality of inner surfaces and a plurality of outer surfaces. In an exemplary embodiment, there may be a combination of arcuate and cylindrical segments. The upper cone segments may be pivotally coupled to anupper cone retainer290. A plurality of circumferentially spaced apart lower cone segments interleaved among the cam arms of a lower cam. In an exemplary embodiment, each lower cone segment includes a first outer surface that defines a hinge groove, a plurality of inner surfaces and a plurality of outer surfaces. In an exemplary embodiment, there may be a combination of arcuate and cylindrical segments. The lower cone segments may be pivotally coupled to alower cone retainer292. Shear pins or another retaining mechanism longitudinally position thelower retainer292 relative to theupper retainer290 such that they remain positioned apart during the positioning of the apparatus within the well. In one embodiment, when the apparatus reaches the bottom of the well, the impact shears the shear pins and drives the lower cone retainer toward the upper cone retainer, causing the cone segments to pivot outward in a lateral direction. As the cone segments pivot outward, the diameter of theexpansion cone140 increases. A locking mechanism then locks the cone segments together in an expanded configuration.
• Thelower cone retainer292 receives and may be threadably coupled to an end of arelease housing300 that defines alongitudinal passage302. Alower end304 of therelease housing300 defines aexternal flange305 adapted to mate into asleeve306 in theanchoring device148. In some exemplary embodiments, atubular cementing probe308 may be slidingly disposed within thelongitudinal passage302. The cementingprobe308 may be a tubular shaped member which defines alongitudinal passage310. A top end of thecementing probe308 has an annular exterior flange orrim312, the diameter of which is slightly smaller than the interior diameter of thelongitudinal passage302. During operation, an interiorannular seat314 defined within therelease housing300 keeps theflange312 of cementing probe within thelongitudinal passage302. A lower end of the concrete probe narrows to form aneck316 which, as will be explained below, is adapted to mate with a collet of theanchoring device148. During positioning of the apparatus, a probe shear pin318 longitudinally retains the sliding sleeve within thelongitudinal passage302. Once thecement probe308 has been extended during operation, however, aprobe locking ring320 may maintain the probe in an extended configuration.
• In the illustrative embodiment, theanchoring device148 may be a anexpandable float shoe340. In some exemplary embodiments, thefloat shoe340 may be made out of aluminum or another expandable material which may be relative easy to drill out. The top end of the float shoe defines atubular sleeve342 defining anannual passage344. Thetubular sleeve342 is adapted to mate within therelease housing300. A slidingsleeve valve346 is slidingly disposed within thelongitudinal passage344.
• The slidingsleeve valve346 is generally tubular in shape defining anlongitudinal passage348. At a top end of the slidingsleeve valve346, there is an outwardly protruding flange orrim350 which circumferentially extends around the top end of slidingsleeve valve346. Below therim350, there is a flexible or top section defining acollet346a. Below thecollet346a, there is alower section346bof the slidingsleeve valve346. The wall thickness of thecollet346ais narrow relative to thelower section346b. There are also a predetermined number of longitudinal slots (not shown) extending from the top of therim350 through thecollet346a. Preferably these longitudinal slots are equally spaced around the periphery of thecollet346a. The combination of the longitudinal slots and the narrowed wall thickness of thecollet346aallow the diameter of therim350 to decrease when therim350 is not radially supported by a supporting mechanism. Thus, therim350 can be considered “flexible” in that it can contract from a first radial position of a particular diameter to a second radial position of a lesser diameter. In the running configuration illustrated inFIG. 2f, therim350 is positioned in aninterior recess352 defined in thesleeve342. Theneck316 of thecementing probe308 radially supportsrim350, preventing therim350 from slipping out of therecess352 and thus longitudinally maintains the slidingsleeve valve346 within thesleeve342. Aside port354 may be defined within the side wall of thelower section346b.
• In several exemplary embodiments, there is aannular seat355 positioned within thelongitudinal passage344 of thefloat shoe340. Theannular seat355 is adapted to sealingly couple to a plug. The plug may be any conventional plug, such as drill pipe dart or phenolic ball that would provide a hydraulic seal upon reaching theannular seat355. Thesleeve342 of thefloat shoe340 increases in diameter to accommodate abypass passage356. Thebypass passage356 defines a passage that connects the portion of thelongitudinal passage344 above theseat356 to a portion of thelongitudinal passage344 below theseat356, thereby creating a “bypass” around theseat356. In the running position illustrated inFIGS. 2a-2e, an entrance port356aof thebypass passage356 is blocked by the slidingsleeve valve346.
• Positioned below theannular seat355 is a one-way valve358. In several exemplary embodiments, the oneway valve358 may be a float valve assembly which allows for a fluid to flow in a downward direction, but prevents fluid to flow in an upward direction. The one-way valve358 opens into anlongitudinal passage360. A sleeve, such as adog locking sleeve362 may be slidingly disposed within thelongitudinal passage360. Ashear pin364 maintains the relative position of the dog locking sleeve relative to thefloat shoe340 such that alower end368 of the dog locking sleeve is disposed below thefloat shoe340. At the top end of thedog locking sleeve362, there is anexternal flange366 adapted such that an upward movement by theexternal flange366 “expands” or pushes out a plurality ofdogs370 through a plurality ofradial side openings372 defined in thefloat shoe340. In several alternative embodiments, thedogs370 orexpansion mechanism150 within thefloat shoe340 may be replaced by a shoulder on the float shoe for engaging the end of the radially expanded tubular member.
• In an exemplary embodiment, during operation of theapparatus200, as illustrated inFIGS. 2a-2e, the apparatus may be initially positioned in thewellbore100, partially within thecasing110, with theexpansion cone140, the cementingprobe144, and thefloat shoe340 positioned outside the casing. In this manner, fluidic materials within the interior of theapparatus200 may pass through thelongitudinal passages203,250a,261,283,293,302,310,344,348, and360 out of the apparatus through thefloat valve358, into the annulus between theapparatus200 and thecasing110 thereby preventing over pressurization of the annulus.
• Referring now toFIGS. 3a-3e, there is illustrated theapparatus200 positioned at the bottom of thewellbore100. When theapparatus200 contacts with the bottom of thewellbore100, thedog locking sleeve368 is driven up into thefloat shoe340, shearing theshear pin360. The upward movement of the lockingsleeve368 forces thedogs370 through theside openings372, where a locking mechanism prevents their retraction.
• In an alternative embodiment of the expansion cone, the force of impact with the bottom of the well shears the retaining mechanism, forcing the lowerexpansion cone retainer292 towards the upperexpansion cone retainer290. The interleaved cone segments pivot outward in a lateral direction on top of one another. As the cone segments pivot outward, the diameter of theexpansion cone140 increases. A locking mechanism then locks the upper cone segments in place. Thus, the expansion cone may expand to a diameter that is greater than the interior diameter of thecasing110.
• Referring now toFIGS. 4a-4f, there is illustrated theapparatus200 when a plug, such as aball374 is then injected into the apparatus with the fluidic material through thepassages203,250a,261,283,293,302,310,344 and348 until the dart is positioned and seated on theannular seat355 in thefloat shoe340. As a result of the positioning of theball374 in thepassage344 of thefloat shoe340, thepassage344 of the float shoe is thereby closed.
• The fluidic material is then injected into the apparatus thereby increasing the operating pressure within thepassages203,250a,261,283,293,302,310,344 and348. Furthermore, the continued injection of the fluidic material into theapparatus200 causes the fluidic material to pass through theradial passages220aand220b, into theannular pressure chamber222 of thegripping device132. When the pressure of thecentral passage203 is large enough to overcome the biasing of thesprings208aand208b, thepressure chamber222 expands by driving the upper flange207 away from theexternal flange224. Thus, theupper flange207aacts like a piston pushing the retainingsleeve206 in an upperwardly direction with respect to thecentral mandrel202. When the retaining sleeve moves up, the steel balls218a-218dare forced up into thinner regions of the retaining chambers216a-216d. A portion of the steels balls218a-218d, therefore, projects radially through the circular openings214a-214d. As the steel balls218a-218dproject through the circular openings214a-214d, they engage the interior surface of thecasing110.
• The fluidic material is then injected into the apparatus thereby increasing the operating pressure within thepassages203,250a,261,283,293,302,310,344 and348. Furthermore, the continued injection of the fluidic material into theapparatus200 also causes the fluidic material to pass through theradial tubes270athrough270f, of thepiston tube260 into anannular pressure chambers268,268a, and268b, respectively.
• The pressurization of the annular pressure chambers,268a,268b, and268cthen cause thepiston flanges262a,262b,262cto be displaced upwardly relative to thecasing100. As a result, the upperpacker cup assembly280, the lowerpacker cup assembly286,expansion cone140, therelease housing300, the cementingprobe308, and thefloat shoe340 are displaced upwardly relative to thecasing110.
• The continued injection of the fluidic material into theapparatus200 continues to pressurize annular pressure chambers,268a,268b, and268c. The further upward displacement of thepiston flanges262a,262b,262cin turn displaces theexpansion cone140 upwardly relative to thecasing110. As a result, theexpansion cone140 radially expands and plastically deforms a portion of thecasing110.
• Referring toFIGS. 5a-5f, during the continued injection of the fluidic material, theexpansion cone140 will continue to be displaced upwardly relative to thecasing110 thereby continuing to radially expand and plastically deform the casing until the lockingdogs370a-370bengage the lower end of thecasing110. The continued upward movement of theexpansion cone140,cement probe308, and releasehousing300 causes therelease housing300 to move longitudinally upward—out of thesleeve306 of thefloat shoe340. Theexternal flange305 of therelease housing300 causes thesleeve306 to radially expand against thecasing110. In some embodiments, this radial expansion of thesleeve306 also causes an expansion and plastic deformation of a portion of thecasing110 which may also hydraulically seal thesleeve306 to thecasing110. Optionally, a elastomeric sealing material may be applied to the exterior of thesleeve306 to create a seal between thesleeve306 and thecasing110.
• Referring toFIGS. 6ato6e, The continued upward movement of theexpansion cone140,cement probe308, and releasehousing300 causes the probe shear pin318 to shear. The force on thecement probe308 pulls the probe downward until theexternal flange312 impacts theseat314 defined with thepassage302 preventing further movement of the cement probe. Aprobe lock ring313 disposed on the exterior surface of the concrete probe contacts a downward facingseat315, thereby “locking” the concrete probe in place. The continued upward movement of thecement probe308 causes thecement probe308 to separate from thefloat shoe340. At the top of the stroke of thetension actuator134, thecasing lock130 may be released. After separation, theapparatus200 is free to continue to advance up causing thecasing110 to expand as necessary. Because there is an hydraulic seal between thesleeve306 and thecasing110, the region between thefloat shoe340 and thepacker cup assemblies280 and286 may be pressurized. This pressurized region forces theexpansion cone140 upwardly, thereby causing a continued radial expansion and plastic deformation of theexpandable casing110. In this manner, the fluid pressure below thepacker cup assemblies280 and286 pulls theexpansion cone140 upwardly through theexpandable casing110. Thus, the use of thetension actuator134 to pull the expansion cone upwards is no longer necessary.
• At some point (e.g., at the top of the liner), it may become desirable to stop expanding and to inject a hardenable fluidic sealing material such as, for example, cement into the well annulus. Referring toFIGS. 7ato7f, to begin the cementing operation, theapparatus200 may be lowered into thewellbore100 until theneck316 of thecementing probe308 impacts thecollet346aforcing therim350 of the collet from therecess352, which allows the slidingsleeve valve346 to move downward until the sliding sleeve valve impacts an upward facingseat345 in thepassage344. In this position, thesideport354 is aligned with the opening of thebypass flowpath356 to permit fluidic materials to bypass around the ball in thepassage344. As a result, thebypass flow path356 allows for cement or other fluidic materials to flow around the ball.
• Thus, the cement may flow through the through thebypass flow path356, and out through the one-way valve358 into the annulus between the radially expanded tubular member and the wellbore. After the cement has been injected into the annulus, the one way valve may prevent the cement from flowing backwards into theflowpath356.
• After completing the injection of the cement into the annulus, the drilling pipe may then pulled upwardly out of the wellbore. The radial expansion and plastic deformation of the expandable tubular member may then be continued by the resumed injection of fluidic material into the apparatus. After the cement has cured, thefloat shoe340 may be drilled out and another expandable tubular member may then be radially expanded and plastically deformed within the wellbore with the upper end of the other tubular member overlapping with the lower end of the earlier expanded tubular member. In this manner, a mono diameter wellbore casing may be formed that includes a plurality of radially expanded tubular members.
• In several alternative embodiments, a packer may be used instead of thefloat shoe340 to couple the end of the casing to the apparatus. Referring toFIGS. 8ato8e, an alternative embodiment, anapparatus500 for forming a monodiameter wellbore casing502 provides a one step monobore wellbore casing radial expansion system. The one step monobore system can also be used as a cased or open hole radial expansion system, or an open hole cladding system where an expandable casing is clad against a formation in open hole.
• In an exemplary embodiment, theapparatus500 includes anexpansion assembly504 and apacker506. Theexpansion assembly504 includes, among other things, asafety sub508, a gripping device510, acasing lock device512, a force multiplier ortension actuator514, an expansion cone516, a packer setting sleeve518, aninternal sleeve520 and a stinger522.
• In an exemplary embodiment, thesafety sub508 allows a quick connection and disconnection of the drill string to and from the expansion system.
• In several exemplary embodiments, the gripping device510 may be any device capable of engaging the inside surface of the tubular member or casing502 in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: (1) PCT application no. serial no. PCT/US02/36267, attorney docket no. 25791.88, filed on Nov. 12, 2002, (2) U.S. provisional patent application Ser. No. 60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001, (3) U.S. provisional patent application Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13, 2002, and (4) U.S. provisional patent application Ser. No. 60/339,013, attorney number attorney docket no. 25791.88, filed on Nov. 12, 2001, the disclosures of which are incorporated herein by reference. In the embodiment as illustrated inFIGS. 8a-8f, the gripping device510 comprises hydraulic slips510a-510care isolated from internal pressure by arupture disc524. In an exemplary embodiment, apacker cup526 acts as a check valve to allow external pressure to equalize behind the hydraulic slips510a-510cwhen in a running configuration, but holds internal pressure when the rupture disc is ruptured. In an exemplary embodiment, the hydraulic slips510a-510care actuated by rupturing therupture disc524 with internal pressure. In an exemplary embodiment, the internal pressure then acts on the hydraulic slips510a-510c, moving them out against the internal diameter of theexpandable casing502. The hydraulic slips510a-510cthereby provide an anchor for the tension actuator to pull theexpansion cone504 against and expand the expandable casing. When the internal pressure is released, the hydraulic slips510a-510cretract away from the internal diameter of theexpandable casing502.
• In an exemplary embodiment, acasing lock512 holds the weight of the expandable casing string as it is run in the well. In several exemplary embodiments, thecasing lock512 may be any device capable of coupling the apparatus to the casing while the apparatus is being positioned within the wellbore in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: (1) PCT application no. serial no. PCT/US02/36267, attorney docket no. 25791.88, filed on Nov. 12, 2002, (2) U.S. provisional patent application Ser. No. 60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001, (3) U.S. provisional patent application Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13, 2002, and (4) U.S. provisional patent application Ser. No. 60/339,013, attorney number attorney docket no. 25791.88, filed on Nov. 12, 2001, the disclosures of which are incorporated herein by reference.
• In the illustrative embodiment,casing lock dogs530 fit in upsets formed in the internal diameter of the expandable casing and are held in place with a retainingsleeve532. When the retainingsleeve532 is shifted by thetension actuator514, thedogs530 retract and theexpansion504 is released from theexpandable casing502.
• In several exemplary embodiments, thetension actuator514 may be any device capable of pulling theexpansion cone140 into thecasing110 in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: (1) PCT application no. serial no. PCT/US02/36267, attorney docket no. 25791.88, filed on Nov. 12, 2002, (2) U.S. provisional patent application Ser. No. 60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001, (3) U.S. provisional patent application Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13, 2002, and (4) U.S. provisional patent application Ser. No. 60/339,013, attorney number attorney docket no. 25791.88, filed on Nov. 12, 2001, the disclosures of which are incorporated herein by reference. Thetension actuator514 may also be similar to thetension actuator134 described above.
• In an exemplary embodiment, thetension actuator514 provides several stages of differential area for internal pressure to act upon and thereby provide an upward force to theexpansion cone504 to thereby expand theexpandable casing502. Thetension actuator514 may be used to initially expand theexpandable casing502 and to pull thepacker506 into the radially expandedcasing502. Thetension actuator514 may be used at any time during radial expansion process when the hydraulic slips510a-510bare actuated to provide additional upward force to the expansion cone. In an exemplary embodiment, thetension actuator514 may be used to assist in the radial expansion process when the portion of the expandable casing that overlaps with another casing is radially expanded and plastically deformed.
• In several exemplary embodiments, theexpansion cone504 be any device capable of expanding the casing ortubing member110 within thewellbore105 in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: (1) PCT application no. serial no. PCT/US02/36267, attorney docket no. 25791.88, filed on Nov. 12, 2002, (2) U.S. provisional patent application Ser. No. 60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001, (3) U.S. provisional patent application Ser. No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13, 2002, and (4) U.S. provisional patent application Ser. No. 60/339,013, attorney number attorney docket no. 25791.88, filed on Nov. 12, 2001, the disclosures of which are incorporated herein by reference. Thus, the expansion cone516 may be an adjustable expandable expansion cone, or it may be expandable or non-expandable for use in cased or open hole expansion systems or open hole clad systems.
• In an exemplary embodiment, an internal sleeve534blocks ports536 which lead from the internal passage528 to thepacker setting sleeve538. In an exemplary embodiment, the internal sleeve534 may be moved away from theports536 by thetension actuator514 at the end of the tension actuator stroke to allow internal pressure to act on thepacker setting sleeve538 and thereby set thepacker506 in the expandedcasing502. Thus, in an exemplary embodiment, thepacker setting sleeve538 is moved downwardly against thepacker506 to set the packer by internal pressure.
• In an exemplary embodiment, thepacker506 may be a fas dril packer which is a composite drillable packer that is set in the expanded casing and contains the expansion pressure. The fas dril packer includes an internal pressure balanced slidingsleeve valve540 which is used to open andclose fluid ports542 Thesleeve valve540 has two external seals which seal against the internal diameter of the fas dril packer and isolate fluid ports in the fas dril packer when the sleeve valve is in the up position. When the sleeve valve is moved downwardly,ports544 in thesleeve valve540 align withports542 in the fas dril packer and allow fluid to be displaced into abypass passage546 in the fas dril packer. Collets at the top of the sleeve valve fit in an internal groove provided in the internal diameter of the fas dril packer when the sleeve valve is in the up position and allow the end of the stinger to pass and shoulder against the sleeve valve. When astinger548 pushes thesleeve valve540 downwardly to open theports542, the collets are pulled out of the groove and retract inward into an external undercut on the bottom of thestinger548.
• When thestinger548 is moved up to close theports542, a lower shoulder on the external undercut contacts the inward retracted collets and pulls the slidingsleeve valve540 upwardly until the collets expand out into the internal groove. Thesleeve valve540 is operated with astinger548 attached to theexpansion assembly504. Below thesleeve valve540 are twoball seats550aand550bwith arupture disc552 in between. Thebypass passage546 connects theports542 covered by the sleeve valve, therupture disc ports554, andports556 positioned below the bottom ball seat.
• Acheck valve558 may be disposed at the bottom of the fas dril packer. Other types of commercially available drillable packers may also be used, such as, for example, the EZ Drill. Additionally, for open and cased hole cladding systems where cement is not going to be used, retrievable packers can be used and retrieved after expansion instead of drilled.
• In an exemplary embodiment, thestinger548 may be attached to theexpansion assembly504 and includes anexternal seal560 which seals against the inside diameter of the fas dril packer. At the bottom end of the stinger is an external undercut which is used to close the sliding sleeve valve.
• Turning now toFIGS. 9a-9e, which illustrates some aspects of the operation of theapparatus500. InFIG. 9a, theexpansion assembly504 is run through thecasing502 until thepacker506 is in open hole beyond the casing.
• A first plug, which may be a ball or a dart, may be dropped to theplug seat550ain the packer central passage528. Continued pumping of fluids causes the internal pressure to be increased. As described above with reference toFIGS. 1ato7f, the pressure actuates thetension actuator514 which pulls the expansion cone516 up against the bottom of the casing510.
• The expansion cone516 expands in size and then expands theexpandable casing502, pulling thepacker506 upwardly along with it. Near the end of the tension actuator stroke, thepacker506 is positioned in the expanded casing and the lower end of the tension actuator shoulders against theinternal sleeve520, shifting it downward. As a result, theports536 open allowing fluidic communication from the central passage528 to thepacker setting sleeve538. The internal pressure then causes the settingsleeve538 to down, which pushes against and sets thepacker506.
• The tension actuator514 then pulls against a connecting mechanism, such as a plurality of shear pins, connecting thepacker506 to theexpansion assembly504 until they shear.
• At the end of the tension actuator stroke, anupper end562 of thetension actuator514 shoulders against thedog retaining sleeve532 and moves it upward, releasing thedogs530 and unlocking theexpansion assembly504 from thecasing502.
• Continued injection of the fluidic material into theapparatus500 causes an increase in the internal pressure in the central passage528. The increase pressure ruptures therupture disc554, which allows the fluid to flow into thebypass passage546. Thecasing502 can now be run to the bottom of the well.
• Once the casing has reached the bottom of the well, a second plug may be dropped. The second plug sized to sealingly fit thesecond plug seat550b. The second plug stops circulation through thebypass passage546. Continued injection of fluid increases the internal pressure in the central passage528 so that the casing expansion can be partially or completely continued, or the expansion assembly can be set down to open the sliding sleeve valve to circulate mud or displace cement. Picking back up on theexpansion assembly504 will close the sliding sleeve valve. At any point during expansion, theexpansion assembly504 can be set down on thepacker506 to open the slidingsleeve valve540 to continue circulation.
• Once theexpansion assembly504 reaches an overlap section of theexpandable casing502, the expansion pressure increases until theupper rupture disc524 ruptures. The hydraulic slips510a-510cthen move out against the internal diameter of theexpandable casing502, providing an anchor for the tension actuator to pull the expansion cone against. When thetension actuator514 reaches the end of its stroke, the internal pressure is released, the hydraulic slips510a-510cretract, and thetension actuator514 is extended for another stroke. In an exemplary embodiment, the hydraulic slips510a-510cmay be designed to not only contact the unexpanded casing, but will also extend out far enough the contact the previously expanded casing string at the final expansion stroke.
• After theexpansion assembly504 is pulled out of the well, thepacker506 may be drilled out and another section of hole may be drilled. An identical expansion system is then run and expanded to the same ID as the previous string.
• 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.
• 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.
• 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 (60)

1. An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising:

an anchoring mechanism adapted to mate with an end of the expandable tubular member;

a tubular support member releasably coupled to the anchoring mechanism,

an adjustable expansion mandrel coupled to the tubular support member adapted to be controllably expanded to a larger outside dimension for radial expansion of the expandable tubular member or collapsed to a smaller outside dimension;

an actuator coupled to the tubular support member and the adjustable expansion mandrel adapted to controllably longitudinally displace the adjustable expansion mandrel relative to the tubular support member and the expandable tubular member; and

a gripping device coupled to the tubular support member adapted to controllably engage the expandable tubular member.

2. The apparatus ofclaim 1 further comprising a locking device coupled to the actuator adapted to controllably engage the expandable tubular member.

3. The apparatus ofclaim 1 further comprising a sealing device for sealingly engaging the expandable tubular member adapted to define an annular pressure chamber above the adjustable expansion mandrel during radial expansion of the expandable tubular member.

4. The apparatus ofclaim 1 wherein the gripping device comprises:

a tubular mandrel having a plurality of tapered grooves defined on an exterior surface of the tubular mandrel,

a retaining sleeve coupled to the tubular mandrel and adapted to slidingly move longitudinally with respect to the tubular mandrel, the retaining sleeve having a plurality of openings,

a plurality of gripping elements positioned within the tapered grooves, wherein when the retaining sleeve is in a first longitudinal configuration, portions of the gripping elements protrude through the plurality of openings, and when the retaining sleeve is in a second longitudinal configuration, portions of the gripping elements do not protrude through plurality of tapered openings.

5. The apparatus ofclaim 1 wherein the anchoring device is a float shoe, comprising:

an expandable sleeve adapted to mate with the tubular member, wherein the tubular member is adapted to controllably expand the expandable sleeve to a larger outside dimension for radial expansion of the expandable sleeve to the expandable tubular member.

6. The apparatus ofclaim 5 wherein the anchoring device comprises:

a first passage,

a second passage,

a seat within the first passage adapted to receive a plug,

a sliding valve disposed within the first passage, adapted to direct flow from the first passage to the second passage, and

a one-way valve coupled to the first and second passages.

7. The apparatus ofclaim 1 wherein the anchoring mechanism is a packer.

8. The apparatus ofclaim 7 wherein the packer is hydraulically actuated.

9. The apparatus ofclaim 7 wherein the packer comprises:

a first passage,

a second passage,

a first seat within the first passage adapted to receive a plug, and

a sliding valve disposed within the first passage, adapted to direct flow from the first passage to the second passage.

10. A method for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising:

positioning an adjustable expansion mandrel, an anchoring device, and a coupling mechanism below the expandable tubular member such that the anchoring device contacts a bottom of the borehole,

increasing the outside dimension of the adjustable expansion mandrel; and

displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member,

displacing the anchoring device upwardly relative to the expandable tubular member such that the anchoring device contacts the bottom of the expandable tubular member,

coupling the anchoring device to the bottom of the casing,

uncoupling the expansion mandrel from the anchoring device, and

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.

11. The method ofclaim 10, further comprising:

lowering the adjustable expansion mandrel to couple the expansion mandrel to the anchoring device, and

cementing the borehole, wherein the cementing flows through a flow path located in the anchoring device.

12. The method ofclaim 10 further comprising expanding an expansion device coupled to the anchoring device such that the anchoring device couples to the casing.

13. An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising:

an anchoring mechanism adapted to mate with an end of the expandable tubular member;

a tubular support member releasably coupled to the anchoring mechanism,

an adjustable expansion device coupled to the tubular support member adapted to be controllably expanded to a larger outside dimension for radial expansion of the expandable tubular member or collapsed to a smaller outside dimension;

an actuator coupled to the tubular support member and the adjustable expansion device adapted to controllably longitudinally displace the adjustable expansion device relative to the tubular support member and the expandable tubular member; and

a gripping device coupled to the tubular support member adapted to controllably engage the expandable tubular member.

14. The apparatus ofclaim 13 further comprising a locking device coupled to the actuator adapted to controllably engage the expandable tubular member.

15. The apparatus ofclaim 13 further comprising a sealing device for sealingly engaging the expandable tubular member adapted to define an annular pressure chamber above the adjustable expansion device during radial expansion of the expandable tubular member.

16. The apparatus ofclaim 13 wherein the gripping device comprises:

a tubular member having a plurality of tapered grooves defined on an exterior surface of the tubular member,

a retaining sleeve coupled to the tubular member and adapted to slidingly move longitudinally with respect to the tubular member, the retaining sleeve having a plurality of openings,

a plurality of gripping elements positioned within the tapered grooves, wherein when the retaining sleeve is in a first longitudinal configuration, portions of the gripping elements protrude through the plurality of openings, and when the retaining sleeve is in a second longitudinal configuration, portions of the gripping elements do not protrude through plurality of tapered openings.

17. The apparatus ofclaim 13 wherein the anchoring device is a float shoe, comprising:

an expandable sleeve adapted to mate with the tubular member, wherein the tubular member is adapted to controllably expand the expandable sleeve to a larger outside dimension for radial expansion of the expandable sleeve to the expandable tubular member.

18. The apparatus ofclaim 17 wherein the anchoring device comprises:

a first passage,

a second passage,

a seat within the first passage adapted to receive a plug,

a sliding valve disposed within the first passage, adapted to direct flow from the first passage to the second passage, and

a one-way valve coupled to the first and second passages.

19. The apparatus ofclaim 13 wherein the anchoring mechanism is a packer.

20. The apparatus ofclaim 19 wherein the packer is hydraulically actuated.

21. The apparatus ofclaim 19 wherein the packer comprises:

a first passage,

a second passage,

a first seat within the first passage adapted to receive a plug, and

a sliding valve disposed within the first passage, adapted to direct flow from the first passage to the second passage.

22. A method for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising:

positioning an adjustable expansion device, an anchoring device, and a coupling mechanism below the expandable tubular member such that the anchoring device contacts a bottom of the borehole,

increasing the outside dimension of the adjustable expansion device; and

displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member,

displacing the anchoring device upwardly relative to the expandable tubular member such that the anchoring device contacts the bottom of the expandable tubular member,

coupling the anchoring device to the bottom of the casing,

uncoupling the adjustable expansion device from the anchoring 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.

23. The method ofclaim 22, further comprising:

lowering the adjustable expansion device to couple the expansion device to the anchoring device, and

cementing the borehole, wherein the cementing flows through a flow path located in the anchoring device.

24. The method ofclaim 22 further comprising expanding an expansion device coupled to the anchoring device such that the anchoring device couples to the casing.

25. An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising:

an anchoring mechanism adapted to mate with an end of the expandable tubular member;

a tubular support member releasably coupled to the anchoring mechanism,

an expansion device coupled to the tubular support member adapted to be controllably expanded to a larger outside dimension for radial expansion of the expandable tubular member or collapsed to a smaller outside dimension;

an actuator coupled to the tubular support member and the adjustable expansion device adapted to controllably longitudinally displace the adjustable expansion device relative to the tubular support member and the expandable tubular member; and

a gripping device coupled to the tubular support member adapted to controllably engage the expandable tubular member.

26. The apparatus ofclaim 25 further comprising a locking device coupled to the actuator adapted to controllably engage the expandable tubular member.

27. The apparatus ofclaim 25 further comprising a sealing device for sealingly engaging the expandable tubular member adapted to define an annular pressure chamber proximate the expansion device during radial expansion of the expandable tubular member.

28. The apparatus ofclaim 25 wherein the gripping device comprises:

a tubular member having a plurality of tapered grooves defined on an exterior surface of the tubular member,

a retaining sleeve coupled to the tubular member and adapted to slidingly move longitudinally with respect to the tubular member, the retaining sleeve having a plurality of openings,

a plurality of gripping elements positioned within the tapered grooves, wherein when the retaining sleeve is in a first longitudinal configuration, portions of the gripping elements protrude through the plurality of openings, and when the retaining sleeve is in a second longitudinal configuration, portions of the gripping elements do not protrude through plurality of tapered openings.

29. The apparatus ofclaim 25 wherein the anchoring device is a float shoe, comprising:

an expandable sleeve adapted to mate with the tubular member, wherein the tubular member is adapted to controllably expand the expandable sleeve to a larger outside dimension for radial expansion of the expandable sleeve to the expandable tubular member.

30. The apparatus ofclaim 29 wherein the anchoring device comprises:

a first passage,

a second passage,

a seat within the first passage adapted to receive a plug,

a sliding valve disposed within the first passage, adapted to direct flow from the first passage to the second passage, and

a one-way valve coupled to the first and second passages.

31. The apparatus ofclaim 25 wherein the anchoring mechanism is a packer.

32. The apparatus ofclaim 31 wherein the packer is hydraulically actuated.

33. The apparatus ofclaim 31 wherein the packer comprises:

a first passage,

a second passage,

a first seat within the first passage adapted to receive a plug, and

a sliding valve disposed within the first passage, adapted to direct flow from the first passage to the second passage.

34. A method for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising:

positioning an expansion device, an anchoring device, and a coupling mechanism below the expandable tubular member;

displacing the expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member,

displacing the anchoring device upwardly relative to the expandable tubular member,

coupling the anchoring device to the bottom of the casing,

uncoupling the expansion device from the anchoring device, and

displacing the expansion device upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member.

35. The method ofclaim 34, further comprising:

lowering the expansion device to couple the expansion device to the anchoring device, and

cementing the borehole, wherein the cementing flows through a flow path defined in the anchoring device.

36. The method ofclaim 34 further comprising expanding an expansion device coupled to the anchoring device such that the anchoring device couples to the casing.

37. A gripping device for gripping a wellbore casing, comprising:

a tubular member having a plurality of tapered grooves defined on an exterior surface of the tubular member,

a retaining sleeve coupled to the tubular member and adapted to slidingly move longitudinally with respect to the tubular member, the retaining sleeve having a plurality of openings,

a plurality of gripping elements positioned within the tapered grooves, wherein when the retaining sleeve is in a first longitudinal configuration, portions of the gripping elements protrude through the plurality of openings, and when the retaining sleeve is in a second longitudinal configuration, portions of the gripping elements do not protrude through plurality of tapered openings.

38. An anchoring device for anchoring the position of a wellbore casing, comprising:

an expandable sleeve adapted to mate with the wellbore casing.

39. An anchoring device for anchoring the position of a wellbore casing, comprising:

a housing,

a first passage defined within the housing,

a second passage defined within the housing,

a seat within the first passage adapted to receive a plug,

a sliding valve disposed within the first passage, adapted to direct flow from the first passage to the second passage, and

a one-way valve coupled to the first and second passages.

40. A system for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising:

means for positioning an adjustable expansion mandrel, an anchoring device, and a coupling mechanism below the expandable tubular member such that the anchoring device contacts a bottom of the borehole,

means for increasing the outside dimension of the adjustable expansion mandrel;

means for displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member,

means for displacing the anchoring device upwardly relative to the expandable tubular member such that the anchoring device contacts the bottom of the expandable tubular member,

means for coupling the anchoring device to the bottom of the casing,

means for uncoupling the expansion mandrel from the anchoring device, and

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.

41. The system ofclaim 40, further comprising:

means for lowering the adjustable expansion mandrel to couple the expansion mandrel to the anchoring device, and

means for cementing the borehole, wherein the cementing flows through a flow path located in the anchoring device.

42. The system ofclaim 40 further comprising means for expanding an expansion device coupled to the anchoring device such that the anchoring device couples to the casing.

43. A method for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising:

means for positioning an adjustable expansion device, an anchoring device, and a coupling mechanism below the expandable tubular member such that the anchoring device contacts a bottom of the borehole,

means for increasing the outside dimension of the adjustable expansion device;

means for displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member,

means for displacing the anchoring device upwardly relative to the expandable tubular member such that the anchoring device contacts the bottom of the expandable tubular member,

means for coupling the anchoring device to the bottom of the casing,

means for uncoupling the adjustable expansion device from the anchoring 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.

44. The system ofclaim 43, further comprising:

means for lowering the adjustable expansion device to couple the expansion device to the anchoring device, and

means for cementing the borehole, wherein the cementing flows through a flow path located in the anchoring device.

45. The system ofclaim 43 further comprising means for expanding an expansion device coupled to the anchoring device such that the anchoring device couples to the casing.

46. A system for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising:

means for positioning an expansion device, an anchoring device, and a coupling mechanism below the expandable tubular member;

means for displacing the expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member,

means for displacing the anchoring device upwardly relative to the expandable tubular member,

means for coupling the anchoring device to the bottom of the casing,

means for uncoupling the expansion device from the anchoring device, and

means for displacing the expansion device upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member.

47. The system ofclaim 46, further comprising:

means for lowering the expansion device to couple the expansion device to the anchoring device, and

means for cementing the borehole, wherein the cementing flows through a flow path defined in the anchoring device.

48. The method ofclaim 46 further comprising means for expanding an expansion device coupled to the anchoring device such that the anchoring device couples to the casing.

49. A method of gripping a wellbore casing, comprising:

gripping the interior surface of the wellbore casing at a plurality of discrete spaced apart locations.

50. A method of anchoring the position of a wellbore casing, comprising:

radially expanding and plastically deforming a sleeve within the wellbore casing into contact with the interior surface of the wellbore casing.

51. A system for gripping a wellbore casing, comprising:

means for gripping the interior surface of the wellbore casing at a plurality of discrete spaced apart locations; and

means for actuating the means for gripping.

52. A system for anchoring the position of a wellbore casing, comprising:

means for radially expanding and plastically deforming a sleeve within the wellbore casing into contact with the interior surface of the wellbore casing; and

means for controlling the means for radially expanding and plastically deforming the sleeve.

53. A method of radially expanding and plastically deforming a tubular member, comprising:

pressurizing an interior portion of the tubular member; and

displacing an expansion device through the pressurized interior portion of the tubular member.

54. The method ofclaim 53, wherein pressurizing an interior portion of the tubular member comprises pressurizing an annular interior portion of the tubular member.

55. The method ofclaim 53, wherein displacing an expansion device through the pressurized interior portion of the tubular member comprises pulling the expansion device through the pressurized interior portion of the tubular member.

56. The method ofclaim 53, wherein pulling the expansion device through the pressurized interior portion of the tubular member comprises using the operating pressure of the pressurized interior portion of the tubular member to pull the expansion device through the pressurized interior portion of the tubular member.

57. A system for radially expanding and plastically deforming a tubular member, comprising:

means for pressurizing an interior portion of the tubular member; and

means for displacing an expansion device through the pressurized interior portion of the tubular member.

58. The system ofclaim 57, wherein means for pressurizing an interior portion of the tubular member comprises means for pressurizing an annular interior portion of the tubular member.

59. The system ofclaim 57, wherein means for displacing an expansion device through the pressurized interior portion of the tubular member comprises means for pulling the expansion device through the pressurized interior portion of the tubular member.

60. The system ofclaim 57, wherein means for pulling the expansion device through the pressurized interior portion of the tubular member comprises means for using the operating pressure of the pressurized interior portion of the tubular member to pull the expansion device through the pressurized interior portion of the tubular member.

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