Note: Descriptions are shown in the official language in which they were submitted.
CA 02414449 2005-10-19
LINER HANGER WITH SLIP JOINT
SEALING MEMBERS
Background of the Invention
This invention relates generally to wellbore casings, and in particular to
apparatus and methods for repairing wellbore casings.
Conventionally, when a wellbore casing is damaged, a tubular liner is
positioned within the damaged section of the wellbore casing in order to
provide
structural support and prevent the undesired outflow of drilling fluid into
the
formation or inflow of fluid from the formation into the borehole. However,
conventional tubular liners used for repairing damaged sections of wellbore
casings
suffer from a number of serious drawbacks. For example, conventional tubular
liners used for repairing damaged sections of wellbore casings are not
designed to
accommodate variable loading conditions.
The present invention is directed to overcoming one or more of the
limitations of the existing apparatus and methods for repairing damaged
sections of
the wellbore casings.
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CA 02414449 2005-10-19
Summary of the Invention
According to one aspect of the present invention, a method of
repairing a damaged section of a wellbore casing is provided that includes
removing at least a portion of the damaged section of the wellbore casing
to create an opening in the wellbore casing, and covering at least a portion
of the opening in the wellbore casing with a floating tubular member.
According to another aspect of the present invention, a radially
ea~andable tubular member for repairing an opening in a wellbore casing
is provided that includes a tubular member and a slip joint coupled to the
e~erior surface of the tubular member.
According to another aspect of the present invention, an apparatus
for repairing an opening in a.wellbore casing is provided that includes a
tubular support member including a first passage, an expansion cone
coupled to the tubular support member including a second passage
~m~cly coupled to the first passage, an e~-pansion cone launcher coupled
to the ea-pansion cone including a shoe having an exhaust passage, and an
eh-pandable tubular member coupled to the e~-pansion cone launcher
including one or more sealing members having slip joints.
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According to another aspect of the present invention, an apparatus
is provided that includes a wellbore casing including an opening, and a
floating tubular member coupled to the wellbore casing in opposing
relation to the opening.
According to another aspect of the present invention, a system for
repairing a damaged section of a wellbore casing is provided that includes
means for removing at least a portion of the damaged section of the
wellbore casing to create an opening in the wellbore casing, and means for
covering at least a portion of the opening in the wellbore casing with a
floating tubular member.
Brief Description of the Drawings
FIG. 1 is a cross-sectional view illustrating a wellbore casing
including a damaged section.
FIG. 2 is a fragmentary cross-sectional view illustrating the
introduction of a milling device into the wellbore casing of FIG. 1.
FIG. 3 is a fragmentary cross-sectional view illustrating the
removal of at least a portion of the damaged section of the wellbore casing
using the milling device to form an opening in the wellbore casing of FIG.
..,.
FIG. 4 is a fragmentary cross-sectional view illustrating the
placement of a repair apparatus for covering the opening in the wellbore
casing of FIG. 3.
FIG. 5 is a fragmentary cross-sectional view illustrating the
injection of fluidic materials into the repair apparatus of FIG. 4.
?5 FIG. G is a fr agmentary cross-sectional ~riew illustr ating the
pressurization of the interior of the repair apparatus of FIG. 5.
FIG. 7 is a fragmentary cross-sectional view illustrating the
completion of the radial expansion of the eh-pandable tubular member of
the repair apparatus of FIG. 6.
FIG. 8 is a cross-sectional view illustrating the milling out of the
shoe of the radially expanded tubular member of FIG. 7.
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FIG. 9 is a cross-sectional illustration of an embodiment of upper
and lower sealing members that include internal slip joints.
Detailed Description of the Illustrative Embodiments
An apparatus and method for repairing an opening in a damaged
section of a wellbore casing within a subterranean formation is provided.
The apparatus and method provides a system for repairing an opening in
a damaged section of a wellbore casing within a subterranean formation
in which a tubular member is radially expanded into contact with the
wellbore casing. The physical connection between the radially eh~anded
tubular member and the wellbore casing is preferably compliant and
permits movement of the radially eh-panded tubular member relative to
the wellbore casing in at least the longitudinal direction. In this manner,
the radially expanded tubular member is capable of absorbing a wide
range of loading conditions.
Referring initially to Fig. 1, a wellboxe 100 positioned within a
subterranean formation 105 includes a preexisting casing 110 that
traverses a producing formation l I5. The portion of the casing 110 that
traverses the producing formation 115 includes a damaged section 120.
As will be recognized by persons having ordinary skill in the art, the
damaged section 120 may be caused by, for example, structural
instabilities in the producing formation 115 such as, for example,
subsidence that can cause buckling of the wellbore casing 110.
Referring to Figs. 2 and 3, in order to repair the damaged section
120 of the wellbore casing 110, a conventional milling device 125 is then
inserted into the wellbore casing 110. The milling device 125 is then used
to remove at least a portion of the damaged section 120 of the wellbore
casing 110 and thereby form an opening 130 in the wellbore casing 110.
Referring to Fig. 4, an apparatus 200 for repairing the opening 130
in the wellbore casing 110 may then be positioned within the wellbore
casing proximate the opening in the wellbore casing.
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The apparatus 200 includes a tubular support member 205 having a
longitudinal passage 210 and a transverse passage 215 that is coupled to an
expansion cone 220 having a longitudinal passage 225 that is fluidicly coupled
to
the longitudinal passage 210. The expansion cone 220 is at least partially
received
within an expansion cone launcher 230 that includes a thin-walled annular
member
235 and a shoe 240 having an exhaust passage 245. An expandable tubular member
250 extends from the expansion cone launcher 230 that includes upper and lower
sealing members 255a and 255b affixed to the exterior surface of the
expandable
tubular member. A sealing cup 260 is attached to the exterior surface of the
tubular
support member 205 for preventing foreign materials from entering the interior
of
the expandable tubular member 250.
In a preferred embodiment, the apparatus 200 is provided as disclosed in one
or more of the following: (1) U.S. patent no. 6,328,113 issued on
December 11, 2001, (2) U.S. patent no. 6,497,289 issued on December 24, 2002,
(3)
U.S. patent no. 6,823,937 issued on November 30, 2004, (5) U.S. patent no.
6,575,240 issued on June 10, 2003, (6) U.S. patent no. 6,640,903 issued on
November 4, 2003, (7) U.S. patent no. 6,604,763 issued on August 12, 2003, (8)
U.S. patent no. 6,557,640 issued on May 6, 2003, (12) U.S. patent no.
6,568,471
issued on May 27, 2003.
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As illustrated in Fig. 4, during placement of the apparatus 200
within the wellbore casing 110, fluidic materials displaced by the
apparatus 200 are conveyed through the longitudinal passages 210 and
225 to the transverse passage 215. In this manner, surge pressures
during the placement of the apparatus 200 within the wellbore casing 110
are minimized. Furthermore, as illustrated in Fig. 4, the apparatus 200 is
preferably positioned with the tubular member 250 in opposing relation to
the opening 130 i.n the wellbore casing 110. In this manner, the upper
and lower sealing members 255a and 255b may engage portions of the
wellbore casing 110 above and below the opening 130 after radially
expanding the tubular member 250.
As illustrated in Fig. 5, the transverse passage 215 may then be
closed and fluidic materials injected into the apparatus 200 through the
longitudinal passage 210. In this manner, any blockages within any of the
passages 210, 225, and 245 may be detected by monitoring the operating
pressure whereby an increase in operating pressure above nominal, or
predetermined, conditions may indicate a blockage of one of the passages.
As illustrated in Fig. 6, a plug 265 or other conventional stop
member may then be introduced into the fluidic materials injected into
the apparatus 200 through the passage 210, and the plug 265 may be
positioned within the passage 245. In this manner, the passage 245 may
be sealed off. Thus, continued injection of fluidic materials into the
apparatus 200 through the passage 210 may thereby pressurize a region
270 below the eh-pansion cone 220.
As illustrated in Fig: 7, continued pressurization of the region 270
causes the expansion cone 220 to radially expand the expandable tubular
member 250 off of the expansion cone. In this manner, the upper and
lower sealing members 255a and 255b preferably engage the interior walls
of the wellbore casing 110 above and below the opening 130 thereby
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sealing off the opening. In a preferred embodiment, during the radial
expansion process, the tubular support member 205 is raised out of the
wellbore 100.
As illustrated in Fig. 8, the shoe 240 may then be removed using a
conventional milling device. In this manner, exploration and production
of subterranean regions beyond the opening 130 in the wellbore casing
110 may be conducted.
In several alternative embodiments, the upper sealing member
255a or the lower sealing member 255b are omitted from the tubular
member 250. In this manner, the radially expanded tubular member 250
is permitted to float relative to the wellbore casing 110. Furthermore, in
this manner, relative longitudinal and/or transverse movements of the
sections of the wellbore casing 110 above and below the opening 130 may
be optimally accommodated by the radially expanded tubular member
250. Finally, in this manner, damage to the radially expanded tubular
member 250 that can be caused by longitudinal stresses, such as buckling,
may be minimized or eliminated.
In another alternative embodiment, as illustrated in Fig. 9, the
upper sealing member 255a and/or the lower sealing member 255b include
internal slip joints 300a and 300b in order to permit the radially expanded
tubular member 250 to float relative to the wellbore casing 110. In this
manner, relative longitudinal and/or transverse movements of the sections
of the wellbore casing 110 above and below the opening 130 may be
optimally accommodated. Furthermore, in this manner, damage to the
radially expanded tubular member 250 that can be caused by longitudinal
stresses, such as buckling, may be minimized or eliminated.
In a preferred embodiment, the sealing members 255a and 255b
permit the radially eh-panded tubular member 250 to move in the
longitudinal direction while also maintaining a fluidic seal. In several
alternative embodiments, the sealing members 255a and 255b are
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fabricated from a resilient material such as, for example, synthetic or
natural rubber.
It is understood that variations may be made in the foregoing
without departing from the scope of the invention. For example, the
apparatus 200 may be used to repair, for example, a wellbore casing, a
pipeline, or a structural support.
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.
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