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Patent 2704662 Summary

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(12) Patent Application: (11) CA 2704662
(54) English Title: SYSTEM FOR DRILLING A WELLBORE
(54) French Title: SYSTEME POUR LE FORAGE D'UN PUITS
Status: Dead
Bibliographic Data
(51) International Patent Classification (IPC):
  • E21B 7/20 (2006.01)
  • E21B 43/10 (2006.01)
(72) Inventors :
  • BLANGE, JAN-JETTE (Netherlands (Kingdom of the))
  • KRIESELS, PETRUS CORNELIS (Netherlands (Kingdom of the))
(73) Owners :
  • SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V. (Netherlands (Kingdom of the))
(71) Applicants :
  • SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V. (Netherlands (Kingdom of the))
(74) Agent: SMART & BIGGAR
(74) Associate agent:
(45) Issued:
(86) PCT Filing Date: 2008-12-08
(87) Open to Public Inspection: 2009-06-18
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): Yes
(86) PCT Filing Number: PCT/EP2008/066994
(87) International Publication Number: WO2009/074526
(85) National Entry: 2010-05-04

(30) Application Priority Data:
Application No. Country/Territory Date
07122725.0 European Patent Office (EPO) 2007-12-10

Abstracts

English Abstract



A system is disclosed for drilling a wellbore (1) into
an earth formation. The system comprises an expandable tubular
element (4) extending into the wellbore, whereby a lower end portion
(11) of the wall of the tubular element (8) extends radially outward and
in axially reverse direction so as to define an expanded tubular section
(10) extending around a remaining tubular section (4) of the tubular
element. The expanded tubular section is extendable by downward
movement of the remaining tubular section relative to the expanded
tubular section whereby said lower end portion (14) of the wall bends
radially outward and in axially reverse direction.




French Abstract

L'invention porte sur un système pour le forage d'un puits (1) dans une formation terrestre. Le système comprend un élément tubulaire extensible (4) s'étendant dans le puits, ce par quoi une partie d'extrémité inférieure (11) de la paroi de l'élément tubulaire (8) s'étend radialement vers l'extérieur et dans une direction axialement inverse de façon à définir une section tubulaire étendue (10) s'étendant autour d'une section tubulaire restante (4) de l'élément tubulaire. La section tubulaire étendue peut être étendue par un déplacement vers le bas de la section tubulaire restante par rapport à la section tubulaire étendue, ce par quoi ladite partie d'extrémité inférieure (14) de la paroi s'incurve radialement vers l'extérieur et dans une direction axialement inverse.

Claims

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



- 14 -


C L A I M S


1. A system for drilling a wellbore into an earth
formation, comprising
- an expandable tubular element extending into the
wellbore, whereby a lower end portion of the wall of the
tubular element extends radially outward and in axially
reverse direction so as to define an expanded tubular
section extending around a remaining tubular section of
the tubular element, the expanded tubular section being
extendable by downward movement of the remaining tubular
section relative to the expanded tubular section whereby
said lower end portion of the wall bends radially outward
and in axially reverse direction; and

- a drill string extending through the remaining
tubular section, wherein the tubular element and the
drill string are arranged for transferring a thrust force
from the tubular element to the drill string, and wherein
the drill string includes a jetting head for deepening
the wellbore by jetting a stream of fluid against the
bottom of the wellbore.


2. The system of claim 1, further comprising means for
centralising the jetting head in the remaining tubular
section.

3. The system of claim 1 or 2, wherein the expanded
tubular section has an outer diameter, and wherein the
drill string is provided with a reamer for reaming the
wellbore to at least the outer diameter of the expanded
tubular section.


4. The system of any one of claims 1-3, wherein the
remaining tubular section and the drill string are
arranged for simultaneous lowering in the wellbore.


- 15 -


5. The system of claim 4, wherein said lower end portion
of the wall is arranged for lowering into the wellbore at
substantially the same speed as lowering of the drill
string during drilling of the wellbore.

6. The system of any one of claims 1-5, wherein the wall
of the tubular element includes a material susceptible of
plastic deformation during said bending of the wall so
that the expanded tubular section retains an expanded
shape as a result of said plastic deformation.


7. The system of any one of claims 1-6, wherein the
remaining tubular section is subjected to an axially
compressive force acting to induce said downward movement
of the remaining tubular section.

8. The system of claim 7, wherein said axially
compressive force results at least partly from the weight
of the remaining tubular section.


9. The system substantially as described hereinbefore
with reference to the drawings.

Description

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



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SYSTEM FOR DRILLING A WELLBORE

The present invention relates to a system for
drilling a wellbore into an earth formation whereby an
expandable tubular element extends into the wellbore.
The technology of radially expanding tubular elements
in wellbores finds increasing application in the industry
of oil and gas production from subterranean formations.
Wellbores are generally provided with one or more casings
or liners to provide stability to the wellbore wall,
and/or to provide zonal isolation between different earth
formation layers. The terms "casing" and "liner" refer to
tubular elements for supporting and stabilising the
wellbore wall, whereby it is generally understood that a
casing extends from surface into the wellbore and that a
liner extends from a certain depth further into the
wellbore. However, in the present context, the terms
"casing" and "liner" are used interchangeably and without
such intended distinction.
In conventional wellbore construction, several
casings are set at different depth intervals, and in a
nested arrangement, whereby each subsequent casing is
lowered through the previous casing and therefore has a
smaller diameter than the previous casing. As a result,
the cross-sectional wellbore size that is available for
oil and gas production, decreases with depth. To
alleviate this drawback, it has become general practice
to radially expand one or more tubular elements at the
desired depth in the wellbore, for example to form an
expanded casing, expanded liner, or a clad against an
existing casing or liner. Also, it has been proposed to
radially expand each subsequent casing to substantially
the same diameter as the previous casing to form a


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monobore wellbore. It is thus achieved that the available
diameter of the wellbore remains substantially constant
along (a portion of) its depth as opposed to the
conventional nested arrangement.
EP 1438483 B1 discloses a system for expanding a
tubular element in a wellbore whereby the tubular
element, in unexpanded state, is initially attached to a
drill string during drilling of a new wellbore section.
To expand such wellbore tubular element, generally a
conical expander is used with a largest outer diameter
substantially equal to the required tubular diameter
after expansion. The expander is pumped, pushed or pulled
through the tubular element. Such method can lead to high
friction forces between the expander and the tubular

element. Also, there is a risk that the expander becomes
stuck in the tubular element.
EP 0044706 A2 discloses a flexible tube of woven
material or cloth that is expanded in a wellbore by
eversion to separate drilling fluid pumped into the
wellbore from slurry cuttings flowing towards the
surface.

However there is a need for an improved system for
drilling a wellbore whereby an expandable tubular element
extends into the wellbore.
In accordance with the invention there is provided a
system for drilling a wellbore into an earth formation,
comprising
- an expandable tubular element extending into the
wellbore, whereby a lower end portion of the wall of the
tubular element extends radially outward and in axially
reverse direction so as to define an expanded tubular
section extending around a remaining tubular section of
the tubular element, the expanded tubular section being


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extendable by downward movement of the remaining tubular
section relative to the expanded tubular section whereby
said lower end portion of the wall bends radially outward
and in axially reverse direction; and

- a drill string extending through the remaining
tubular section, wherein the tubular element and the
drill string are arranged for transferring a thrust force
from the remaining tubular section to the drill string,
and wherein the drill string includes a jetting head for

deepening the wellbore by jetting a stream of fluid
against the bottom of the wellbore.
By moving the remaining tubular section downward
relative to the expanded tubular section during drilling,
the tubular element is effectively turned inside out

whereby the lower end portion of the wall of the tubular
element is continuously bent radially outward and in
axially reverse direction so that the tubular element is
progressively expanded without the need for an expander
that is pushed, pulled or pumped through the tubular
element. In this manner the expanded tubular section
forms a casing or liner that is installed in the wellbore
during the drilling process, so that a relatively short
open-hole section can be maintained during drilling.

Furthermore, the thrust force transmitted from the
remaining tubular section to the drill string can be kept
small since the jetting head requires only a small thrust
force when compared to the large thrust force required
for drilling with a conventional drill bit. In view
thereof, the downward force that must be exerted to the
remaining tubular section to move it downward includes
only a small component for thrusting the drill string
during drilling. It is thereby achieved that the risk of
exceeding the yield strength of the remaining tubular


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section is significantly reduced, when compared to
drilling with a conventional drill bit.

Suitably the system of the invention comprises means
for centralising the jetting head in the remaining
tubular section.
In a preferred embodiment, the drill string is
provided with a reamer for reaming the wellbore to at
least an outer diameter of the expanded tubular section.
To maintain a short open-hole section while drilling,
it is preferred that the remaining tubular section and
the drill string are arranged for simultaneous lowering
in the wellbore whereby, for example, said lower end
portion of the wall is arranged for lowering into the
wellbore at substantially the same speed as the speed of

lowering of the drill string during drilling of the
wellbore.
It is preferred that the wall of the tubular element
includes a material that is plastically deformed during
the bending process, so that the expanded tubular section
retains an expanded shape as a result of said plastic
deformation. Thus, there is no need for an external force
or pressure to be applied to the expanded tubular section
to maintain its expanded form. If, for example, the
expanded tubular section is expanded against the wellbore
wall as a result of said bending of the wall, no external
radial force or pressure needs to be exerted to the
expanded tubular section to keep it against the wellbore
wall. Suitably the wall of the tubular element is made of
a metal such as steel or any other ductile metal capable

of being plastically deformed by eversion of the tubular
element. The expanded tubular section then has adequate
collapse resistance, for example in the order of 100-150
bars.


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Suitably the remaining tubular section is induced to
move downward while the expanded tubular section is kept
stationary in the wellbore.
In order to induce said downward movement it is
5 preferred that the remaining tubular section is subjected
to an axially compressive force, which at least partly
can result from the weight of the remaining tubular
section. If necessary the weight can be supplemented by
an external, downward, force applied to the remaining
tubular section to induce said movement. As the length,
and hence the weight, of the remaining tubular section
increases, an upward force may need to be applied to the
remaining tubular section to prevent uncontrolled bending
or buckling of the wall.

Suitably the remaining tubular section is axially
extended at its upper end in correspondence with its
downward movement. This is done, for example, by adding
tubular portions at the upper end in any suitable manner
such as by welding. Alternatively, the remaining tubular
section is formed as a coiled tubing that is unreeled
from a reel and subsequently inserted into the wellbore.
In this way the process of eversion of the tubular
element can be continued until a desired length of the
tubular element is expanded.

The invention will be described hereinafter in more
detail and by way of example, with reference to the
accompanying drawing in which:
Fig. 1 schematically shows a lower portion of a first
embodiment of the system of the invention;

Fig. 2 schematically shows the first embodiment
during cutting of a tubular element in a wellbore; and
Fig. 3 schematically shows a lower portion of a

second embodiment of the system of the invention.


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In the drawing and the description, like reference
numerals relate to like components.

Referring to Figs. 1 and 2, there is shown a system
including a wellbore 1 extending into an earth formation
2, and an expandable tubular element in the form of liner
4 extending from surface downwardly into the wellbore 1.
The liner 4 has been partially radially expanded by
eversion of the wall of the liner whereby a radially
expanded tubular section 10 of the liner 4 has been
formed, which has an outer diameter substantially equal
to the wellbore diameter. A remaining tubular section of
the liner 4, in the form of unexpanded liner section 8,
extends concentrically within the expanded tubular
section 10.

The wall of the liner 4 is, due to eversion at its
lower end, bent radially outward and in axially reverse
(i.e. upward) direction so as to form a U-shaped lower
section 11 of the liner interconnecting the unexpanded
liner section 8 and the expanded liner section 10. The U-
shaped lower section 11 of the liner 4 defines a bending
zone 12 of the liner.

The expanded liner section 10 is axially fixed to the
wellbore wall 14 by any suitable anchoring means (not
shown), or by frictional forces between the expanded
liner section 10 and the wellbore wall 14 resulting from
the expansion process. The U-shaped lower section 11 of
liner 4 is positioned a short distance above the bottom
of the wellbore so that an open-hole wellbore section 13
is defined below the U-shaped lower section 11.

A drill string 20 extends from surface through the
unexpanded liner section 8 to the bottom of the wellbore
1, with a jetting head 22 at its lower end. The jetting
head 22 comprises a plurality of jetting nozzles 24 and


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cutting nozzles 26. The jetting nozzles 24 are directed
so as to eject fluid jets 28 against the bottom and/or
the wall of the wellbore 1. Each fluid jet 28 suitably
includes a stream of fluid, e.g. water, with abrasive
particles entrained therein. The cutting nozzles 26 are
directed radially outward from the jetting head.

The drill string 20 is provided with a guide device
30 having a curved surface portion 32 arranged to
transfer a thrust force from the liner 4 to the drill
string 20, and to support and guide the U-shaped lower
section 11 of the liner 4 during eversion of the liner 4.
The guide device 30 is rotatable relative to the drill
string 20 about its central longitudinal axis.
Furthermore, the guide device 30 is collapsible so as to

allow it to pass through the unexpanded liner section 4
(Fig. 2).
In Fig. 3 is shown the second embodiment, which is
substantially similar to the first embodiment, except
that the cutting head 22 is provided with reamers 33
adapted to ream the wellbore 1 to a nominal diameter
substantially equal to the outer diameter of the expanded
liner section 10. The reamers 33 are radially retractable
to allow the reamers 33 to pass through the unexpanded
liner section 4 when in retracted mode.
During normal operation or the first embodiment
(Figs. 1 and 2), a lower end portion of the liner 4 is
initially everted. That is, the lower end portion is bent
radially outward and in axially reverse direction,
whereby the U-shaped lower section 11 and a short length
of expanded liner section 10 are initiated. Subsequently,
the expanded liner section 10 is anchored to the wellbore
wall 14 by the anchoring means. Depending on the geometry
and/or material properties of the liner 4, the expanded


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liner section 10 alternatively can become anchored to the
wellbore wall automatically by friction forces between
the expanded liner section 10 and the wellbore wall 14.
A downward force is then applied to the unexpanded
liner section 8 so as to move it gradually downward. As a
result, the unexpanded liner section 8 becomes
progressively everted whereby the unexpanded liner
section 8 is transformed into the expanded liner section
10. The bending zone 12 moves in downward direction
during the eversion process at approximately half the
speed of downward movement of the unexpanded liner
section B.

If desired, the mechanical properties and dimensions
of the liner 4 can be selected such that the expanded
liner section 10 becomes pressed against the wellbore
wall 14 as a result of the expansion process so as to
seal against the wellbore wall and/or to stabilize the
wellbore wall.
Since the length, and hence the weight, of the
unexpanded liner section 8 gradually increases, the
magnitude of the downward force can be gradually lowered
in correspondence with the increasing weight of
unexpanded liner section 8. Eventually, the downward
force may need to be replaced by an upward force to
prevent buckling of liner section 8.
The unexpanded liner section 8 is at its upper end
extended in correspondence with its downward movement,
for example by adding tubular sections to the liner, or
by continuously forming the liner from metal sheet on a
reel.
Simultaneously with downward movement of the
unexpanded liner section 8 into the wellbore, the drill
string 20 is operated to deepen the wellbore bottom by


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ejecting the fluid jets 28 against the wellbore bottom
whereby the drill string is rotated slowly. The drill
string 20 thereby gradually moves downward into the
wellbore 1. The force applied to the unexpanded liner
section 4 is controlled such that the U-shaped section 11
of the liner 4 moves downward at the same speed as the
drill string 20 and remains in contact with the curved
surface portion 32 of guide device 30 whereby the U-
shaped lower section 11 exerts a small thrust force to
the drill string 20. With increasing eversion of the
liner 4, an increasing portion of the thrust force
results from the weight of the unexpanded liner section
8.

Since the jetting head 22 requires only a small

thrust force for excavating the welibore, relative to the
thrust force required for drilling with a conventional
drill bit, the compressive load in unexpanded liner
section 4 can be kept relatively low. It is thereby
achieved that the risk of inadvertent buckling of the
unexpanded liner section 4 is significantly reduced.
If it is required to cut the unexpanded liner section
4, the guide device 30 is collapsed and the drill string
20 is raised until the cutting nozzles 26 are positioned
at the desired cutting level (Fig. 2). Subsequently fluid
jets 36 with entrained abrasive particles are jetted
through cutting nozzles 26 against the unexpanded liner
section 4 thereby cutting the liner section 4.
Normal operation of the second embodiment is
substantially similar to normal operation of the first
embodiment. In addition, the reamers 33 are kept in

expanded mode during drilling with the drill string 20
thereby enlarging the diameter of the wellbore 1 to the
nominal diameter.


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In a modified version of the second embodiment (not
shown), the drill string is at its lower end provided
with a conventional pilot drill bit for drilling a pilot
bore of relatively small diameter, and the reamers are
provided with jetting nozzles to enlarge the borehole to
its nominal diameter. Since the jetting nozzles can be
precisely controlled with respect to direction and
velocity of the fluid jets, the jetting nozzles in the
reamers allow accurate drilling of the borehole to its
nominal diameter.

When it is required to retrieve the drill string 20
to surface the guide device 30 and the reamers 33 (if
present) are radially retracted and the drill string 20
is retrieved through the unexpanded liner section 8.

With the system of the invention, it is achieved that
the wellbore is progressively lined with the everted
liner directly above the jetting head during the drilling
process. As a result, there is only a relatively short
open-hole section of the wellbore at all times. The
advantages of such short open-hole section will be most
pronounced during drilling into a hydrocarbon fluid
containing layer of the earth formation. In view thereof,
for many applications it will be sufficient if the
process of liner eversion during drilling is applied only
during drilling into the hydrocarbon fluid reservoir,
while other sections of the wellbore are lined or cased
in conventional manner. Alternatively, the process of
liner eversion during drilling may be commenced at
surface or at a selected downhole location, depending on
circumstances.
In view of the short open-hole section during
drilling, there is a significantly reduced risk that the
wellbore fluid pressure gradient exceeds the fracture


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gradient of the rock formation, or that the wellbore
fluid pressure gradient drops below the pore pressure
gradient of the rock formation. Therefore, considerably
longer intervals can be drilled at a single nominal
diameter than in a conventional drilling practice whereby
casings of stepwise decreasing diameter must be set at
selected intervals.
Also, if the wellbore is drilled through a shale
layer, such short open-hole section eliminates possible
problems due to a heaving tendency of the shale.

After the wellbore has been drilled to the desired
depth and the drill string has been removed from the
wellbore, the length of unexpanded liner section that is
still present in the wellbore can be left in the wellbore
or it can be cut-off from the expanded liner section and
retrieved to surface.
In case the length of unexpanded liner section is
left in the wellbore, there are several options for
completing the wellbore. These are, for example, as
follows:
A) A fluid, for example brine, is pumped into the
annulus between the unexpanded and expanded liner
sections so as to pressurise the annulus and increase
the collapse resistance of the expanded liner
section. Optionally one or more holes are provided in
the U-shaped lower section to allow the pumped fluid
to be circulated.
B) A heavy fluid is pumped into the annulus so as to
support the expanded liner section and increase its
collapse resistance.

C) Cement is pumped into the annulus in order to create,
after hardening of the cement, a solid body between
the unexpanded liner section and the expanded liner


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section, whereby the cement may expand upon
hardening.
D) The unexpanded liner section is radially expanded
(i.e. clad) against the expanded liner section, for
example by pumping, pushing or pulling an expander
through the unexpanded liner section.

In the above examples, expansion of the liner is
started at surface or at a downhole location. In case of
an offshore wellbore whereby an offshore platform is
positioned above the wellbore, at the water surface, it
can be advantageous to start the expansion process at the
offshore platform. In such process, the bending zone
moves from the offshore platform to the seabed and from
there further into the wellbore. Thus, the resulting

expanded tubular element not only forms a liner in the
wellbore, but also a riser extending from the offshore
platform to the seabed. The need for a separate riser
from is thereby obviated.
Furthermore, conduits such as electric wires or
optical fibres for communication with downhole equipment
can be extended in the annulus between the expanded and
unexpanded sections. Such conduits can be attached to the
outer surface of the tubular element before expansion
thereof. Also, the expanded and unexpanded liner sections
can be used as electricity conductors to transfer data
and/or power downhole.
Since any length of unexpanded liner section that is
still present in the wellbore after completion of the
eversion process, will be subjected to less stringent
loading conditions than the expanded liner section, such
length of unexpanded liner section may have a smaller
wall thickness, or may be of lower quality or steel
grade, than the expanded liner section. For example, it


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may be made of a material having a relatively low yield
strength or relatively low collapse rating.
Instead of leaving a length of unexpanded liner
section in the wellbore after the expansion process, the
entire liner can be expanded with the method described
above so that no unexpanded liner section remains in the
wellbore. In such case, an elongate member, for example a
pipe string, can be used to exert the necessary downward
force to the unexpanded liner section during the last

phase of the eversion process.

In order to reduce friction forces between the
unexpanded and expanded liner sections during the
expansion process, suitably a friction reducing layer,
such as a Teflon layer, is applied between the unexpanded
and expanded liner sections. For example, a friction
reducing coating can be applied to the outer surface of
the liner before expansion. Such layer of friction
reducing material furthermore reduces the annular
clearance between the unexpanded and expanded sections,
which results in a reduced tendency of the unexpanded
section to buckle. Instead of, or in addition to, such
friction reducing layer, centralizing pads and/or rollers
can be applied between the unexpanded and expanded
sections to reduce the friction forces and the annular
clearance there-between.
Instead of expanding the expanded liner section
against the wellbore wall (as described), the expanded
liner section can be expanded against the inner surface
of another tubular element already present in the

wellbore.

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 2008-12-08
(87) PCT Publication Date 2009-06-18
(85) National Entry 2010-05-04
Dead Application 2014-12-09

Abandonment History

Abandonment Date Reason Reinstatement Date
2013-12-09 FAILURE TO REQUEST EXAMINATION
2013-12-09 FAILURE TO PAY APPLICATION MAINTENANCE FEE

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $400.00 2010-05-04
Maintenance Fee - Application - New Act 2 2010-12-08 $100.00 2010-05-04
Maintenance Fee - Application - New Act 3 2011-12-08 $100.00 2011-11-09
Maintenance Fee - Application - New Act 4 2012-12-10 $100.00 2012-10-11
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Past Owners on Record
BLANGE, JAN-JETTE
KRIESELS, PETRUS CORNELIS
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) 
Abstract 2010-05-04 2 74
Claims 2010-05-04 2 55
Drawings 2010-05-04 3 95
Description 2010-05-04 13 490
Representative Drawing 2010-05-04 1 30
Cover Page 2010-07-07 2 50
PCT 2010-05-04 3 77
Assignment 2010-05-04 2 100
Correspondence 2011-01-31 2 133