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Patent 2489283 Summary

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(12) Patent Application: (11) CA 2489283
(54) English Title: COLLAPSIBLE EXPANSION CONE
(54) French Title: CONE D'EXPANSION RETRACTABLE
Status: Dead
Bibliographic Data
(51) International Patent Classification (IPC):
  • E21B 43/10 (2006.01)
(72) Inventors :
  • WATSON, BROCK WAYNE (United States of America)
  • BRISCO, DAVID PAUL (United States of America)
(73) Owners :
  • ENVENTURE GLOBAL TECHNOLOGY (United States of America)
(71) Applicants :
  • ENVENTURE GLOBAL TECHNOLOGY (United States of America)
(74) Agent: KIRBY EADES GALE BAKER
(74) Associate agent:
(45) Issued:
(86) PCT Filing Date: 2003-06-12
(87) Open to Public Inspection: 2003-12-24
Examination requested: 2008-05-12
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): Yes
(86) PCT Filing Number: PCT/US2003/018530
(87) International Publication Number: WO2003/106130
(85) National Entry: 2004-12-10

(30) Application Priority Data:
Application No. Country/Territory Date
60/387,961 United States of America 2002-06-12

Abstracts

English Abstract




An apparatus (910) for radially expanding and plastically deforming an
expandable tubular member (66) includes a collapsible expansion cone (44, 46).


French Abstract

L'invention concerne un appareil assurant l'expansion radiale et la d~formation plastique d'un ~l~ment tubulaire expansible et comprenant un cÙne d'expansion r~tractable.

Claims

Note: Claims are shown in the official language in which they were submitted.



Claims
What is claimed is:
1. An apparatus for radially expanding and plastically deforming an expandable
tubular member,
comprising:
an upper tubular support member defining a first passage;
one or more cup seals coupled to the exterior surface of the upper tubular
support
member for sealing an interface between the upper tubular support member and
the
expandable tubular member;
an upper cam assembly coupled to the upper tubular support member comprising:
a tubular base coupled to the upper tubular support member; and
a plurality of cam arms extending from the tubular base in a downward
longitudinal direction, each cam arm defining an inclined surface;
a plurality of upper expansion cone segments interleaved with the cam arms of
the
upper cam assembly and pivotally coupled to the tubular support member;
a lower tubular support member defining a second passage fluidicly coupled to
the
first passage releasably coupled to the upper tubular support member;
a lower cam assembly coupled to the lower tubular support member comprising:
a tubular base coupled to the lower tubular support member; and
a plurality of cam arms extending from the tubular base in an upward
longitudinal direction, each cam arm defining an inclined surface that mates
with the inclined surface of a corresponding one of the upper expansion cone
segments;
wherein the cams arms of the upper cam assembly are interleaved with and
overlap the cam arms of the lower cam assembly; and
a plurality of lower expansion cone segments interleaved with cam arms of the
lower
cam assembly, each lower expansion cone segment pivotally coupled to the lower
tubular support member and mating with the inclined surface of a corresponding
one
of the cam arms of the upper cam assembly;
wherein the lower expansion cone segments interleave and overlap the upper
expansion cone segments; and
wherein the upper and lower expansion cone segments together define an
arcuate spherical external surface for plastically deforming and radially
expanding the expandable tubular member.
2. The apparatus of claim 1, wherein the upper tubular support member
comprises:
a safety collar;
26


a torque plate coupled to the safety collar comprising a plurality of
circumferentially
spaced apart meshing teeth at an end;
an upper mandrel comprising a plurality of circumferentially spaced apart
meshing
teeth at one end for engaging the meshing teeth of the torque plate and an
external
flange at another end; and
a lower mandrel coupled to the external flange of the upper mandrel comprising
an
external flange comprising a plurality of circumferentially spaced apart
meshing
teeth.
3. The apparatus of claim 2, wherein the tubular base of the upper cam
assembly comprises a
plurality of circumferentially spaced apart meshing teeth for engaging the
meshing teeth of the
external flange of the lower mandrel.
4. The apparatus of claim 2, further comprising:
a stop nut coupled to an end of the lower mandrel for limiting the movement of
the
lower tubular member relative to the lower mandrel.
5. The apparatus of claim 2, further comprising:
locking dogs coupled to the lower mandrel.
6. The apparatus of claim 1, wherein the lower tubular support member
comprises:
a float shoe adapter comprising a plurality of circumferentially spaced apart
meshing
teeth at one end, an internal flange, and a torsional coupling at another end;
a lower retaining sleeve coupled to an end of the float shoe adapter
comprising an
internal flange for pivotally engaging the lower expansion cone segments; and
a retaining sleeve received within the float shoe adapter releasably coupled
to the
upper tubular support member.
7. The apparatus of claim 6, wherein an end of the retaining sleeve abuts an
end of the tubular
base of the lower cam assembly.
8. The apparatus of claim 6, wherein the tubular base of the lower cam
assembly comprises a
plurality of circumferentially spaced apart meshing teeth for engaging the
meshing teeth of the float
shoe adaptor.
9. The apparatus of claim 6, further comprising:
a float shoe releasably coupled to the torsional coupling of the float shoe
adaptor; and
27



an expandable tubular member coupled to the float shoe and supported by and
movably coupled to the upper and lower expansion cone segments.
10. The apparatus of claim 1, further comprising:
one or more shear pins coupled between the upper tubular support member and
the
lower tubular support member.
11. The apparatus of claim 1, further comprising:
a stop member coupled to the upper tubular support member for limiting
movement
of the upper tubular support member relative to the lower tubular support
member.
12. The apparatus of claim 1, further comprising:
a float shoe releasably coupled to the lower tubular support member that
defines a
valveable passage; and
an expandable tubular member coupled to the float shoe and supported by and
movably coupled to the upper and lower expansion cone segments.
13. The apparatus of claim 1, wherein each upper expansion cone segment
comprises:
an inner portion defining an arcuate cylindrical upper surface including a
hinge
groove for pivotally coupling the upper expansion cone segment to the upper
tubular
support member and arcuate cylindrical lower surfaces;
an intermediate portion defining arcuate cylindrical and spherical upper
surfaces and
an arcuate conical lower surface; and
an outer portion defining arcuate cylindrical upper and lower surfaces; and
wherein each lower expansion cone segment comprises:
an inner portion defining an arcuate cylindrical upper surface including a
hinge
groove for pivotally coupling the lower expansion cone segment to the lower
tubular
support member and arcuate cylindrical lower surfaces;
an intermediate portion defining arcuate cylindrical and spherical upper
surfaces and
an arcuate conical lower surface; and
an outer portion defining arcuate cylindrical upper and lower surfaces.
14. The apparatus of claim 13, wherein each upper expansion cone segment is
tapered in the
longitudinal direction from the intermediate portion to the outer portion; and
wherein each lower
expansion cone segment is tapered in the longitudinal direction from the
intermediate portion to the
outer portion.
28



15. The apparatus of claim 1, wherein each of the one or more cup seals
comprise:
a sealing cup comprising
a substantially unrestricted lip for sealing engaging the expandable tubular
member,
and
a base portion for sealingly engaging the tubular support member,
a protecting member positioned longitudinally along the tubular support
member, and
a conical bushing positioned partially between the sealing cup and the tubular
support
member for supporting the base portion of the sealing cup.
16. The apparatus of claim 15 further comprising a pliant backup member
positioned between the
protecting member and the sealing cup.
17. The apparatus of claim 16 wherein the pliant backup member is made from a
material
selected from the group consisting of fluropolymer, fluoroelastomer, Telflon,
or PEEK.
18. The apparatus of claim 15 further comprising a restraining member
surrounding the base
portion of the sealing cup for restraining the sealing cup.
19. The apparatus of claim 15 wherein the protecting member is a thimble
surrounding the base
portion of the sealing cup.
20. The apparatus of claim 19 wherein the sealing cup further comprises an
unsupported portion
between the thimble and a point of engagement with the expandable tubular
member, and a means for
reducing the unsupported portion of the sealing cup.
21. An apparatus for radially expanding and plastically deforming an
expandable tubular member,
comprising:
a safety collar;
a torque plate coupled to the safety collar comprising a plurality of
circumferentially spaced
apart meshing teeth at an end;
an upper mandrel comprising a plurality of circumferentially spaced apart
meshing teeth at
one end for engaging the meshing teeth of the torque plate and an external
flange at
another end;
a lower mandrel coupled to the external flange of the upper mandrel comprising
an external
flange comprising a plurality of circumferentially spaced apart meshing teeth;
a stop nut coupled to an end of the lower mandrel;
an upper retaining sleeve coupled to the lower mandrel comprising an internal
flange;



29




one or more cup seals coupled to the upper mandrel for sealing an interface
between the upper
mandrel and the expandable tubular member;
an upper cam assembly coupled to the lower mandrel comprising:
a tubular base comprising a plurality of circumferentially spaced apart
meshing teeth
for engaging the meshing teeth of the external flange of the lower mandrel;
and
a plurality of cam arms extending from the tubular base in a downward
longitudinal
direction, each cam arm defining an inclined surface;
a plurality of upper expansion cone segments interleaved with the cam arms of
the upper cam
assembly and pivotally coupled to the internal flange of the upper retaining
sleeve;
a float shoe adapter comprising a plurality of circumferentially spaced apart
meshing teeth at
one end, an internal flange, and a torsional coupling at another end;
a lower retaining sleeve coupled to an end of the float shoe adapter
comprising an internal
flange;
a retaining sleeve received within the float shoe adapter;
one or more shear pins for releasably coupling the retaining sleeve to the
stop nut;
a lower cam assembly coupled to the float shoe adapter comprising:
a tubular base comprising a plurality of circumferentially spaced apart
meshing teeth
for engaging the meshing teeth of the float shoe adapter; and
a plurality of cam arms extending from the tubular base in an upward
longitudinal
direction, each cam arm defining an inclined surface that mates with the
inclined surface of a corresponding one of the upper expansion cone
segments;
wherein the cams arms of the upper cam assembly are interleaved with and
overlap
the cam arms of the lower cam assembly;
a plurality of lower expansion cone segments interleaved with cam arms of the
lower cam
assembly, each lower expansion cone segment pivotally coupled to the internal
flange
of the lower retaining sleeve and mating with the inclined surface of a
corresponding
one of the cam arms of the upper cam assembly;
a float shoe releasably coupled to the torsional coupling of the float shoe
adaptor; and
an expandable tubular member coupled to the float shoe and supported by and
movably
coupled to the upper and lower expansion cone segments;
wherein the lower expansion cone segments interleave and overlap the upper
expansion cone
segments;
wherein the upper and lower expansion cone segments together define an arcuate
spherical
external surface for plastically deforming and radially expanding the
expandable
tubular member;



30


wherein each upper expansion cone segment comprises:
an inner portion defining an arcuate cylindrical upper surface including a
hinge
groove for pivotally coupling the upper expansion cone segment to the upper
tubular
support member and arcuate cylindrical lower surfaces;
an intermediate portion defining arcuate cylindrical and spherical upper
surfaces and
an arcuate conical lower surface; and
an outer portion defining arcuate cylindrical upper and lower surfaces;
wherein each lower expansion cone segment comprises:
an inner portion defining an arcuate cylindrical upper surface including a
hinge
groove for pivotally coupling the lower expansion cone segment to the lower
tubular
support member and arcuate cylindrical lower surfaces;
an intermediate portion defining arcuate cylindrical and spherical upper
surfaces and
an arcuate conical lower surface; and
an outer portion defining arcuate cylindrical upper and lower surfaces;
wherein each upper expansion cone segment is tapered in the longitudinal
direction from the
intermediate portion to the outer portion; and
wherein each lower expansion cone segment is tapered in the longitudinal
direction from the
intermediate portion to the outer portion.
22. A collapsible expansion cone assembly comprising:
an upper tubular support member comprising an internal flange;
an upper cam assembly coupled to the upper tubular support member comprising:
a tubular base coupled to the upper support member; and
a plurality of cam arms extending from the tubular base in a downward
longitudinal
direction, each cam arm defining an inclined surface;
a plurality of upper expansion cone segments interleaved with the cam arms of
the upper cam
assembly and pivotally coupled to the internal flange of the upper tubular
support
member;
a lower tubular support member comprising an internal flange;
one or more frangible couplings for releasably coupling the upper and lower
tubular support
members;
a lower cam assembly coupled to the lower tubular support member comprising:
a tubular base coupled to the lower tubular support member; and
a plurality of cam arms extending from the tubular base in an upward
longitudinal
direction, each cam arm defining an inclined surface that mates with the
inclined surface of a corresponding one of the upper expansion cone
segments;



31




wherein the cams arms of the upper cam assembly are interleaved with and
overlap
the cam arms of the lower cam assembly; and
a plurality of lower expansion cone segments interleaved with cam arms of the
lower cam
assembly, each lower expansion cone segment pivotally coupled to the internal
flange
of the lower tubular support member and mating with the inclined surface of a
corresponding one of the cam arms of the upper cam assembly;
wherein the lower expansion cone segments interleave and overlap the upper
expansion cone
segments; and
wherein the upper and lower expansion cone segments together define an arcuate
spherical
external surface for plastically deforming and radially expanding the
expandable
tubular member.
23. The assembly of claim 22, wherein each upper expansion cone segment
comprises:
an inner portion defining an arcuate cylindrical upper surface including a
hinge
groove for pivotally coupling the upper expansion cone segment to the upper
tubular support member and arcuate cylindrical lower surfaces;
an intermediate portion defining arcuate cylindrical and spherical upper
surfaces and
an arcuate conical lower surface; and
an outer portion defining arcuate cylindrical upper and lower surfaces; and
wherein each lower expansion cone segment comprises:
an inner portion defining an arcuate cylindrical upper surface including a
hinge
groove for pivotally coupling the lower expansion cone segment to the lower
tubular support member and arcuate cylindrical lower surfaces;
an intermediate portion defining arcuate cylindrical and spherical upper
surfaces and
an arcuate conical lower surface; and
an outer portion defining arcuate cylindrical upper and lower surfaces.
24. The assembly of claim 22, wherein each upper expansion cone segment is
tapered in the
longitudinal direction from the intermediate portion to the outer portion; and
wherein each lower expansion cone segment is tapered in the longitudinal
direction from the
intermediate portion to the outer portion.
25. A collapsible expansion cone assembly, comprising:
an upper tubular support member comprising an internal flange;
an upper cam assembly coupled to the upper tubular support member comprising:
a tubular base coupled to the upper support member; and



32




a plurality of cam arms extending from the tubular base in a downward
longitudinal
direction, each cam arm defining an inclined surface;
a plurality of upper expansion cone segments interleaved with the cam arms of
the upper cam
assembly and pivotally coupled to the internal flange of the upper tubular
support
member;
a lower tubular support member comprising an internal flange;
one or more frangible couplings for releasably coupling the upper and lower
tubular support
members;
a lower cam assembly coupled to the lower tubular support member comprising:
a tubular base coupled to the lower tubular support member; and
a plurality of cam arms extending from the tubular base in an upward
longitudinal
direction, each cam arm defining an inclined surface that mates with the
inclined surface of a corresponding one of the upper expansion cone
segments;
wherein the cams arms of the upper cam assembly are interleaved with and
overlap
the cam arms of the lower cam assembly; and
a plurality of lower expansion cone segments interleaved with cam arms of the
lower cam
assembly, each lower expansion cone segment pivotally coupled to the internal
flange
of the lower tubular support member and mating with the inclined surface of a
corresponding one of the cam arms of the upper cam assembly;
wherein the lower expansion cone segments interleave and overlap the upper
expansion cone
segments;
wherein the upper and lower expansion cone segments together define an arcuate
spherical
external surface for plastically deforming and radially expanding the
expandable
tubular member;
wherein each upper expansion cone segment comprises:
an inner portion defining an arcuate cylindrical upper surface including a
hinge
groove for pivotally coupling the upper expansion cone segment to the upper
tubular support member and arcuate cylindrical lower surfaces;
an intermediate portion defining arcuate cylindrical and spherical upper
surfaces and
an arcuate conical lower surface; and
an outer portion defining arcuate cylindrical upper and lower surfaces;
wherein each lower expansion cone segment comprises:
an inner portion defining an arcuate cylindrical upper surface including a
hinge
groove for pivotally coupling the lower expansion cone segment to the lower
tubular support member and arcuate cylindrical lower surfaces;



33




CLAIMS


an intermediate portion defining arcuate cylindrical and spherical upper
surfaces and
an arcuate conical lower surface; and
an outer portion defining arcuate cylindrical upper and lower surfaces;
wherein each upper expansion cone segment is tapered in the longitudinal
direction-from the
intermediate portion to the outer portion; and
wherein each lower expansion cone segment is tapered in the longitudinal
direction from the
intermediate portion to the outer portion.
26. An apparatus for radially expanding and plastically deforming an
expandable tubular member,
comprising:
a tubular support member;
a collapsible expansion cone coupled to the tubular support member;
an expandable tubular member coupled to the collapsible expansion cone;
means for displacing the collapsible expansion cone relative to the expandable
tubular
member using fluid pressure; and
means for collapsing the expansion cone.
27. The apparatus of claim 26, wherein the tubular support member comprises an
upper tubular
support member comprising an internal flange and a lower tubular support
member comprising an
internal flange; wherein the expansion cone comprises:
an upper cam assembly coupled to the upper tubular support member comprising:
a tubular base coupled to the upper support member; and
a plurality of cam arms extending from the tubular base in a downward
longitudinal
direction, each cam arm defining an inclined surface;
a plurality of upper expansion cone segments interleaved with the cam arms of
the upper cam
assembly and pivotally coupled to the internal flange of the upper tubular
support
member;
a lower cam assembly coupled to the lower tubular support member comprising:
a tubular base coupled to the lower tubular support member; and
a plurality of cam arms extending from the tubular base in an upward
longitudinal
direction, each cam arm defining an inclined surface that mates with the
inclined surface of a corresponding one of the upper expansion cone
segments;
wherein the cams arms of the upper cam assembly are interleaved with and
overlap
the cam arms of the lower cam assembly; and
a plurality of lower expansion cone segments interleaved with cam arms of the
lower cam
assembly, each lower expansion cone segment pivotally coupled to the internal
flange



39


of the lower tubular support member and mating with the inclined surface of a
corresponding one of the cam arms of the upper cam assembly; and wherein the
apparatus further comprises:
means for releasably coupling the upper tubular support member to the lower
tubular support
member; and
means for limiting movement of the upper tubular support member relative to
the lower
tubular support member.
28. The apparatus of claim 26, further comprising:
means for pivoting the upper expansion cone segments; and
means for pivoting the lower expansion cone segments.
29. The apparatus of claim 26, further comprising:
means for pulling the collapsible expansion cone through the expandable
tubular
member using fluid pressure.
30. A collapsible expansion cone, comprising:
an upper cam assembly comprising:
a tubular base; and
a plurality of cam arms extending from the tubular base in a downward
longitudinal
direction, each cam arm defining an inclined surface;
a plurality of upper expansion cone segments interleaved with the cam arms of
the upper cam
assembly;
a lower cam assembly comprising:
a tubular base; and
a plurality of cam arms extending from the tubular base in an upward
longitudinal
direction, each cam arm defining an inclined surface that mates with the
inclined surface of a corresponding one of the upper expansion cone
segments;
wherein the cams arms of the upper cam assembly are interleaved with and
overlap
the cam arms of the lower cam assembly;
a plurality of lower expansion cone segments interleaved with cam arms of the
lower cam
assembly, each lower expansion cone segment mating with the inclined surface
of a
corresponding one of the cam arms of the upper cam assembly;
means for moving the upper cam assembly away from the lower expansion cone
segments;
and
means for moving the lower cam assembly away from the upper expansion cone
segments.

40



31. The apparatus of claim 30, wherein the upper and lower expansion cone
segments together
define an arcuate spherical external surface.
32. The apparatus of claim 30, wherein each upper expansion cone segment
comprises:
an inner portion defining an arcuate cylindrical upper surface and arcuate
cylindrical
lower surfaces;
an intermediate portion defining arcuate cylindrical and spherical upper
surfaces and
an arcuate conical lower surface; and
an outer portion defining arcuate cylindrical upper and lower surfaces; and
wherein each lower expansion cone segment comprises:
an inner portion defining an arcuate cylindrical upper surface and arcuate
cylindrical
lower surfaces;
an intermediate portion defining arcuate cylindrical and spherical upper
surfaces and
an arcuate conical lower surface; and
an outer portion defining arcuate cylindrical upper and lower surfaces.
33. The apparatus of claim 30, wherein each upper expansion cone segment is
tapered in the
longitudinal direction from the intermediate portion to the outer portion; and
wherein each lower expansion cone segment is tapered in the longitudinal
direction from the
intermediate portion to the outer portion.
34. A packer cup apparatus comprising:
a central mandrel,
a sealing cup comprising
a substantially unrestricted tip for sealing engaging a tubular member, and
a base portion for sealingly engaging the central mandrel,
a protecting member positioned longitudinally along the central mandrel,
a pliant backup member positioned between the protecting member and the
sealing cup,
a conical bushing positioned partially between the sealing cup and the central
mandrel for
supporting the base portion of the sealing cup.
35. The apparatus of claim 34 wherein the pliant backup member is made from a
material
selected from the group consisting of fluropolymer, fluoroelastomer, Telflon,
or PEEK.
36. The apparatus of claim 34 further comprising a restraining member
surrounding the base
portion of the sealing cup for restraining the sealing cup.

41



37. The apparatus of claim 34 wherein the protecting member is a thimble
surrounding the base
portion of the sealing cup.
38. The apparatus of claim 37 wherein the sealing cup further comprises an
unsupported portion
between the thimble and a point of engagement with the expandable tubular
member, and a means for
reducing the unsupported portion of the sealing cup.
39. A method of radially expanding and plastically deforming an expandable
tubular member,
comprising:
supporting the expandable tubular member using a tubular support member and a
collapsible
expansion cone;
injecting a fluidic material into the tubular support member;
sensing the operating pressure of the injected fluidic material within a first
interior portion of
the tubular support member;
displacing the collapsible expansion cone relative to the expandable tubular
member when the
sensed operating pressure of the injected fluidic material exceeds a
predetermined
level within the first interior portion of the tubular support member;
sensing the operating pressure of the injected fluidic material within a
second interior portion
of the tubular support member; and
collapsing the collapsible expansion cone when the sensed operating pressure
of the injected
fluidic material exceeds a predetermined level within the second interior
portion of
the tubular support member.
40. The method of claim 39, further comprising:
pulling the collapsible expansion cone through the expandable tubular member
when the
sensed operating pressure of the infected fluidic material exceeds a
predetermined
level within the first interior portion of the tubular support member.
41. The method of claim 40, wherein pulling the collapsible expansion cone
through the
expandable tubular member comprises:
coupling one or more cup seals to the tubular support member above the
collapsible
expansion cone;
pressuring the interior of the expandable tubular member below the cup seals;
and
pulling the collapsible expansion cone through the expandable tubular member
using the cup
seals.

42


42. The method of claim 39, wherein the tubular support member comprises an
upper tubular
support member and a lower tubular support member; and wherein collapsing the
collapsible expansion cone comprises displacing the upper tubular member
relative to
the lower tubular support member.
43. The method of claim 42, wherein the collapsible expansion cone comprises:
an upper cam assembly comprising:
a tubular base; and
a plurality of cam arms extending from the tubular base in a downward
longitudinal direction,
each cam arm defining an inclined surface;
a plurality of upper expansion cone segments interleaved with the cam arms of
the upper cam
assembly and pivotally coupled to the upper tubular support member;
a lower cam assembly comprising:
a tubular base; and
a plurality of cam arms extending from the tubular base in an upward
longitudinal direction,
each cam arm defining an inclined surface that mates with the inclined surface
of a
corresponding one of the upper expansion cone segments;
wherein the cams arms of the upper cam assembly are interleaved with and
overlap the cam
arms of the lower cam assembly; and
a plurality of lower expansion cone segments interleaved with cam arms of the
lower cam assembly,
each lower expansion cone segment pivotally coupled to the lower tubular
support member
and mating with the inclined surface of a corresponding one of the cam arms of
the upper cam
assembly.
44. An apparatus for radially expanding and plastically deforming an
expandable tubular member,
comprising:
a tubular support member;
a collapsible expansion device coupled to the tubular support member;
an expandable tubular member coupled to the collapsible expansion cone;
means for displacing the collapsible expansion device relative to the
expandable tubular
member using fluid pressure; and
means for collapsing the expansion cone.
45. The apparatus of claim 44, further comprising:
means for pulling the collapsible expansion device through the expandable
tubular member
using fluid pressure.

43



46. A method of radially expanding and plastically deforming an expandable
tubular member,
comprising:
supporting the expandable tubular member using a tubular support member and a
collapsible
expansion device;
injecting a fluidic material into the tubular support member;
sensing the operating pressure of the injected fluidic material within a first
interior portion of
the tubular support member;
displacing the collapsible expansion device relative to the expandable tubular
member when
the sensed operating pressure of the injected fluidic material exceeds a
predetermined
level within the first interior portion of the tubular support member;
sensing the operating pressure of the injected fluidic material within a
second interior portion
of the tubular support member; and
collapsing the collapsible expansion device when the sensed operating pressure
of the injected
fluidic material exceeds a predetermined level within the second interior
portion of
the tubular support member.
47. The method of claim 46, further comprising:
pulling the collapsible expansion device through the expandable tubular member
when the
sensed operating pressure of the injected fluidic material exceeds a
predetermined
level within the first interior portion of the tubular support member.
48. The method of claim 47, wherein pulling the collapsible expansion device
through the
expandable tubular member comprises:
coupling one or more cup seals to the tubular support member above the
collapsible
expansion device;
pressuring the interior of the expandable tubular member below the cup seals;
and
pulling the collapsible expansion device through the expandable tubular member
using the
cup seals.
49. The method of claim 46, wherein the tubular support member comprises an
upper tubular
support member and a lower tubular support member; and wherein collapsing the
collapsible
expansion device comprises displacing the upper tubular member relative to the
lower tubular support
member.

44


Description

Note: Descriptions are shown in the official language in which they were submitted.




CA 02489283 2004-12-10
WO 03/106130 PCT/US03/18530
COLLAPSIBLE EXPANSION CONE
Cross Reference To Related Applications
[001] The present application claims the benefit of the filing dates of (1)
U.S. provisional patent
application serial no. 60/387,961, attorney docket no 25791.108, filed on
6/12/2002, which is a
continuation-in-part of U.S. provisional patent application serial no.
60/363,829, attorney docket no.
25791.95, filed on 3/12/2002, the disclosures of which are incorporated herein
by reference.
[002] The present application is related to the following: ( 1 ) U.S. patent
application serial no.
09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, (2) U.S.
patent application serial no.
09/510,913, attorney docket no. 25791.7.02, filed on 2/23/2000, (3) U.S.
patent application serial no.
09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, (4) U.S.
patent application serial no.
09/440,338, attorney docket no. 25791.9.02, filed on 11/15/1999, (5) U.S.
patent application serial no.
09/523,460, attorney docket no. 25791.11.02, filed on 3/10/2000, (6) U.S.
patent application serial no.
09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, (7) U.S.
patent application serial no.
09/511,941, attorney docket no. 25791.16.02, filed on 2/24/2000, (8) U.S.
patent application serial no.
09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, (9) U.S.
patent application serial no.
09/559,122, attorney docket no. 25791.23.02, filed on 4/26/2000, (10) PCT
patent application serial
no. PCT/US00/18635, attorney docket no. 25791.25.02, filed on 7/9/2000, (11)
U.S. provisional
patent application serial no. 60/162,671, attorney docket no. 25791.27, filed
on 11/1/1999, (12) U.S.
provisional patent application serial no. 60/154,047, attorney docket no.
25791.29, filed on 9/16/1999,
(13) U.S. provisional patent application serial no. 60/159,082, attorney
docket no. 25791.34, filed on
10/12/1999, (14) U.S. provisional patent application serial no. 60/159,039,
attorney docket no.
25791.36, filed on 10/12/1999, (15) U.S. provisional patent application serial
no. 60/159,033, attorney
docket no. 25791.37, filed on 10/12/1999, (16) U.S. provisional patent
application serial no.
60/212,359, attorney docket no. 25791.38, filed on 6/19/2000, (17) U.S.
provisional patent application
serial no. 60/165,228, attorney docket no. 25791.39, filed on 11/12/1999, (18)
U.S. provisional patent
application serial no. 60/221,443, attorney docket no. 25791.45, filed on
7/28/2000, (19) U.S.
provisional patent application serial no. 60/221,645, attorney docket no.
25791.46, filed on 7/28/2000,
(20) U.S. provisional patent application serial no. 60/233,638, attorney
docket no. 25791.47, filed on
9/18/2000, (21) U.S. provisional patent application serial no. 60/237,334,
attorney docket no.
25791.48, filed on 10/2/2000, (22) U.S. provisional patent application serial
no. 60/270,007, attorney
docket no. 25791.50, filed on 2/20/2001, (23) U.S. provisional patent
application serial no.
60/262,434, attorney docket no. 25791.51, filed on 1/17/2001, (24) U.S.
provisional patent application
serial no. 60/259,486, attorney docket no. 25791.52, filed on 1/3/2001, (25)
U.S. provisional patent
application serial no. 60/303,740, attorney docket no. 25791.61, filed on
7/6/2001, (26) U.S.
provisional patent application serial no. 60/313,453, attorney docket no.
25791.59, filed on 8/20/2001,
(27) U.S. provisional patent application serial no. 60/317,985, attorney
docket no. 25791.67, filed on
9/6/2001, (28) U.S. provisional patent application serial no. 60/3318,386,
attorney docket no.
1



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25791.67.02, filed on 9/10/2001, (29) U.S. utility patent application serial
no. 09/969,922, attorney
docket no. 25791.69, filed on 10/3/2001, (30) U.S. utility patent application
serial no. 10/016,467,
attorney docket no. 25791.70, filed on 12/10/2001; (31) U.S. provisional
patent application serial no.
60/343,674, attorney docket no. 25791.68, filed on 12/27/2001; (32) U.S.
provisional patent
application serial no. 60/346,309, attorney docket no. 25791.92, filed on
1/7/2002; (33) U.S.
provisional patent application serial no. 60/372,048, attorney docket no.
25791.93, filed on 4/12/2002;
(34) U.S. provisional patent application serial no. 60/363,829, attorney
docket no. 25791.95, filed on
3/13/2002; (35) U.S. provisional patent application serial no. 60/372,632,
attorney docket no.
25791.101, filed on 4/15/2002; (36) U.S. provisional patent application serial
no. 60/380,147, attorney
docket no. 25791.104, filed on 5/6/2002; and (37) U.S. provisional patent
application serial no.
60/387,486, attorney docket no. 25791.107, filed on 6/10/2002, the disclosures
of which are
incorporated herein by reference.
Background Of The Invention
[003] This invention relates generally to oil and gas exploration, and in
particular to forming and
repairing wellbore casings to facilitate oil and gas exploration.
[004] 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.
[005] The present invention is directed to overcoming one or more of the
limitations of the existing
procedures for forming new sections of casing in a wellbore.
Summary of the Invention
[006] According to one aspect of the present invention, an apparatus for
radially expanding and
plastically deforming an expandable tubular member is provided that includes
an upper tubular
support member defining a first passage, one or more cup seals coupled to the
exterior surface of the
upper tubular support member for sealing an interface between the upper
tubular support member and
the expandable tubular member, an upper cam assembly coupled to the upper
tubular support member
2



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comprising: a tubular base coupled to the upper tubular support member, and a
plurality of cam arms
extending from the tubular base in a downward longitudinal direction, each cam
arm defining an
inclined surface, a plurality of upper expansion cone segments interleaved
with the cam arms of the
upper cam assembly and pivotally coupled to the tubular support member, a
lower tubular support
member defining a second passage fluidicly coupled to the first passage
releasably coupled to the
upper tubular support member, and a lower cam assembly coupled to the lower
tubular support
member comprising: a tubular base coupled to the lower tubular support member,
and a plurality of
cam arms extending from the tubular base in an upward longitudinal direction,
each cam arm defining
an inclined surface that mates with the inclined surface of a corresponding
one of the upper expansion
cone segments, wherein the cams arms of the upper cam assembly are interleaved
with and overlap
the cam arms of the lower cam assembly, a plurality of lower expansion cone
segments interleaved
with cam arms of the lower cam assembly, each lower expansion cone segment
pivotally coupled to
the lower tubular support member and mating with the inclined surface of a
corresponding one of the
cam arms of the upper cam assembly, wherein the lower expansion cone segments
interleave and
overlap the upper expansion cone segments, and wherein the upper and lower
expansion cone
segments together define an arcuate spherical external surface for plastically
deforming and radially
expanding the expandable tubular member.
[007] According to another aspect of the present invention, a collapsible
expansion cone assembly
is provided that includes an upper tubular support member comprising an
internal flange, an upper
cam assembly coupled to the upper tubular support member comprising: a tubular
base coupled to the
upper support member, and a plurality of cam arms extending from the tubular
base in a downward
longitudinal direction, each cam arm defining an inclined surface, a plurality
of upper expansion cone
segments interleaved with the cam arms of the upper cam assembly and pivotally
coupled to the
internal flange of the upper tubular support member, a lower tubular support
member comprising an
internal flange, one or more frangible couplings for releasably coupling the
upper and lower tubular
support members, a lower cam assembly coupled to the lower tubular support
member comprising: a
tubular base coupled to the lower tubular support member, and a plurality of
cam arms extending from
the tubular base in an upward longitudinal direction, each cam arm defining an
inclined surface that
mates with the inclined surface of a corresponding one of the upper expansion
cone segments,
wherein the cams arms of the upper cam assembly are interleaved with and
overlap the cam arms of
the lower cam assembly, and a plurality of lower expansion cone segments
interleaved with cam arms
of the lower cam assembly, each lower expansion cone segment pivotally coupled
to the internal
flange of the lower tubular support member and mating with the inclined
surface of a corresponding
one of the cam arms of the upper cam assembly, wherein the lower expansion
cone segments
interleave and overlap the upper expansion cone segments, and wherein the
upper and lower
expansion cone segments together define an arcuate spherical external surface
for plastically
deforming and radially expanding the expandable tubular member.
3



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[008] According to another aspect of the present invention, an apparatus for
radially expanding and
plastically deforming an expandable tubular member is provided that includes a
tubular support
member, a collapsible expansion cone coupled to the tubular support member, an
expandable tubular
member coupled to the collapsible expansion cone, means for displacing the
collapsible expansion
cone relative to the expandable tubular member, and means for collapsing the
expansion cone.
[009] According to another aspect of the present invention, a collapsible
expansion cone is provided
that includes an upper cam assembly comprising: a tubular base, and a
plurality of cam arms
extending from the tubular base in a downward longitudinal direction, each cam
arm defining an
inclined surface, a plurality of upper expansion cone segments interleaved
with the cam arms of the
upper cam assembly, a lower cam assembly comprising: a tubular base, and a
plurality of cam arms
extending from the tubular base in an upward longitudinal direction, each cam
arm defining an
inclined surface that mates with the inclined surface of a corresponding one
of the upper expansion
cone segments, wherein the cams arms of the upper cam assembly are interleaved
with and overlap
the cam arms of the lower cam assembly, a plurality of lower expansion cone
segments interleaved
with cam arms of the lower cam assembly, each lower expansion cone segment
mating with the
inclined surface of a corresponding one of the cam arms of the upper cam
assembly, means for
moving the upper cam assembly away from the lower expansion cone segments, and
means for
moving the lower cam assembly away from the upper expansion cone segments.
[0010] According to another aspect of the invention, an apparatus for radially
expanding and
plastically deforming an expandable tubular member is provided that includes a
tubular support
member, a collapsible expansion cone coupled to the tubular support member, an
expandable tubular
member coupled to the collapsible expansion cone, means for displacing the
collapsible expansion
cone relative to the expandable tubular member, and means for collapsing the
expansion cone.
[0011] According to another aspect of the invention, a collapsible expansion
cone is provided that
includes an upper cam assembly comprising: a tubular base, and a plurality of
cam arms extending
from the tubular base in a downward longitudinal direction, each cam arm
defining an inclined
surface, a plurality of upper expansion cone segments interleaved with the cam
arms of the upper cam
assembly, a lower cam assembly comprising: a tubular base, and a plurality of
cam arms extending
from the tubular base in an upward longitudinal direction, each cam arm
defining an inclined surface
that mates with the inclined surface of a corresponding one of the upper
expansion cone segments,
wherein the cams arms of the upper cam assembly are interleaved with and
overlap the cam arms of
the lower cam assembly, a plurality of lower expansion cone segments
interleaved with cam arms of
the lower cam assembly, each lower expansion cone segment mating with the
inclined surface of a
corresponding one of the cam arms of the upper cam assembly, means for moving
the upper cam
assembly away from the lower expansion cone segments, and means for moving the
lower cam
assembly away from the upper expansion cone segments.
4



CA 02489283 2004-12-10
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[0012] According to another aspect of the invention, a method of radially
expanding and plastically
deforming an expandable tubular member is provided that includes supporting
the expandable tubular
member using a tubular support member and a collapsible expansion cone,
injecting a fluidic material
into the tubular support member, sensing the operating pressure of the
injected fluidic material within
a first interior portion of the tubular support member, displacing the
collapsible expansion cone
relative to the expandable tubular member when the sensed operating pressure
of the injected fluidic
material exceeds a predetermined level within the first interior portion of
the tubular support member,
sensing the operating pressure of the injected fluidic material within a
second interior portion of the
tubular support member, and collapsing the collapsible expansion cone when the
sensed operating
pressure of the injected fluidic material exceeds a predetermined level within
the second interior
portion of the tubular support member.
Brief Description of the Drawings
[0013] Fig. la is a fragmentary cross-sectional illustration of the placement
of a portion of an
exemplary embodiment of an apparatus for radially expanding and plastically
deforming a tubular
member that includes a collapsible expansion cone within a preexisting
structure.
[0014] Fig. 1 b is a fragmentary cross-sectional illustration of another
portion of the apparatus of Fig.
1 a.
[0015] Figs. 2a and 26 are fragmentary cross-sectional illustration of a
portion of the apparatus of
Figs. 1 a and 1 b.
[0016] Fig. 3 is a fragmentary cross-sectional illustration of a portion of
the apparatus of Figs. 1 a and
lb.
[0017] Fig. 3a is a fragmentary cross-sectional illustration of a portion of
the apparatus of Fig 3.
[0018] Fig. 3b is a fragmentary cross-sectional illustration of a portion of
the apparatus of Fig 3.
[0019] Fig. 4 is a fragmentary cross-sectional illustration of a portion of
the apparatus of Figs. 1 a and
I b.
[0020] Fig. 4a is a fragmentary cross-sectional illustration of a portion of
the apparatus of Fig 4.
[0021] Fig. 5 is a fragmentary cross-sectional illustration of a portion of
the apparatus of Figs. 1 a and
1 b.
[0022] Fig. 6 is a fragmentary cross-sectional illustration of a portion of
the apparatus of Figs. 1 a and
1 b.
[0023] Figs. 7a-7e are fragmentary cross-sectional and perspective
illustrations of the upper cam
assembly of the apparatus of Figs. 1 a and 1 b.
[0024] Fig. 7f is a fragmentary cross-sectional illustration of the lower cam
assembly of the
apparatus of Figs. 1 a and 1 b.
[0025] Figs. 8a-8d are fragmentary cross-sectional and perspective
illustrations of one of the upper
cone segments of the apparatus of Figs. 1 a and 1 b.



CA 02489283 2004-12-10
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[0026] Fig. 8e is a fragmentary cross-sectional illustration of one of the
lower cone segments of the
apparatus of Figs. 1 a and 1 b.
[0027] Fig. 9 is a side view of a portion of the apparatus of Figs. 1 a and 1
b.
[0028] Fig. l0a is a fragmentary cross sectional illustration of a portion of
the apparatus of Figs. 1 a
and 1 b during the radial expansion of the expandable tubular member.
[0029] Fig. l Ob is a fragmentary cross sectional illustration of another
portion of the apparatus of
Fig. 10a.
[0030] Fig. 11 a. is a fragmentary cross sectional illustration of a portion
of the apparatus of Figs. l0a
and l Ob during the adjustment of the expansion cone to a collapsed position.
[0031] Fig. 11 b is a fragmentary cross sectional illustration of another
portion of the apparatus of
Fig. l la.
[0032] Fig. 12 is a fragmentary cross sectional illustration of a portion of
the apparatus of Figs. 11 a
and 11 b.
[0033] Fig. 13 is a fragmentary cross sectional illustration of a portion of
the apparatus of Figs. 11 a
and 11 b.
[0034] FIG. 14 is a fragmentary cross sectional illustration of a portion of
the apparatus of Figs. 11 a
and 11 b with the expansion cone in a half collapsed position.
[0035] F1G. 15 is a fragmentary cross sectional illustration of a portion of
the apparatus of Figs. 11 a
and 11 b with the expansion cone in a fully collapsed position.
[0036] Fig. 16 is a side view of a portion of the apparatus of Figs. l0a and 1
Ob.
[0037] Fig. 17a. is a fragmentary cross sectional illustration of a portion of
the apparatus of Figs. 1 la
and 11 b after the removal of the apparatus from interior of the expandable
tubular member.
[0038] Fig. 17b is a fragmentary cross sectional illustration of another
portion of the apparatus of
Fig. 17a.
[0039] Fig. 18 is a fragmentary cross sectional illustration of a cup seal.
[0040] Fig. 19a is a fragmentary cross sectional illustration of an
alternative embodiment of a cup
seal.
[0041] Fig. 19b is a fragmentary cross sectional illustration of an
alternative embodiment of a cup
seal.
[0042] Fig. 19c is a fragmentary cross sectional illustration of an
alternative embodiment of a cup
seal.
[0043] Fig. 19d is a fragmentary cross sectional illustration of an
alternative embodiment of a cup
seal.
[0044] Fig. 19e is a fragmentary cross sectional illustration of an
alternative embodiment of a cup
seal.
Detailed Description of the Illustrative Embodiments
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[0045] Referring to Figs. la, lb, 2a, 2b, 3, 3a, 4, 4a, 5, 6, 7a, 7b, 7c, 7d,
7e, 7f, 8a, 8b, 8c, 8d, 8e, and
9, an exemplary embodiment of an apparatus 10 for radially expanding and
plastically deforming a
tubular member includes a tubular support member 12 that defines a passage
12a. An end of the
tubular support member 12 is coupled to an end of a safety collar 14 that
defines a passage 14a, a
recess 14b at one end for receiving the end of the tubular support member, and
recesses 14c and 14d
at another end.
[0046] A torque plate I 6 is received within and is coupled to the recess 14c
of the safety collar 14
that defines a passage 16a and a plurality of meshing teeth 16b at one end. An
end of an upper
mandrel collar 18 is received with and is coupled to the recess 14d of the
safety collar 14 proximate
and end of the torque plate 16 that defines a passage 18a. Torque pins 20a and
20b further couple the
end of the upper mandrel collar 18 to the end of the safety collar 14.
[0047] An end of an upper mandrel 22 is received within and is coupled to the
upper mandrel collar
18 that defines a passage 22a, a plurality of meshing teeth 22b that mate with
and transmit torque to
and from the meshing teeth 16b of the torque plate 16, and an external flange
22c at another end.
[0048] An upper cup seal or packer cup 24 mates with, receives and is coupled
to the upper mandrel
22 proximate the end of the upper mandrel collar 18. An upper spacer sleeve 26
mates with, receives,
and is coupled to the upper mandrel 22 proximate an end of the upper packer
cup 24. A lower cup
seal or packer cup 28 mates with, receives and is coupled to the upper mandrel
22 proximate an end of
the upper spacer sleeve 26. In an exemplary embodiment, the packer cups 24 and
28 may be
GuibersonT"' packer cups. One embodiment of a Guiberson packer cup is
discussed in detail below in
reference to Fig. 18. Alternative embodiments of packer cups 24 and 28 are
discussed below in
reference to Figs. 19a-19e.
[0049] Turning back to Fig. 1, a lower spacer sleeve 30 mates with, receives,
and is coupled to the
upper mandrel 22 proximate an end of the lower packer cup 28 and the external
flange 22c of the
upper mandrel. A retaining sleeve 32 mates with, receives, and is coupled to
an end of the lower
spacer sleeve proximate the external flange 22c of the upper mandrel 22.
[0050] An end of a lower mandrel 34 defines a recess 34a that mates with,
receives, and is coupled to
the external flange 22c of the upper mandrel 22, a recess 34b that mates with,
receives, and is coupled
to the end of the upper mandrel, a passage 34c, and an external flange 34d
including circumferentially
spaced apart meshing teeth 34da on an end face of the external flange. Torque
pins 36a and 36b
further couple the recess 34a of the end of the lower mandrel 34 to the
external flange 22c of the
upper mandrel 22. During operation, the torque pins 36a and 36b transmit
torque loads between the
recess 34a of the end of the lower mandrel 34 and the external flange 22c of
the upper mandrel 22.
[0051] An upper cam assembly 38 includes a tubular base 38a for receiving and
mating with the
lower mandrel 34 that includes an external flange 38aa, a plurality of
circumferentially spaced apart
meshing teeth 38b that extend from one end of the tubular base in the
longitudinal and radial
directions for engaging the meshing teeth 34da of the end face of the external
flange 34d of the lower



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mandrel, and a plurality of circumferentially spaced apart cam arms 38c that
extend from the other
end of the tubular base in the opposite longitudinal direction and mate with
and receive the lower
mandrel. During operation, the meshing teeth 34da of the end face of the
external flange 34d of the
lower mandrel 34 transmit torque loads to the meshing teeth 38b of the upper
cam assembly 38.
Each of the cam arms 38c include an inner portion 38ca extending from the
tubular base 38a
that has arcuate cylindrical inner and outer surfaces, 38caa and 38cab, a
tapered intermediate portion
38cb extending from the inner portion that has an arcuate cylindrical inner
surface 38cba and an
arcuate conical outer surface 38cbb, and an outer portion 38cc extending from
the intermediate
portion that has arcuate cylindrical inner and outer surfaces, 38cca and
38ccb. In an exemplary
embodiment, the radius of curvatures of the arcuate outer cylindrical surfaces
38cab are greater than
the radius of curvatures of the arcuate outer cylindrical surfaces 38ccb. In
an exemplary embodiment,
the radius of curvatures of the arcuate inner cylindrical surfaces, 38caa,
38cba, and 38cca are equal.
[0052] A lower cam assembly 40 includes a tubular base 40a for receiving and
mating with the lower
mandrel 34 that includes an external flange 40aa, a plurality of
circumferentially spaced apart
meshing teeth 40b that extend from one end of the tubular base in the
longitudinal and radial
directions, and a plurality of circumferentially spaced apart cam arms 40c
that extend from the other
end of the tubular base in the opposite longitudinal direction and mate with
and receive the lower
mandrel. Each of the cam arms 40c include an inner portion 40ca extending from
the tubular base 40a
that has arcuate cylindrical inner and outer surfaces, 40caa and 40cab, a
tapered intermediate portion
40cb extending from the inner portion 40ca that has an arcuate cylindrical
inner surface 40cba and an
arcuate conical outer surface 40cbb, and an outer portion 40cc extending from
the intermediate
portion that has arcuate cylindrical inner and outer surfaces, 40cca and
40ccb. In an exemplary
embodiment, the radius of curvatures of the arcuate outer cylindrical surfaces
40cab are greater than
the radius of curvatures the arcuate outer cylindrical surfaces 40ccb. In an
exemplary embodiment,
the radius of curvatures of the arcuate inner cylindrical surfaces, 40caa,
40cba, and 40cca are equal.
In an exemplary embodiment, the upper and lower cam assemblies, 38 and 40, are
substantially
identical. In an exemplary embodiment, the cam arms 38c of the upper cam
assembly 38 interleave
the cam arms 40c of the lower cam assembly 40. Furthermore, in an exemplary
embodiment, the cam
arms 38c of the upper cam assembly also overlap with the cam arms 40c of the
lower cam assembly
40 in the longitudinal direction thereby permitting torque loads to be
transmitted between the upper
and lower cam assemblies.
[0053] An end of an upper retaining sleeve 42 receives and is threadably
coupled to the external
flange 34d of the lower mandrel 34 that defines a passage 42a for receiving
and mating with the outer
circumferential surfaces of the external flange 38aa and the meshing teeth 38b
of the upper cam
assembly 38, and an inner annular recess 42b, and includes an internal flange
42c for retaining the
external flange 38aa of the upper cam assembly, and an internal flange 42d at
one end of the upper
retaining sleeve that includes a rounded interior end face. An o-ring seal 44
is received within the



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annular recess 42b for sealing the interface between the upper retaining
sleeve 42 and the external
flange 34d of the lower mandrel 34. A disc shaped shim 43 is positioned within
the upper retaining
sleeve 42 between the opposing end faces of the internal flange 42c of the
retaining sleeve and the
meshing teeth 38b of the upper cam assembly 38.
[0054] A plurality of upper expansion cone segments 44 are interleaved among
the cam arms 38c of
the upper cam assembly 38. Each of the upper expansion cone segments 44
include inner portions
44a having arcuate cylindrical inner surfaces, 44aaa and 44aab, and an arcuate
cylindrical outer
surface 44ab, intermediate portions 44b extending from the interior portions
that have an arcuate
conical inner surface 44ba and arcuate cylindrical and spherical outer
surfaces, 44bba and 44bbb, and
outer portions 44c having arcuate cylindrical inner and outer surfaces, 44ca
and 44cb. In an
exemplary embodiment, the outer surfaces 44ab of the inner portions 44a of the
upper expansion cone
segments define hinge grooves 44aba that receive and are pivotally mounted
upon the internal flange
42d of the upper retaining sleeve 42.
[0055] The arcuate inner cylindrical surfaces 44aaa mate with and receive the
lower mandrel 34, the
arcuate inner cylindrical surfaces 44aab mate with and receive the arcuate
cylindrical outer surfaces
40ccb of the outer portions 40cc of the corresponding cam arms 40c of the
lower cam assembly 40,
and the arcuate inner conical surfaces 44ba mate with and receive the arcuate
conical outer surfaces
40cbb of the intermediate portions 40cb of the corresponding cam arms of the
lower cam assembly.
[0056] In an exemplary embodiment, the radius of curvature of the arcuate
cylindrical inner surface
44aaa is less than the radius of curvature of the arcuate cylindrical inner
surface 44aab. In an
exemplary embodiment, the radius of curvature of the arcuate cylindrical inner
surface 44ca is greater
than the radius of curvature of the arcuate cylindrical surface 44aab. In an
exemplary embodiment,
the arcuate cylindrical inner surfaces, 44aaa and 44aab, are parallel. In an
exemplary embodiment,
the arcuate cylindrical outer surface 44ab is inclined relative to the arcuate
cylindrical inner surface
44aaa. In an exemplary embodiment, the arcuate cylindrical outer surface 44bba
is parallel to the
arcuate cylindrical inner surfaces, 44aaa and 44aab. In an exemplary
embodiment, the arcuate
cylindrical outer surface 44cb is inclined relative to the arcuate cylindrical
inner surface 44ca.
[0057] A plurality of lower expansion cone segments 46 are interleaved among,
and overlap, the
upper expansion cone segments 44 and the cam arms 38c of the lower cam
assembly 38. In this
manner, torque loads may be transmitted between the upper and lower expansion
cone segments, 44
and 46. Each of the lower expansion cone segments 46 include inner portions
46a having arcuate
cylindrical inner surfaces, 46aaa and 46aab, and an arcuate cylindrical outer
surface 46ab,
intermediate portions 46b extending from the interior portions that have an
arcuate conical inner
surface 46ba and arcuate cylindrical and spherical outer surfaces, 46bba and
46bbb, and outer portions
46c having arcuate cylindrical inner and outer surfaces, 46ca and 46cb. In an
exemplary embodiment,
the outer surfaces 46ab of the inner portions 46a of the upper expansion cone
segments 46 define
hinge grooves 46aba.
9



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[0058] The arcuate inner cylindrical surfaces 46aaa mate with and receive the
lower mandrel 34, the
arcuate inner cylindrical surfaces 46aab mate with and receive the arcuate
cylindrical outer surfaces
38ccb of the outer portions 38cc of the corresponding cam arms 38c of the
upper cam assembly 38,
and the arcuate inner conical surfaces 46ba mate with and receive the arcuate
conical outer surfaces
38cbb of the intermediate portions 38cb of the corresponding cam arms of the
lower cam assembly.
[0059] In an exemplary embodiment, the radius of curvature of the arcuate
cylindrical inner surface
46aaa is less than the radius of curvature of the arcuate cylindrical inner
surface 46aab. In an
exemplary embodiment, the radius of curvature of the arcuate cylindrical inner
surface 46ca is greater
than the radius of curvature of the arcuate cylindrical surface 46aab. In an
exemplary embodiment,
the arcuate cylindrical inner surfaces, 46aaa and 46aab, are parallel. In an
exemplary embodiment,
the arcuate cylindrical outer surface 46ab is inclined relative to the arcuate
cylindrical inner surface
46aaa. In an exemplary embodiment, the arcuate cylindrical outer surface 46bba
is parallel to the
arcuate cylindrical inner surfaces, 46aaa and 46aab. In an exemplary
embodiment, the arcuate
cylindrical outer surface 46cb is inclined relative to the arcuate cylindrical
inner surface 46ca.
[0060] In an exemplary embodiment, the geometries of the upper and lower
expansion cone
segments 44 and 46 are substantially identical. In an exemplary embodiment,
the upper expansion
cone segments 44 are tapered in the longitudinal direction from the ends of
the intermediate portions
44b to the ends of the outer portions 44c, and the lower expansion cone
segments 46 are tapered in the
longitudinal direction from the ends of the intermediate portions 46b to the
ends of the outer portions
46c. In an exemplary embodiment, when the upper and lower expansion segments,
44 and 46, are
positioned in a fully expanded position, the arcuate cylindrical outer
surfaces, 44bba and 46cb, of the
upper and lower expansion cone segments define a contiguous cylindrical
surface, the arcuate
spherical outer surfaces, 44bbb and 46bbb, of the upper and lower expansion
cone segments define an
contiguous arcuate spherical surface, and the arcuate cylindrical outer
surfaces, 44cb and 46bba, of
the upper and lower expansion cone segments define a contiguous cylindrical
surface.
[0061] An end of a lower retaining sleeve 48 defines a passage 48a for
receiving and mating with the
outer circumferential surfaces of the external flange 40aa and the meshing
teeth 40b of the lower cam
assembly 40, and an inner annular recess 48b, and includes an internal flange
48c for retaining the
external flange of the lower cam assembly, and an internal flange 48d at one
end of the lower
retaining sleeve that includes a rounded interior end face for mating with the
hinge grooves 46 aba of
the lower expansion cone segments 46 thereby pivotally coupling the lower
expansion cone segments
to the lower retaining sleeve. An o-ring seal 50 is received within the
annular recess 486. A disc
shaped shim 49 is positioned within the lower retaining sleeve 48 between the
opposing end faces of
the internal flange 48c of the retaining sleeve and the external flange 40aa
of the lower cam assembly
40.
[0062] In an exemplary embodiment, the arcuate cylindrical outer surfaces
44bba of the upper
expansion cone segments 44 and the arcuate cylindrical outer surfaces 46cb of
the lower expansion



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cone segments 46 are aligned with the outer surface of the upper retaining
sleeve 42. In an exemplary
embodiment, the arcuate cylindrical outer surfaces 44cb of the upper expansion
cone segments 44 and
the arcuate cylindrical outer surfaces 46 bba of the lower expansion cone
segments are aligned with
the outer surface of the lower retaining sleeve 48.
[0063] An end of a float shoe adaptor 50 that includes a plurality of
circumferentially spaced apart
meshing teeth SOa for engaging the meshing teeth 40b of the lower cam assembly
40 is received
within and threadably coupled to an end of the lower retaining sleeve 48 that
defines a passage SOb at
one end for receiving an end of the lower mandrel 34, a passage SOc having a
reduced inside diameter
at another end, a plurality of radial passages SOd at the other end, and
includes an internal flange SOe,
and a torsional coupling SOf at the other end that includes a plurality of
torsional coupling members
SOfa. During operation, the meshing teeth 40b of the lower cam assembly 40
transmit toque loads to
and from the meshing teeth SOa of the float shoe adaptor.
[0064] An end of a retaining sleeve 52 abuts the end face of the tubular base
40a of the lower cam
assembly 40 and is received within and mates with the passage 506 of the float
shoe adaptor 50 that
defines a passage 52a for receiving an end of the lower mandrel 34, a throat
passage 52b including a
ball valve seat 52c, and includes a flange 52d, and another end of the
retaining sleeve, having a
reduced outside diameter, is received within and mates with the passage SOc of
the float shoe adaptor
50.
[0065] A stop nut 54 receives and is threadably coupled to the end of the
lower mandrel 34 within the
passage 52a of the retaining sleeve 52, and shear pins 56 releasably couple
the stop nut 54 to the
retaining sleeve 52. Locking dogs 58 are positioned within an end of the
retaining sleeve 52 that
receive and are releasably coupled to the lower mandrel 34, and a disc shaped
adjustment shim 60
receives the lower mandrel 34 and is positioned within an end of the retaining
sleeve 52 between the
opposing ends of the tubular base 40a of the upper cam assembly 40 and the
locking dogs 58. Burst
discs 62 are releasably coupled to and positioned within the radial passages
SOd of the float shoe
adaptor 50.
[0066] An end of a float shoe 64 mates with and is releasably coupled to the
torsional coupling
members SOfa of the torsional coupling SOf of the float shoe adaptor 50 that
defines a passage 64a and
a valveable passage 64b. In this manner torsional loads may be transmitted
between the float shoe
adaptor 50 and the float shoe 64. An end of an expandable tubular member 66
that surrounds the
tubular support member 12, the safety collar 14, the upper mandrel collar I 8,
the upper packer cup 24,
the lower packer cup 28, the lower mandrel 34, the upper expansion cone
segments 44, the lower
expansion cone segments 46, and the float shoe adaptor 50, is coupled to and
receives an end of the
float shoe 64 and is movably coupled to and supported by the arcuate spherical
external surfaces,
44bbb and 46bbb, of the upper and lower expansion cone segments, 44 and 46.
[0067] During operation, as illustrated in Figs. la and lb, the apparatus 10
is at least partially
positioned within a preexisting structure such as, for example, a borehole 100
that traverses a
I1



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subterranean formation that may include a preexisting wellbore casing 102. The
borehole 100 may
be oriented in any position, for example, from vertical to horizontal. A
fluidic material 104 is then
injected into the apparatus 10 through the passages 12a, 14a, 22a, 34c, SOc,
64a, and 646 into the
annulus between the expandable tubular member 66 and the borehole 100. In an
exemplary
embodiment, the fluidic material 104 is a hardenable fluidic sealing material.
In this manner, an
annular sealing layer may be formed within the annulus between the expandable
tubular member 66
and the borehole 100.
[0068] As illustrated in Figs. l0a and l Ob, a ball 106 is then be positioned
within and blocking the
valveable passage 64b of the float shoe 64 by injecting a fluidic material 108
into the apparatus 10
through the passages 12a, 14a, 22a, 34c, and SOc. As a result, the increased
operating pressure within
the passage SOc bursts open the burst discs 62 positioned within the radial
passages SOd of the float
shoe adaptor 50. The continued injection of the fluidic material 108 thereby
pressurizes the interior of
the expandable tubular member 66 below the lower packer cup 28 thereby
displacing the upper and
lower expansion cone segments, 44 and 46, upwardly relative to the float shoe
64 and the expandable
tubular member 66. As a result, the expandable tubular member 66 is
plastically deformed and
radially expanded. Thus, the burst discs 62 sense the operating pressure of
the injected fluidic
material 108 within the passage SOc and thereby control the initiation of the
radial expansion and
plastic deformation of the expandable tubular member 66.
[0069] In an exemplary embodiment, any leakage of the pressurized fluidic
material 108 past the
lower packer cup 28 is captured and sealed against further leakage by the
upper packer cup 24. In this
manner, the lower packer cup 28 provides the primary fluidic seal against the
interior surface of the
expandable tubular member 66, and the upper packer cup 24 provides a
secondary, back-up, fluidic
seal against the interior surface of the expandable tubular member.
Furthermore, because the lower
packer cup 28 and/or the upper packer cup 24 provide a fluid tight seal
against the interior surface of
the expandable tubular member 66, the upper and lower expansion cone segments,
44 and 46, are
pulled upwardly through the expandable tubular member by the axial forces
created by the packer
cups.
[0070] In an exemplary embodiment, during the radial expansion process, the
interface between the
arcuate spherical external surfaces, 44bbb and 46bbb, of the upper and lower
expansion cone
segments, 44 and 46, and the interior surface of the expandable tubular member
66 is not fluid tight.
As a result, the fluidic material 108 may provide lubrication to the entire
extent of the interface
between the cylindrical external surfaces, 44bba and 46cb, and the arcuate
spherical external surfaces,
44bbb and 46bbb, of the upper and lower expansion cone segments, 44 and 46,
and the interior
surface of the expandable tubular member 66. Moreover, experimental test
results have indicated the
unexpected result that the required operating pressure of the fluidic material
108 for radial expansion
of the expandable tubular member 66 is less when the interface between the
cylindrical external
surfaces, 44bba and 46cb, and the arcuate spherical external surfaces, 44bbb
and 46bbb, of the upper
12



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and lower expansion cone segments, 44 and 46, and the interior surface of the
expandable tubular
member 66 is not fluid tight. Furthermore, experimental test results have also
demonstrated that the
arcuate spherical external surface provided by the arcuate spherical external
surfaces, 446bb and
46bbb, of the upper and lower expansion cone segments, 44 and 46, provides
radial expansion and
plastic deformation of the expandable tubular member 66 using lower operating
pressures versus an
expansion cone having a conical outer surface.
[0071] In an exemplary embodiment, as illustrated in Figs. l la, l lb, 12, 13,
14, 15, and 16, the upper
and lower expansion cone segments, 44 and 46, may then be adjusted to a
collapsed position by
placing a ball 110 within the ball valve seat 52c of the throat passage 52b of
the retaining sleeve 52.
The continued injection of the fluidic material 108, after the placement of
the ball 110 within the ball
valve seat 52c, creates a differential pressure across the ball 110 thereby
applying a downward
longitudinal force onto the retaining sleeve 52 thereby shearing the shear
pins 56. As a result, the
retaining sleeve 52 is displaced in the downward longitudinal direction
relative to the float shoe
adaptor 50 thereby permitting the locking dogs 58 to be displaced outwardly in
the radial direction.
The outward radial displacement of the locking dogs 58 disengages the locking
dogs from
engagement with the lower mandrel 34. Thus, the shear pins 56 sense the
operating pressure of the
injected fluidic material 108 within the throat passage 52b and thereby
controling the initiation of the
collapsing of the upper and lower expansion cone segments, 44 and 46.
[0072] The continued injection of the fluidic material 108 continues to
displace the retaining sleeve
52 in the downward longitudinal direction relative to the float shoe adaptor
50 until the external
flange 52d of the retaining sleeve 52 impacts, and applies a downward
longitudinal force to, the
internal flange 50e of the float shoe adaptor. As a result, the float shoe
adaptor 50 is then also
displaced in the downward longitudinal direction relative to the lower mandrel
34. The downward
longitudinal displacement of the float shoe adaptor 50 relative to the lower
mandrel 34 causes the
lower cam assembly 40, the lower expansion cone segments 46, and the lower
retaining sleeve 48,
which are rigidly attached to the float shoe adaptor, to also be displaced
downwardly in the
longitudinal direction relative to the lower mandrel 34, the upper cam
assembly 38, and the upper
expansion cone segments 44.
[0073] The downward longitudinal displacement of the lower cam assembly 40
relative to the upper
expansion cone segments 44 causes the upper expansion cone segments to slide
off of the conical
external surfaces 40cbb of the lower cam assembly and thereby pivot inwardly
in the radial direction
about the internal flange 42d of the upper retaining sleeve 42. The downward
longitudinal
displacement of the lower expansion cone segments 46 relative to the upper cam
assembly 38 causes
the lower expansion cone segments 46 to slide off of the external conical
surfaces 38cbb of the upper
cam assembly and thereby pivot inwardly in the radial direction about the
internal flange 48d of the
lower retaining sleeve. As a result of the inward radial movement of the upper
and lower expansion
cone segments, 44 and 46, the arcuate external spherical surfaces, 44bbb and
46bbb, of the upper and
13



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lower expansion cone segments, 44 and 46, no longer provide a substantially
contiguous outer arcuate
spherical surface.
[0074] The downward longitudinal movement of the retaining sleeve 42 and float
shoe adaptor SO
relative to the lower mandrel 34 is stopped when the stop nut 54 impacts the
locking dogs 58. At this
point, as illustrated in Figs. 17a and 17b, the apparatus 10 may then be
removed from the interior of
the expandable tubular member 66.
[0075] Thus, the apparatus 10 may be removed from the expandable tubular
member 66 prior to the
complete radial expansion and plastic deformation of the expandable tubular
member by controllably
collapsing the upper and lower expansion cone segments, 44 and 46. As a
result, the apparatus 10
provides the following benefits: (1) the apparatus is removable when expansion
problems are
encountered; (2) lower expansion forces are required because the portion of
the expandable tubular
member 66 between the packer cups, 24 and 28, and the expansion cone segments
is exposed to the
expansion fluid pressure; and (3) the expansion cone segments can be run down
through the
expandable tubular member, prior to radial expansion, and then the expansion
cone segments can be
expanded.
[0076] In several alternative embodiments, resilient members such as, for
example, spring elements
are coupled to the upper and lower expansion cone segments, 44 and 46, for
resiliently biasing the
expansion cone segments towards the expanded or collapsed position.
[0077] In several alternative embodiments, the placement of the upper and
lower expansion cone
segments, 44 and 46, in an expanded or collapsed position is reversible.
[0078] In several alternative embodiments, a small gap is provided between the
upper and lower
expansion cone segments, 44 and 46, when positioned in the expanded condition
that varies from
about .005 to .030 inches.
[0079] Turning back to Fig. 10a, as previously discussed, the lower packer cup
28 may be used to
provide a primary fluidic seal against the interior surface of the expandable
tubular member 66, and
the upper packer cup 24 provides a secondary, back-up, fluidic seal against
the interior surface of the
expandable tubular member. Furthermore, because the lower packer cup 28 and/or
the upper packer
cup 24 provide a fluid tight seal against the interior surface of the
expandable tubular member 66,
when the region is pressurized, the upper and lower expansion cone segments,
44 and 46, are pulled
upwardly through the expandable tubular member by the axial forces created by
the packer cups.
[0080] The packer cups may be made from an elastomer, the type of which
depends on design
pressures, fluids and temperatures. In several embodiments, the packer cups 24
and 28 are coupled to
annular reinforcing elements or supports which are bonded to the elastomer to
hold the elastomer in
place when running in and out of the casing and when pressurized.
Conventionally, the support may
be wire or a single insert, such as used in the "TP" cup from Halliburton of
Duncan, Oklahoma. The
support may be more complicated, for instance, it may comprise a bushing and a
plurality of
overlapping springs, such as used in the GW-HD cup from Guiberson Oil Tools of
Alberta Canada.
14



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[0081] Conventional packer cups are intended to remain stationary when
pressurized. Any significant
movement of a conventional packer cup when the cup has been pressurized may
destroy the packer
cup. Additionally, conventional packer cups may not be designed to hold the
high pressures necessary
for a casing expansion when moving through the casing. Pressure cycling and
movement which
occurs during casing expansion procedures may cause degradation of the
elastomer and the bond
between the elastomer and inserts. Eventually the elastomer disintegrates and
the packer cup is unable
to hold pressure. What is needed, therefore is a packer cup which can
withstand the movement and
pressures associated with the casing expansion procedure.
[0082] Turning now to Fig. 18, one side of a conventional cup seal or packer
cup 70 is illustrated in
detail. The opposing side is symmetrical about the center line of the packer
cup. In the illustrated
configuration, the packer cup 70 is shown located outside of the casing.
Therefore, dashed lines
represent the position of an expandable casing 71 relative to the packer cup
70. The packer cup 70
may be used as the upper packer cup 24 or lower packer cup 28 as described
previously in reference
to Figs. la and 10a. In several alternative embodiments, the central mandrel
72 has an external flange
74, which may provide longitudinal support for a retaining sleeve or adjusting
ring 76. The adjusting
ring 76 receives and is coupled to the central mandrel 72. A spacer sleeve 78
also receives and is
coupled to the central mandrel 72 and is longitudinally positioned between the
packer cup 70 and the
adjusting ring 76. In several embodiments, the adjusting ring 76 threadingly
engages the spacer
sleeve 78 so that the longitudinal position of the spacer sleeve may be
adjusted by rotating the spacer
sleeve relative to the adjusting ring 76. In turn, the spacer sleeve 78
longitudinally positions and
supports the packer cup 70.
[0083] In several exemplary embodiments, the packer cup 70 comprises one or
more springs 80a and
80b which are bonded to and radially support an elastomeric sealing cup 82 to
form a cup assembly
83. The elastomeric sealing cup 82 is generally conical in shape, having a
substantially unrestricted
lip portion 85 for sealingly engaging the interior ID of the expandable casing
71. Opposite the lip
portion 85 is a base portion 87 which is supported by a conical bushing 84
positioned between the
interior side of the cup assembly 83 and the central mandrel 72. A radial
thimble 86 surrounds the
base portion 87 of the cup assembly 83. The radial thimble 86 has an exterior
diameter which is
smaller than the interior diameter of the casing by a distance "A." In the
embodiment illustrated in
Fig. 18, the elastomeric sealing cup 82 is unsupported in a region "B" which
may be generally defined
as the region between a support, such as a radial thimble 86, and a point of
contact "C" with the
expandable casing 71.
[0084] Fig. 19a illustrates an alternative embodiment of a packer cup 90. In
several exemplary
embodiments, the packer cup 90 comprises one or more springs 92a and 92b which
are bonded to and
radially support an elastomeric sealing cup 94 to form a cup assembly 95. The
elastomeric sealing cup
94 is generally conical in shape, having a substantially unrestricted lip
portion 93 for sealingly
engaging the interior ID of the expandable casing 71. Opposite the lip portion
93 is a base portion 97



CA 02489283 2004-12-10
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which is supported by a conical bushing 96 positioned between the cup assembly
and the central
mandrel 72. The supported end of the cup assembly 95 is surrounded by a radial
thimble 98. The
radial thimble 98 has an exterior diameter which is slightly smaller than the
interior diameter, causing
the distance "A" to be reduced when compared to a conventional packer cup,
such as illustrated in
Fig. 18.
[0085] In the embodiment illustrated in Fig. 19a, the elastomeric sealing cup
94 is unsupported in a
region "B" which may be generally defined as the region between a support,
such as the radial
thimble 98, and a point of contact "C" with the expandable casing 71. In this
embodiment, the
longitudinal length of the radial thimble 98 has been increased, which reduces
the unsupported region
"B" of the elastomeric sealing cup 94 when compared to a conventional packer
cup.
[0086] Reducing the length "B" of the unsupported region and the distance "A"
between the exterior
diameter of the thimble 98 and the ID of the casing limits movement of the
elastomeric sealing cup 94
when the packer cup is pressurized. This reduced movement improves the
durability of the packer
seal under greater pressures than conventional packer cups.
[0087] Fig. 19b illustrates an alternative embodiment of a packer cup 100. In
several exemplary
embodiments, the packer cup 100 comprises one or more springs 102a and 102b
which are bonded to
an elastomeric sealing cup 104 to form a cup assembly 105. The elastomeric
sealing cup 104 is
generally conical in shape, having a substantially unrestricted lip portion
103 for sealingly engaging
the interior 1D of the expandable casing 71. Opposite the lip portion 103 is a
base portion 107 which
is supported by a conical bushing 106 positioned between the elastoermic seal
104 and the central
mandrel 72. A pliant backup member 108 is position between the elastomeric
sealing cup 104 and a
radial thimble 110. The backup member 108 may be made from any suitable pliant
material, such as
a fluoropolymer or fluoroelastomer (e.g., Teflon or PEEK). The use of the
backup member l 08
significantly reduces the unsupported region of the elastomeric sealing cup
104. Additionally, the
backup member 108 easily extrudes when pressurized to expand into any gap
between the outside
diameter of the backup support and the ID of the casing providing a secondary
seal.
[0088] The radial thimble 110 is similar to the radial thimble 98 (Fig. 19a)
in that it has an exterior
diameter which is slightly smaller than the interior diameter, causing the
distance "A" to be reduced.
Similarly, the longitudinal length of the radial thimble 110 has been
increased which reduces the
unsupported length of the elastomeric sealing cup. Reducing the unsupported
region of the
elastomeric sealing cup and the distance between the exterior diameter of the
thimble 98 and the ID of
the casing limits movement of the elastomeric sealing cup 94 when the packer
cup is pressurized.
This reduced movement improves the durability of the packer seal.
[0089] Fig. 19c illustrates an alternative embodiment of a packer cup 120. In
several exemplary
embodiments, the packer cup 120 comprises one or more springs 122a and 122b
which are bonded to
an elastomeric sealing cup 124 to form a cup assembly 125. The elastomeric
sealing cup 124 is
generally conical in shape, having a substantially unrestricted lip portion
123 for sealingly engaging
16



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the interior ID of the expandable casing 71. Opposite the lip portion 123 is a
base portion 127 which
is supported by a conical bushing 126 positioned between the elastomeric
sealing cup 124 and the
central mandrel 72. A pliant backup member 128 is positioned between the
elastomeric sealing cup
124 and a radial shoe 130. The backup member 128 may be made from any suitable
pliant material,
such as a fluoropolymer or fluoroelastomer (e.g., Teflon or PEEK).
Additionally, the backup
member 128 extrudes when pressurized to expand into a gap between the outside
diameter of the
backup member 128 and the ID of the casing. However, the use of the radial
shoe 130 and the cross-
sectional shape of the backup member 128 reduces the degree of extrusion when
compared to packer
cup 100 (Fig. 19b).
[0090] The radial shoe 130 may be made from steel or another harden material
to provide support
and protection for the pliant backup member 128. The pliant backup member 128
reduces the
unsupported length of the elastomeric sealing cup 124 which limits the
movement of the elastomeric
sealing cup 124 when the packer cup is pressurized. This reduced movement
improves the durability
of the packer cup.
[0091] Fig. 19d illustrates an alternative embodiment of a packer cup 140. In
several exemplary
embodiments, the packer cup 140 comprises one or more springs 142a and 142b
which are bonded to
an elastomeric sealing cup 144 to form a cup assembly 145. The elastomeric
sealing cup 144 is
generally conical in shape, having a substantially unrestricted lip portion
143 for sealingly engaging
the interior ID of the expandable casing 71. Opposite the lip portion 143 is a
base portion 149 which
is supported by a conical bushing 146 positioned between the elastomeric
sealing cup 144 and the
central mandrel 72. A support member 147 provides additional stiffness and
support by surrounding
the supported end of cup assembly 145. The support member 147 may be made of
steel or another
suitable material. The use of the support member 147 provides a stiff support
for the elastomeric
sealing cup 144 which reduces the movement of the elastomeric sealing cup 144.
Similar to the
packer cup 120 discussed in reference to Fig. 19c, a pliant backup member 148
is positioned between
the support member 147 and a radial shoe 150. The backup member 148 extrudes
when pressurized
to expand into a gap between the outside diameter of the backup support and
the ID of the casing.
However, the use of the radial shoe 150 reduces the degree of extrusion when
compared to packer cup
100 (Fig. 19b).
[0092] The radial shoe 150 may be made from steel or another harden material
to provide support
and protection for the pliant backup member 148. The use of a pliant backup
member 148 also
reduces the unsupported region of the elastomeric sealing cup 144 which limits
the movement of the
elastomeric sealing cup 144 when the packer cup is pressurized . This reduced
movement improves
the durability of the packer cup.
[0093] Fig. 19e illustrates an alternative embodiment of a packer cup 160. In
several exemplary
embodiments, the packer cup 160 comprises one or more springs 162a and 162b
which are bonded to
an elastomeric sealing cup 164 to form a cup assembly 165. The elastomeric
sealing cup 164 is
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generally conical in shape, having a substantially unrestricted lip portion
163 for sealingly engaging
the interior ID of the expandable casing 71. Opposite the lip portion 163 is a
base portion 167 which
is supported by a conical bushing 166 positioned between the elastomeric
sealing cup 164 and the
central mandrel 72. The supported end of the cup assembly is also surrounded
by a radial thimble
168.
[0094] In this embodiment, the elastomeric sealing cup 164 has additional
elastomeric material
molded proximate to the radial thimble 168 at a point "D". Because of the use
of additional
elastomeric material and a longer longitudinal length of the radial thimble
98, the unsupported region
of the elastomeric sealing cup 164 is significantly reduced. Reducing the
unsupported region of the
elastomeric sealing cup 164 and the distance between the exterior diameter of
the thimble 168 and the
ID of the casing 71 limits movement of the elastomeric sealing cup 164 when
the packer cup is
pressurized. Additionally, the radial thimble 168 has an exterior diameter
which is slightly smaller
than the interior diameter, causing the gap between the radial thimble 168 and
the ID of the casing 71
to be reduced. The reduced gap also limits movement of the elastomeric sealing
cup 164. This
reduced movement improves the durability of the packer seal.
[0095] An apparatus for radially expanding and plastically deforming an
expandable tubular member
has been described that includes an upper tubular support member defining a
first passage, one or
more cup seals coupled to the exterior surface of the upper tubular support
member for sealing an
interface between the upper tubular support member and the expandable tubular
member, an upper
cam assembly coupled to the upper tubular support member comprising: a tubular
base coupled to the
upper tubular support member, and a plurality of cam arms extending from the
tubular base in a
downward longitudinal direction, each cam arm defining an inclined surface, a
plurality of upper
expansion cone segments interleaved with the cam arms of the upper cam
assembly and pivotally
coupled to the tubular support member, a lower tubular support member defining
a second passage
fluidicly coupled to the first passage releasably coupled to the upper tubular
support member, a lower
cam assembly coupled to the lower tubular support member comprising: a tubular
base coupled to the
lower tubular support member, and a plurality of cam arms extending from the
tubular base in an
upward longitudinal direction, each cam arm defining an inclined surface that
mates with the inclined
surface of a corresponding one of the upper expansion cone segments, wherein
the cams arms of the
upper cam assembly are interleaved with and overlap the cam arms of the lower
cam assembly, and a
plurality of lower expansion cone segments interleaved with cam arms of the
lower cam assembly,
each lower expansion cone segment pivotally coupled to the lower tubular
support member and
mating with the inclined surface of a corresponding one of the cam arms of the
upper cam assembly,
wherein the lower expansion cone segments interleave and overlap the upper
expansion cone
segments, and wherein the upper and lower expansion cone segments together
define an arcuate
spherical external surface for plastically deforming and radially expanding
the expandable tubular
member. In an exemplary embodiment, the upper tubular support member includes:
a safety collar, a
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torque plate coupled to the safety collar including a plurality of
circumferentially spaced apart
meshing teeth at an end, an upper mandrel including a plurality of
circumferentially spaced apart
meshing teeth at one end for engaging the meshing teeth of the torque plate
and an external flange at
another end, and a lower mandrel coupled to the external flange of the upper
mandrel including an
external flange including a plurality of circumferentially spaced apart
meshing teeth. In an exemplary
embodiment, the tubular base of the upper cam assembly includes a plurality of
circumferentially
spaced apart meshing teeth for engaging the meshing teeth of the external
flange of the lower
mandrel. In an exemplary embodiment, the apparatus further includes a stop nut
coupled to an end of
the lower mandrel for limiting the movement of the lower tubular member
relative to the lower
mandrel. In an exemplary embodiment, the apparatus further includes locking
dogs coupled to the
lower mandrel. In an exemplary embodiment, the lower tubular support member
includes: a float
shoe adapter including a plurality of circumferentially spaced apart meshing
teeth at one end, an
internal flange, and a torsional coupling at another end, a lower retaining
sleeve coupled to an end of
the float shoe adapter including an internal flange for pivotally engaging the
lower expansion cone
segments, and a retaining sleeve received within the float shoe adapter
releasably coupled to the upper
tubular support member. In an exemplary embodiment, an end of the retaining
sleeve abuts an end of
the tubular base of the lower cam assembly. In an exemplary embodiment, the
tubular base of the
lower cam assembly includes a plurality of circumferentially spaced apart
meshing teeth for engaging
the meshing teeth of the float shoe adaptor. In an exemplary embodiment, the
apparatus further
includes a float shoe releasably coupled to the torsional coupling of the
float shoe adaptor, and an
expandable tubular member coupled to the float shoe and supported by and
movably coupled to the
upper and lower expansion cone segments. In an exemplary embodiment, the
apparatus further
includes: one or more shear pins coupled between the upper tubular support
member and the lower
tubular support member. In an exemplary embodiment, the apparatus further
includes: a stop member
coupled to the upper tubular support member for limiting movement of the upper
tubular support
member relative to the lower tubular support member. In an exemplary
embodiment, the apparatus
further includes: a float shoe releasably coupled to the lower tubular support
member that defines a
valveable passage, and an expandable tubular member coupled to the float shoe
and supported by and
movably coupled to the upper and lower expansion cone segments. In an
exemplary embodiment,
each upper expansion cone segment includes: an inner portion defining an
arcuate cylindrical upper
surface including a hinge groove for pivotally coupling the upper expansion
cone segment to the
upper tubular support member and arcuate cylindrical lower surfaces, an
intermediate portion defining
arcuate cylindrical and spherical upper surfaces and an arcuate conical lower
surface, and an outer
portion defining arcuate cylindrical upper and lower surfaces, and wherein
each lower expansion cone
segment includes: an inner portion defining an arcuate cylindrical upper
surface including a hinge
groove for pivotally coupling the lower expansion cone segment to the lower
tubular support member
and arcuate cylindrical lower surfaces, an intermediate portion defining
arcuate cylindrical and
19



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spherical upper surfaces and an arcuate conical lower surface, and an outer
portion defining arcuate
cylindrical upper and lower surfaces. In an exemplary embodiment, each upper
expansion cone
segment is tapered in the longitudinal direction from the intermediate portion
to the outer portion; and
wherein each lower expansion cone segment is tapered in the longitudinal
direction from the
intermediate portion to the outer portion.
[0096] An apparatus for radially expanding and plastically deforming an
expandable tubular member
has also been described that includes a safety collar, a torque plate coupled
to the safety collar
including a plurality of circumferentially spaced apart meshing teeth at an
end, an upper mandrel
including a plurality of circumferentially spaced apart meshing teeth at one
end for engaging the
meshing teeth of the torque plate and an external flange at another end, a
lower mandrel coupled to
the external flange of the upper mandrel including an external flange
including a plurality of
circumferentially spaced apart meshing teeth, a stop nut coupled to an end of
the lower mandrel, an
upper retaining sleeve coupled to the lower mandrel including an internal
flange, one or more cup
seals coupled to the upper mandrel for sealing an interface between the upper
mandrel and the
expandable tubular member, an upper cam assembly coupled to the lower mandrel
including: a
tubular base including a plurality of circumferentially spaced apart meshing
teeth for engaging the
meshing teeth of the external flange of the lower mandrel, and a plurality of
cam arms extending from
the tubular base in a downward longitudinal direction, each cam arm defining
an inclined surface, a
plurality of upper expansion cone segments interleaved with the cam arms of
the upper cam assembly
and pivotally coupled to the internal flange of the upper retaining sleeve, a
float shoe adapter
including a plurality of circumferentially spaced apart meshing teeth at one
end, an internal flange,
and a torsional coupling at another end, a lower retaining sleeve coupled to
an end of the float shoe
adapter including an internal flange, a retaining sleeve received within the
float shoe adapter, one or
more shear pins for releasably coupling the retaining sleeve to the stop nut,
a lower cam assembly
coupled to the float shoe adapter including: a tubular base including a
plurality of circumferentially
spaced apart meshing teeth for engaging the meshing teeth of the float shoe
adapter, and a plurality of
cam arms extending from the tubular base in an upward longitudinal direction,
each cam arm defining
an inclined surface that mates with the inclined surface of a corresponding
one of the upper expansion
cone segments, wherein the cams arms of the upper cam assembly are interleaved
with and overlap
the cam arms of the lower cam assembly, a plurality of lower expansion cone
segments interleaved
with cam arms of the lower cam assembly, each lower expansion cone segment
pivotally coupled to
the internal flange of the lower retaining sleeve and mating with the inclined
surface of a
corresponding one of the cam arms of the upper cam assembly, a float shoe
releasably coupled to the
torsional coupling of the float shoe adaptor, and an expandable tubular member
coupled to the float
shoe and supported by and movably coupled to the upper and lower expansion
cone segments,
wherein the lower expansion cone segments interleave and overlap the upper
expansion cone
segments, wherein the upper and lower expansion cone segments together define
an arcuate spherical



CA 02489283 2004-12-10
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external surface for plastically deforming and radially expanding the
expandable tubular member,
wherein each upper expansion cone segment includes: an inner portion defining
an arcuate cylindrical
upper surface including a hinge groove for pivotally coupling the upper
expansion cone segment to
the upper tubular support member and arcuate cylindrical lower surfaces, an
intermediate portion
defining arcuate cylindrical and spherical upper surfaces and an arcuate
conical lower surface, and an
outer portion defining arcuate cylindrical upper and lower surfaces, wherein
each lower expansion
cone segment includes: an inner portion defining an arcuate cylindrical upper
surface including a
hinge groove for pivotally coupling the lower expansion cone segment to the
lower tubular support
member and arcuate cylindrical lower surfaces, an intermediate portion
defining arcuate cylindrical
and spherical upper surfaces and an arcuate conical lower surface, and an
outer portion defining
arcuate cylindrical upper and lower surfaces, wherein each upper expansion
cone segment is tapered
in the longitudinal direction from the intermediate portion to the outer
portion, and wherein each
lower expansion cone segment is tapered in the longitudinal direction from the
intermediate portion to
the outer portion.
[0097] A collapsible expansion cone assembly has also been described that
includes an upper tubular
support member including an internal flange, an upper cam assembly coupled to
the upper tubular
support member including: a tubular base coupled to the upper support member,
and a plurality of
cam arms extending from the tubular base in a downward longitudinal direction,
each cam arm
defining an inclined surface, a plurality of upper expansion cone segments
interleaved with the cam
arms of the upper cam assembly and pivotally coupled to the internal flange of
the upper tubular
support member, a lower tubular support member including an internal flange,
one or more frangible
couplings for releasably coupling the upper and lower tubular support members,
a lower cam
assembly coupled to the lower tubular support member including: a tubular base
coupled to the lower
tubular support member, and a plurality of cam arms extending from the tubular
base in an upward
longitudinal direction, each cam arm defining an inclined surface that mates
with the inclined surface
of a corresponding one of the upper expansion cone segments, wherein the cams
arms of the upper
cam assembly are interleaved with and overlap the cam arms of the lower cam
assembly, and a
plurality of lower expansion cone segments interleaved with cam arms of the
lower cam assembly,
each lower expansion cone segment pivotally coupled to the internal flange of
the lower tubular
support member and mating with the inclined surface of a corresponding one of
the cam arms of the
upper cam assembly, wherein the lower expansion cone segments interleave and
overlap the upper
expansion cone segments, and wherein the upper and lower expansion cone
segments together define
an arcuate spherical external surface for plastically deforming and radially
expanding the expandable
tubular member. In an exemplary embodiment, each upper expansion cone segment
includes: an
inner portion defining an arcuate cylindrical upper surface including a hinge
groove for pivotally
coupling the upper expansion cone segment to the upper tubular support member
and arcuate
cylindrical lower surfaces, an intermediate portion defining arcuate
cylindrical and spherical upper
21



CA 02489283 2004-12-10
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surfaces and an arcuate conical lower surface, and an outer portion defining
arcuate cylindrical upper
and lower surfaces, and wherein each lower expansion cone segment includes: an
inner portion
defining an arcuate cylindrical upper surface including a hinge groove for
pivotally coupling the
lower expansion cone segment to the lower tubular support member and arcuate
cylindrical lower
surfaces, an intermediate portion defining arcuate cylindrical and spherical
upper surfaces and an
arcuate conical lower surface, and an outer portion defining arcuate
cylindrical upper and lower
surfaces. In an exemplary embodiment, each upper expansion cone segment is
tapered in the
longitudinal direction from the intermediate portion to the outer portion, and
wherein each lower
expansion cone segment is tapered in the longitudinal direction from the
intermediate portion to the
outer portion.
[0098] A collapsible expansion cone assembly has also been described that
includes an upper tubular
support member including an internal flange, an upper cam assembly coupled to
the upper tubular
support member including: a tubular base coupled to the upper support member,
and a plurality of
cam arms extending from the tubular base in a downward longitudinal direction,
each cam arm
defining an inclined surface, a plurality of upper expansion cone segments
interleaved with the cam
arms of the upper cam assembly and pivotally coupled to the internal flange of
the upper tubular
support member, a lower tubular support member including an internal flange,
one or more frangible
couplings for releasably coupling the upper and lower tubular support members,
a lower cam
assembly coupled to the lower tubular support member including: a tubular base
coupled to the lower
tubular support member, and a plurality of cam arms extending from the tubular
base in an upward
longitudinal direction, each cam arm defining an inclined surface that mates
with the inclined surface
of a corresponding one of the upper expansion cone segments, wherein the cams
arms of the upper
cam assembly are interleaved with and overlap the cam arms of the lower cam
assembly, and a
plurality of lower expansion cone segments interleaved with cam arms of the
lower cam assembly,
each lower expansion cone segment pivotally coupled to the internal flange of
the lower tubular
support member and mating with the inclined surface of a corresponding one of
the cam arms of the
upper cam assembly, wherein the lower expansion cone segments interleave and
overlap the upper
expansion cone segments, wherein the upper and lower expansion cone segments
together define an
arcuate spherical external surface for plastically deforming and radially
expanding the expandable
tubular member, wherein each upper expansion cone segment includes: an inner
portion defining an
arcuate cylindrical upper surface including a hinge groove for pivotally
coupling the upper expansion
cone segment to the upper tubular support member and arcuate cylindrical lower
surfaces, an
intermediate portion defining arcuate cylindrical and spherical upper surfaces
and an arcuate conical
lower surface, and an outer portion defining arcuate cylindrical upper and
lower surfaces, wherein
each lower expansion cone segment includes: an inner portion defining an
arcuate cylindrical upper
surface including a hinge groove for pivotally coupling the lower expansion
cone segment to the
lower tubular support member and arcuate cylindrical lower surfaces, an
intermediate portion defining
22



CA 02489283 2004-12-10
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arcuate cylindrical and spherical upper surfaces and an arcuate conical lower
surface, and an outer
portion defining arcuate cylindrical upper and lower surfaces, wherein each
upper expansion cone
segment is tapered in the longitudinal direction from the intermediate portion
to the outer portion, and
wherein each lower expansion cone segment is tapered in the longitudinal
direction from the
intermediate portion to the outer portion.
[0099] An apparatus for radially expanding and plastically deforming an
expandable tubular member
has also been described that includes a tubular support member, a collapsible
expansion cone coupled
to the tubular support member, an expandable tubular member coupled to the
collapsible expansion
cone, means for displacing the collapsible expansion cone relative to the
expandable tubular member,
and means for collapsing the expansion cone. In an exemplary embodiment, the
tubular support
member includes an upper tubular support member including an internal flange
and a lower tubular
support member including an internal flange, wherein the expansion cone
includes: an upper cam
assembly coupled to the upper tubular support member including: a tubular base
coupled to the upper
support member, and a plurality of cam arms extending from the tubular base in
a downward
longitudinal direction, each cam arm defining an inclined surface, a plurality
of upper expansion cone
segments interleaved with the cam arms of the upper cam assembly and pivotally
coupled to the
internal flange of the upper tubular support member, a lower cam assembly
coupled to the lower
tubular support member including: a tubular base coupled to the lower tubular
support member, and a
plurality of cam arms extending from the tubular base in an upward
longitudinal direction, each cam
arm defining an inclined surface that mates with the inclined surface of a
corresponding one of the
upper expansion cone segments, wherein the cams arms of the upper cam assembly
are interleaved
with and overlap the cam arms of the lower cam assembly, and a plurality of
lower expansion cone
segments interleaved with cam arms of the lower cam assembly, each lower
expansion cone segment
pivotally coupled to the internal flange of the lower tubular support member
and mating with the
inclined surface of a corresponding one of the cam arms of the upper cam
assembly; and wherein the
apparatus further includes: means for releasably coupling the upper tubular
support member to the
lower tubular support member, and means for limiting movement of the upper
tubular support
member relative to the lower tubular support member. In an exemplary
embodiment, the apparatus
further includes: means for pivoting the upper expansion cone segments, and
means for pivoting the
lower expansion cone segments. In an exemplary embodiment, the apparatus
further includes: means
for pulling the collapsible expansion cone through the expandable tubular
member.
[00100] A collapsible expansion cone has also been described that includes an
upper cam assembly
including: a tubular base, and a plurality of cam arms extending from the
tubular base in a downward
longitudinal direction, each cam arm defining an inclined surface, a plurality
of upper expansion cone
segments interleaved with the cam arms of the upper cam assembly, a lower cam
assembly including:
a tubular base, and a plurality of cam arms extending from the tubular base in
an upward longitudinal
direction, each cam arm defining an inclined surface that mates with the
inclined surface of a
23



CA 02489283 2004-12-10
WO 03/106130 PCT/US03/18530
corresponding one of the upper expansion cone segments, wherein the cams arms
of the upper cam
assembly are interleaved with and overlap the cam arms of the lower cam
assembly, a plurality of
lower expansion cone segments interleaved with cam arms of the lower cam
assembly, each lower
expansion cone segment mating with the inclined surface of a corresponding one
of the cam arms of
the upper cam assembly, means for moving the upper cam assembly away from the
lower expansion
cone segments, and means for moving the lower cam assembly away from the upper
expansion cone
segments. In an exemplary embodiment, the upper and lower expansion cone
segments together
define an arcuate spherical external surface. In an exemplary embodiment, each
upper expansion
cone segment includes: an inner portion defining an arcuate upper surface and
arcuate cylindrical
lower surfaces, an intermediate portion defining arcuate cylindrical and
spherical upper surfaces and
an arcuate conical lower surface, and an outer portion defining arcuate
cylindrical upper and lower
surfaces, and wherein each lower expansion cone segment includes: an inner
portion defining an
arcuate cylindrical upper surface and arcuate cylindrical lower surfaces, an
intermediate portion
defining arcuate cylindrical and spherical upper surfaces and an arcuate
conical lower surface, and an
outer portion defining arcuate cylindrical upper and lower surfaces. In an
exemplary embodiment,
each upper expansion cone segment is tapered in the longitudinal direction
from the intermediate
portion to the outer portion, and each lower expansion cone segment is tapered
in the longitudinal
direction from the intermediate portion to the outer portion.
[00101) Also disclosed is a packer cup apparatus comprising a central mandrel,
a sealing cup
comprising a substantially unrestricted lip for sealing engaging a tubular
member, and a base portion
for sealingly engaging the central mandrel, a protecting member positioned
longitudinally along the
central mandrel, and a pliant backup member positioned between the protecting
member and the
sealing cup, a conical bushing positioned partially between the sealing cup
and the tubular support
member for supporting the base portion of the sealing cup.
[00102] A method of radially expanding and plastically deforming an expandable
tubular member has
also been described that includes supporting the expandable tubular member
using a tubular support
member and a collapsible expansion cone, injecting a fluidic material into the
tubular support
member, sensing the operating pressure of the injected fluidic material within
a first interior portion of
the tubular support member, displacing the collapsible expansion cone relative
to the expandable
tubular member when the sensed operating pressure of the injected fluidic
material exceeds a
predetermined level within the first interior portion of the tubular support
member, sensing the
operating pressure of the injected fluidic material within a second interior
portion of the tubular
support member, and collapsing the collapsible expansion cone when the sensed
operating pressure of
the injected fluidic material exceeds a predetermined level within the second
interior portion of the
tubular support member. In an exemplary embodiment, the method further
includes: pulling the
collapsible expansion cone through the expandable tubular member when the
sensed operating
pressure of the injected fluidic material exceeds a predetermined level within
the first interior portion
24



CA 02489283 2004-12-10
WO 03/106130 PCT/US03/18530
of the tubular support member. In an exemplary embodiment, pulling the
collapsible expansion cone
through the expandable tubular member includes: coupling one or more cup seals
to the tubular
support member above the collapsible expansion cone, pressuring the interior
of the expandable
tubular member below the cup seals, and pulling the collapsible expansion cone
through the
expandable tubular member using the cup seals. In an exemplary embodiment, the
tubular support
member includes an upper tubular support member and a lower tubular support
member, and wherein
collapsing the collapsible expansion cone includes displacing the upper
tubular member relative to the
lower tubular support member. In an exemplary embodiment, the collapsible
expansion cone
includes: an upper cam assembly including: a tubular base, and a plurality of
cam arms extending
from the tubular base in a downward longitudinal direction, each cam arm
defining an inclined
surface, a plurality of upper expansion cone segments interleaved with the cam
arms of the upper cam
assembly and pivotally coupled to the upper tubular support member, a lower
cam assembly
including: a tubular base, and a plurality of cam arms extending from the
tubular base in an upward
longitudinal direction, each cam arm defining an inclined surface that mates
with the inclined surface
of a corresponding one of the upper expansion cone segments, wherein the cams
arms of the upper
cam assembly are interleaved with and overlap the cam arms of the lower cam
assembly, and a
plurality of lower expansion cone segments interleaved with cam arms of the
lower cam assembly,
each lower expansion cone segment pivotally coupled to the lower tubular
support member and
mating with the inclined surface of a corresponding one of the cam arms of the
upper cam assembly.
[00103] 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.
[00104]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.

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date Unavailable
(86) PCT Filing Date 2003-06-12
(87) PCT Publication Date 2003-12-24
(85) National Entry 2004-12-10
Examination Requested 2008-05-12
Dead Application 2010-06-14

Abandonment History

Abandonment Date Reason Reinstatement Date
2009-06-12 FAILURE TO PAY APPLICATION MAINTENANCE FEE

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Registration of a document - section 124 $100.00 2004-12-10
Application Fee $400.00 2004-12-10
Maintenance Fee - Application - New Act 2 2005-06-13 $100.00 2005-05-24
Maintenance Fee - Application - New Act 3 2006-06-12 $100.00 2006-05-15
Maintenance Fee - Application - New Act 4 2007-06-12 $100.00 2007-05-18
Request for Examination $800.00 2008-05-12
Maintenance Fee - Application - New Act 5 2008-06-12 $200.00 2008-05-21
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
ENVENTURE GLOBAL TECHNOLOGY
Past Owners on Record
BRISCO, DAVID PAUL
WATSON, BROCK WAYNE
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Cover Page 2005-02-25 1 49
Abstract 2004-12-10 1 67
Claims 2004-12-10 14 648
Drawings 2004-12-10 36 721
Description 2004-12-10 25 1,677
Representative Drawing 2004-12-10 1 37
Claims 2004-12-11 14 760
Claims 2004-12-11 14 760
PCT 2004-12-10 7 295
Assignment 2004-12-10 9 335
PCT 2004-12-11 17 897
Prosecution-Amendment 2008-05-12 1 40