Note: Descriptions are shown in the official language in which they were submitted.
CA 02595540 2007-08-15
METHOD AND APPARATUS FOR CASING EXPANSION
This is a division of co-pending Canadian Patent Application No. 2,419,806
filed on
September 27, 2001.
Background of the Invention
This invention relates generally to wellbore casings, and in particular to
wellbore
casings that are formed using expandable tubing.
Conventionally, when a wellbore is created, a number of casings are installed
in the
borehole to prevent collapse of the borehole wall and to prevent undesired
outflow of drilling
fluid into the formation or inflow of fluid from the formation into the
borehole. The borehole
is drilled in intervals whereby a casing which is to be installed in a lower
borehole interval is
lowered through a previously installed casing of an upper borehole interval.
As a
consequence of this procedure the casing of the lower interval is of smaller
diameter than the
casing of the upper interval. Thus, the casings are in a nested arrangement
with casing
diameters decreasing in downward direction. Cement annuli are provided between
the outer
surfaces of the casings and the borehole wall to seal the casings from the
borehole wall. As a
consequence of this nested arrangement a relatively large borehole diameter is
required at the
upper part of the wellbore. Such a large borehole diameter involves increased
costs due to
heavy casing handling equipment, large drill bits and increased volumes of
drilling fluid and
drill cuttings. Moreover, increased drilling rig time is involved due to
required cement
pumping, cement hardening, required equipment changes due to large variations
in hole
diameters drilled in the course of the well, and the large volume of cuttings
drilled and
removed.
The present invention is directed to overcoming one or more of the limitations
of the
existing procedures for forming wellbores.
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CA 02595540 2007-08-15
Summary of the Invention
In accordance with one aspect of the present invention there is provided a
method of
coupling a first tubular member to a second tubular member, comprising:
plastically
deforming and radially expanding a first portion of the first tubular member
to a first outside
diameter; plastically deforming and radially expanding another portion of the
first tubular
member to a second outside diameter; positioning the second tubular member
inside the first
tubular member in overlapping relation to the first portion of the first
tubular member;
plastically deforming and radially expanding the second tubular member to a
third outside
diameter; and plastically deforming and radially expanding the second tubular
member to a
fourth outside diameter; wherein the first and second tubular members after
the plastic
deformations and radial expansions define a passage having a constant cross
sectional area.
In accordance with another aspect of the present invention there is provided a
method
of forming a mono-diameter wellbore casing within a wellbore, comprising:
supporting a
first tubular member within the wellbore; plastically deforming and radially
expanding a first
portion of the first tubular member to a first outside diameter; plastically
deforming and
radially expanding another portion of the first tubular member to a second
outside diameter;
positioning the second tubular member inside the first tubular member in
overlapping relation
to the radially expanded first portion of the first tubular member;
plastically deforming and
radially expanding the second tubular member to a third outside diameter; and
plastically
deforming and radially expanding the second tubular member to a fourth outside
diameter;
wherein the first and second tubular members after the plastic deformations
and radial
expansions define a passage having a constant cross sectional area.
In accordance with yet another aspect of the present invention there is
provided a
method of forming a mono-diameter wellbore casing within a wellbore,
comprising:
supporting a first tubular member within the wellbore; providing a lipped
portion in a portion
of the first tubular member; plastically deforming and radially expanding
another portion of
the first tubular member; positioning the second tubular member inside the
first tubular
member in overlapping relation to the lipped portion of the first tubular
member; and
plastically deforming and radially expanding the second tubular member;
wherein the inside
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diameters of the first and second tubular members after the plastic
deformations and radial
expansions are substantially equal.
In accordance with still yet another aspect of the present invention there is
provided a
method of bridging an axial gap between opposing pairs of wellbore casing
within a
wellbore, comprising: supporting a tubular member in overlapping relation to
the opposing
ends of the wellbore casings; plastically deforming and radially expanding the
tubular
member; and plastically deforming and radially expanding the tubular member
and the
opposing ends of the wellbore casings.
In accordance with still yet another aspect of the present invention there is
provided a
method of forming a wellbore casing in a wellbore, comprising: supporting a
tubular
member within the wellbore; providing a lipped portion in a portion of the
tubular member;
and plastically deforming and radially expanding another portion of the
tubular member;
wherein the lipped portion comprises an inwardly directed tapered portion.
In accordance with still yet another aspect of the present invention there is
provided a
method of plastically deforming and radially expanding a tubular member,
comprising:
plastically deforming and radially expanding a portion of the tubular member
to a first final
outside diameter; and plastically deforming and radially expanding another
portion of the
tubular member to a second final outside diameter; wherein the first final
outside diameter is
different from the second final outside diameter; and wherein plastically
deforming and
radially expanding the portions of the tubular member comprises applying a
radial force to
the tubular member using a roller expansion device.
In accordance with still yet another aspect of the present invention there is
provided a
method of plastically deforming and radially expanding a tubular member,
comprising:
plastically deforming and radially expanding a portion of the tubular member
to a first
outside diameter; and plastically deforming and radially expanding another
portion of the
tubular member to a second outside diameter; wherein the first outside
diameter is different
from the second outside diameter; and wherein plastically deforming and
radially expanding
the portions of the tubular member comprises applying a radial force to the
tubular member
using an inflatable bladder.
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CA 02595540 2007-08-15
Brief Description of the Drawings
Fig. la is a cross sectional illustration of a wellbore including a
preexisting
wellbore casing.
Fig. lb is a cross-sectional illustration of the placement of an embodiment of
an
apparatus for radially expanding a tubular member into the wellbore of Fig.
la.
Fig. lc is a cross-sectional illustration of the injection of fluidic
materials through
the apparatus of Fig. lb.
Fig. ld is a cross-sectional illustration of the injection of hardenable
fluidic sealing
materials through the apparatus of Fig. ic.
Fig. le is a cross-sectional illustration of the pressurization of the region
below the
expansion cone of the apparatus of Fig. 1d.
Fig. lf is a cross-sectional illustration of the continued pressurization of
the region
below the expansion cone of the apparatus of Fig. le.
Fig. lg is a cross-sectional illustration of the continued pressurization of
the region
below the expansion cone of the apparatus of Fig. if following the removal of
the over-
expansion sleeve.
Fig. lh is a cross-sectional illustration of the completion of the radial
expansion of
the expandable tubular member of the apparatus of Fig. lg.
Fig. 1 i is a cross-sectional illustration of the drilling out of a new
section of the
wellbore below the apparatus of Fig. lh.
Fig. lj is a cross-sectional illustration of the radial expansion of another
expandable tubular member that overlaps with the apparatus of Fig. li.
Fig. lk is a cross-sectional illustration of the secondary radial expansion of
the
other expandable tubular member of the apparatus of Fig. 11.
Fig. 11 is a cross-sectional illustration of the completion of the secondary
radial
expansion of the other expandable tubular member of Fig. lk to form a mono-
diameter
wellbore casing.
Fig. 2a is a cross sectional illustration of a wellbore including a
preexisting
wellbore casing.
Fig. 2b is a cross-sectional illustration of the placement of an embodiment of
an
apparatus for radially expanding a tubular member into the wellbore of Fig.
2a.
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Fig. 2c is a-cross-sectional illustration of the injection of fluidic
materials through
the apparatus of Fig. 2b.
Fig: 2d is a cross-sectional illustration of the injection of hardenable
fluidic sealing
materials through the apparatus of Fig. 2c.
Fig. 2e is a cross-sectional illustration of the pressurization of the region
below the
expansion cone of the apparatus of Fig. 2d.
Fig. 2f is a cross-sectional illustration of the continued pressurization of
the region
below the expansion cone of the apparatus of Fig. 2e.
Fig. 2g is a cross-sectional illustration of the completion of the radial
expansion of
the expandable tubular member of the apparatus of Fig. 2f.
Fig. 2h is a cross-sectional illustration of the drilling out of a new section
of the
wellbore below the apparatus of Fig. 2g.
Fig. 2i is a cross-sectional illustration of the radial expansion of another
expandable tubular member that overlaps with the apparatus of Fig. 2h.
Fig. 2j is a cross-sectional illustration of the secondary radial expansion of
the
other expandable tubular member of the apparatus of Fig. 2i.
Fig. 2k is a cross-sectional illustration of the completion of the secondary
radial
expansion of the other expandable tubular member of Fig. 2j to form a mono-
diameter
wellbore casing.
Fig. 3 is a cross-sectional illustration of the apparatus of Fig. 2b
illustrating the
design and construction of the over-expansion insert.
Fig. 3a is a cross-sectional illustration of an alternative embodiment of the
over-
expansion insert of Fig. 3.
Fig. 4 is a cross-sectional illustration of an alternative embodiment of the
apparatus
of Fig. 2b including a resilient hook for retrieving the over-expansion
insert.
Fig. 5a is a cross-sectional illustration of a wellbore including a
preexisting
wellbore casing.
Fig. 5b is a cross-sectional illustration of the formation of a new section of
wellbore casing in the wellbore of Fig. 5a.
Fig. 5c is a fragmentary cross-sectional illustration of the placement of an
inflatable bladder into the new section of the wellbore casing of Fig. 5b.
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CA 02595540 2007-08-15
Fig. 5d is a fragmentary cross-sectional illustration of the inflation of the
inflatable
bladder of Fig. 5c.
Fig. 5e is a cross-sectional illustration of the new section of welibore
casing of Fig.
5d after over-expansion.
Fig. 5f is a cross-sectional illustration of the new section of wellbore
casing of Fig.
5e after drilling out a new section of the wellbore.
Fig. 5g is a cross-sectional illustration of the formation of a mono-diameter
wellbore casing that includes the new section of the wellbore casing and an
additional
section of wellbore casing.
Fig. 6a is a cross-sectional illustration of a wellbore including a
preexisting
wellbore casing.
Fig. 6b is a cross-sectional illustration of the formation of a new section of
wellbore casing in the wellbore of Fig. 6a.
Fig. 6c is a fragmentary cross-sectional illustration of the placement of a
roller
radial expansion device into the new section of the welibore casing of Fig.
6b.
Fig. 6d is a cross-sectional illustration of the new section of wellbore
casing of Fig.
6c after over-expansion.
Fig. 6e is a cross-sectional illustration of the new section of wellbore
casing of Fig.
6d after drilling out a new section of the wellbore.
Fig. 6f is a cross-sectional illustration of the formation of a mono-diameter
wellbore casing that includes the new section of the wellbore casing and an
additional
section of wellbore casing.
Fig. 7a is a cross sectional illustration of a wellbore including a
preexisting
wellbore casing.
Fig. 7b is a cross-sectional illustration of the placement of an embodiment of
an
apparatus for radially expanding a tubular member into the wellbore of Fig.
7a.
Fig. 7c is a cross-sectional illustration of the injection of fluidic
materials through
the apparatus of Fig. 7b.
Fig. 7d is a cross-sectional illustration of the injection of hardenable
fluidic sealing
materials through the apparatus of Fig. 7c.
Fig. 7e is a cross-sectional illustration of the pressurization of the region
below the
expansion cone of the apparatus of Fig. 7d.
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CA 02595540 2007-08-15
Fig. 7f is a cross-sectional illustration of the continued pressurization of
the region
below the expansion cone of the apparatus of Fig. 7e.
Fig.-ag is a-cross-sectionalillustration ofthe_comp.letion_o.f-the radial
expansion of
the expandable tubular member of the apparatus of Fig. 7f.
Fig. 7h is a cross-sectional illustration of the drilling out of a new section
of the
wellbore below the apparatus of Fig. 7g.
Fig. 7i is a cross-sectional illustration of the completion of the radial
expansion of
another expandable tubular member to form a mono-diameter wellbore casing.
Fig. 8a is cross-sectional illustration of an wellbore including a preexisting
section
of welibore casing having a recessed portion.
Fig. 8b is a cross-sectional illustration of the placement of an apparatus for
radially
expanding a tubular member within the wellbore of Fig. 8a.
Fig. 8c is a cross-sectional illustration of the injection of fluidic
materials through
the apparatus of Fig. 8b:
Fig. 8d is a cross-sectional illustration of the injection of a hardenable
fluidic
sealing material through the apparatus of Fig. 8c.
Fig. 8e is cross-sectional illustration of the isolation of the region below
the
expansion cone and within the expansion cone launcher of the apparatus of Fig.
8d.
Fig. 8f is a cross-sectional illustration of the plastic deformation and
radial
expansion of the upper portion of the expandable tubular member of the
apparatus of Fig.
8e.
Fig. 8g is a cross-sectional illustration of the removal of the upper
expansion cone
from the wellbore of fig. 8f.
Fig. 8h is a cross-sectional illustration of the continued pressurization of
the region
below the expansion cone of the apparatus of Fig. 8g to thereby plastically
deform and
radially expand the expansion cone launcher and expandable tubular member.
Fig. 8i is a cross-sectional illustration of the completion of the initial
radial
expansion process of the apparatus of Fig. 8h.
Fig. 8j is a cross-sectional illustration of the fiu-ther radial expansion of
the
apparatus of Fig. 8i in order to form a mono-diameter wellbore casing.
Fig. 9a is a cross-sectional illustration of a wellbore including upper and
lower
preexisting wellbore casings that are separated by an axial gap.
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CA 02595540 2007-08-15
Fig. 9b is a cross-sectional illustration of the coupling of a tubular member
to the
opposing ends of the wellbore casings of Fig. 9a.
Fig. 9c is a fragmentary eross-seetional il-l-ustr-at-ion of the placement of-
a radial
expansion device into the tubular member of Fig. 9b.
Fig. 9d is a fragmentary cross-sectional illustration of the actuation of the
radial
expansion device of Fig. 9c.
Fig. 9e is a cross-sectional of a mono-diameter wellbore casing generated by
the
actuation of the radial expansion device of Fig. 9d.
Fig. 10 is a cross-sectional illustration of a mono-diameter wellbore casing
that
includes a plurality of layers of radially expanded tubular members along at
least a portion
of the its length.
Fig. 11 a is a cross-sectional illustration of a wellbore including a casing
formed by
plastically deforming and radially expanding a first tubular member.
Fig. 11b is a cross-sectional-illustration of a wellbore including another
casing
coupled to the preexisting casing by plastically deforming and radially
expanding a second
tubular member.
Fig, 1 lc is a cross-sectional illustration of a mono-diameter wellbore casing
formed by radially expanding the second tubular member a second time.
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Detailed Description
Several embodiments of methods and apparatus for forming a mono-diameter
wellbore casing are disclosed. In several alternative embodiments the methods
and
apparatus may be used for form or repair mono-diameter wellbore casings,
pipelines, or
structural supports. Furthermore, while the present illustrative embodiments
are
described with reference to the formation of mono-diameter wellbore casings,
the
teachings of the present disclosure have general application to the formation
or repair of
wellbore casings, pipelines, and structural supports.
Referring initially to Fig. I a, a wellbore 10 includes a preexisting wellbore
casing 15. The wellbore 10 may be oriented in any orientation from the
vertical to the
horizontal. The preexisting wellbore casing 15 may be coupled to the upper
portion of
the wellbore 10 using any number of conventional methods. In a preferred
embodiment,
the wellbore casing 15 is coupled to the upper portion of the wellbore 10
using one or
more of the methods and apparatus disclosed in one or more of the following:
U.S. PatentNos. 6,557,460; 6,604,763; 6,575,240; 6,966,370; 6,712,154;
6,640,903;
6,725,919; 6,892,819; 6,328,113; 6,823,937; 6,568,471; 6,739,392; 6,745,845;
6,758,278;
6,857,473; 6,497,289; 7,011,161; 7,021,390; 6,604,763; 6,564,875; 6,695,012;
7,048,067;
7,100,684; and WO 01/04535. More generally, the preexisting wellbore casing 15
may
be coupled to another preexisting wellbore casing and/or may include one or
more
concentrically positioned tubular members.
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Referring to Fig. lb, an apparatus 100 for radially expanding a tubular member
may then be positioned within the wellbore 10. The apparatus 100 includes a
tubular
support member 105 defining a passage 110 for conveying fluidic materials. An
expansion cone 115 defming a passage 120 and having an outer conical surface
125 for
radially expanding tubular members is coupled to an end of the tubular support
member
105. An annular conical over-expansion sleeve 130 mates with and is removably
coupled
to the outer conical surface 125 of the expansion cone 115. In several
alternative
embodiments, the over-expansion sleeve 130 is fabricated from frangible
materials such
as, for example, ceramic materials, in order to facilitate the removal of the
over-expansion
sleeve during operation of the apparatus 100. In this manner, the amount of
radial
expansion provided by the apparatus may be decreased following the removal of
the over-
expansion sleeve 130.
An expansion cone launcher 135 is movably coupled to and supported by the
expansion cone 115 and the over-expansion sleeve 130. The expansion cone
launcher 135
include an upper portion having an upper outer diameter, an intermediate
portion that
mates with the expansion cone 115 and the over-expansion sleeve 130, an a
lower portion
having a lower outer diameter. The lower outer diameter is greater than the
upper outer
diameter. A shoe 140 defining a valveable passage 145 is coupled to the lower
portion of
the expansion cone launcher 135. In a preferred embodiment, the valveable
passage 145
may be controllably closed in order to fluidicly isolate a region 150 below
the expansion
cone 115 and bounded by the lower portion of the expansion cone launcher 135
and the
shoe 140 from the region outside of the apparatus 100.
An-ex-p- andable-tubular-membe~~s-eotipledte the-upper-por-tion-of the
expansion cone launcher 135. One or more sealing members 160a and 160b are
coupled
to the exterior of the upper portion of the expandable tubular member 155. In
several
alternative embodiments, the sealing members 160a and 160b may include
elastomeric
elements and/or metallic elements and/or composite elements. In several
alternative
embodiments, one or more anchoring elements may substituted for, or used in
addition to,
the sealing members 160a and 160b.
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In a preferred embodiment, the support member 105, the expansion cone 115,
the expansion cone launcher 135, the shoe 140, and the expandable tubular
member 155
are provided substantially as disclosed in one or more of the following: U.S.
Patent
Nos. 6,557,460; 6,604,763; 6,575,240; 6,966,370; 6,712,154; 6,640,903;
6,725,919;
6,892,819; 6,328,113; 6,823,937; 6,568,471; 6,739,392; 6,745,845; 6,758,278;
6,857,473;
6,497,289; 7,011,161; 7,021,390; 6,604,763; 6,564,875; 6,695,012; 7,048,067;
7,100,684;
and WO 01/04535.
As illustrated in Fig. lb, in a preferred embodiment, during placement of the
apparatus 100 within the wellbore 10, fluidic materials 165 within the
wellbore 10 are
conveyed through the apparatus 100 through the passages 110, 120 and 145 to a
location
above the apparatus 100. In this manner, surge pressures during placement of
the
apparatus 100 within the wellbore 10 are reduced. IUi a preferred embodiment,
the
apparatus 100 is initially positioned within the wellbore 10 such that the top
portion of the
tubular member 155 overlaps with the preexisting casing 15. In this manner,
the upper
portion of the expandable tubular member 155 may be radially expanded into
contact with
and coupled to the preexisting casing 15. As will be recognized by persons
having
ordinary skill in the art, the precise initial position of the expandable
tubular member 155
will vary as a function of the amount of radial expansion, the amount of axial
shrinkage
during radial expansion, and the material properties of the expandable tubular
member.
As illustrated in Fig. 1c, a fluidic material 170 may then be injected through
the
apparatus 100 through the passages 110, 120, and 145 in order to test the
proper operation
of these passages.
As illustrated in Fig, ld, a hardenable fluidic sealing materia1175 may then
be
injected through the apparatus 100 through the passages 110, 120 and 145 into
the annulus
between the apparatus and the,welibore 10. In this manner, an annular barrier
to fluid
migration into and out of the wellbore 10 may be formed around the radially
expanded
expansion cone launcher 135 and expandable tubular member 155. The hardenable
fluidic
sealing material may include, for example, a cement mixture. In several
alternative
embodiments, the injection of the hardenable fluidic sealing materia1175 may
be omitted.
In several alternative embodiments, the hardenable fluidic sealing material
175 is
compressible, before, during and/or after, the curing process.
As illustrated in Fig. le, a non-hardenable fluidic material 180 may then be
injected into the apparatus through the passages 110 and 120. A ball plug 185,
or other
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similar device, may then be injected with the fluidic materia1180 to thereby
seal off the
passage 145. In this manner, the region 150 may be pressurized by the
continued injection
of the-#luidie-rnaterial--1-80-intoAe-apparat-as-lOA.-
As illustrated in Fig. lf, the continued injection of the fluidic material 180
into the
apparatus 100 causes the expansion cone launcher 135 and expandable tubular
member
155 to be plastically deformed and radially expanded off of the over-expansion
sleeve 130.
In this manner, the expansion cone 115 and over-expansion sleeve 130 are
displaced
relative to the expansion cone launcher 135 and expandable tubular member 155
in the
axial direction.
After a predetermined time period and/or after a predetermined axial
displacement
of the expansion cone 115 relative to the expansion cone launcher 135 and
expandable
tubular member 155, the over-expansion sleeve 130 may be removed from the
outer
conical surface 125 of the expansion cone 115 by the application of a
predetermined
upward shock load to the-support member 105: - ln-a-preferred embodiment, the
shock load
causes the frangible over-expansion sleeve 130 to fracture into small pieces
that are then
forced off of the outer conical surface 125 of the expansion cone 115 by the
continued
pressurization of the region 150. In a preferred embodiment, the pieces of the
over-
expansion sleeve 130 are pulverized into grains of material by the continued
pressurization
of the region 150.
Referring to Fig. 1 g, following the removal of the frangible over-expansion
sleeve
130, the continued pressurization of the region 150 causes the expandable
tubular member
155 to be plastically deformed and radially expanded and extruded off of the
outer conical
surface 125 of the expansion cone 115. Note that the amount of radial
expansion provided
by the outer conical surface 125 of expansion cone 115 is less than the amount
of radial
expansion provided by the combination of the over-expansion sleeve 130 and the
expansion cone 115. In this manner, as illustrated in Fig. lh, a recess 185 is
formed in the
radially expanded tubular member 155.
After completing the plastic deformation and radial expansion of the tubular
member 155, the hardenable fluidic sealing material is allowed to cure to
thereby form an
annular body 190 that provides a barrier to fluid flow into or out of the
wellbore 10.
Referring to Fig. li, the shoe 140 may then removed by drilling out the shoe
using
a conventional drilling device. A new section of the wellbore 10 may also be
drilled out in
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order to permit additional expandable tubular members to be coupled to the
bottom portion
of the plastically deformed and radially expanded tubular member 155.
3Zeferrirrg-to-Fig.-1j; a t-ubplar-rnember300-may-then be-plastic-afly-
deforrn.ed and
radially expanded using any number of conventional methods of radially
expanding a
tubular member. In a preferred embodiment, the upper portion of the radially
expanded
tubular member 200 overlaps with and mates with the recessed portion 185 of
the tubular
member 155. In a preferred embodiment, one or more sealing members 205 are
coupled to
the exterior surface of the upper portion of the tubular member 200. In a
preferred
embodiment, the sealing members 205 seal the interface between the upper
portion of the
tubular member 200 and the recessed portion 185 of the tubular member 155. In
several
alternative embodiments, the sealing members 205 may include elastomeric
elements
and/or metallic elements and/or composite elements. In several alternative
embodiments,
one or more anchoring elements may substituted for, or used in addition to,
the sealing
-members 205.- In a preferred embodiment, -an annular body 210 of a hardenable
fluidic
sealing material is also formed around the tubular member 200 using one or
more
conventional methods.
In a preferred embodiment, the tubular member 200 is plastically deformed and
radially expanded, and the annular body 210 is formed using one or more of the
apparatus
and methods disclosed in the following:
U.S. Patent Nos. 6,557,460; 6,604,763; 6,575,240; 6,966,370; 6,712,154;
6,640,903; 6,725,919; 6,892,819; 6,328,113; 6,823,937; 6,568,471; 6,739,392;
6,745,845;
6,758,278; 6,857,473; 6,497,289; 7,011,161; 7,021,390; 6,604,763; 6,564,875;
6,695,012;
7,048,067; 7,100,684; and WO 01/04535.
In an altemative embodiment, the annular body 210 may be omitted. In several
alternative embodiments,the-annularbody -21- 0-may-be radially compressed -
before, during
and/or after curing.
Refexring to Fig. 1k, an expansion cone 215 may then be driven in a downward
direction by fluid pressure and/or by a support member 220 to plastically
deform and
radially expand the tubular member 200 such that the interior diameter of the
tubular
members 155 and 200 are substantially equal. In this manner, as illustrated in
Fig. 11, a
mono-diameter wellbore casing may be formed.
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Referring to Figs. 2a and 2b, in an alternative embodiment, an apparatus 300
for
radially expanding a tubular member may then be positioned within the wellbore
10. The
apparatus 300 includes a tubular support member 305 defining a passage 310 for
conveying fluidic materials. An expansion cone 315 defining a passage 320 and
having an
outer coziical surface 325 for radially expanding tubular members is coupled
to an end of
the tubular support member 305. An annular conical over-expansion insert 330
mates with
and is removably coupled to the outer conical surface 325 of the expansion
cone 315.
An expansion cone launcher 335 is movably coupled to and supported by the
expansion cone 315 and the over-expansion insert 330. The expansion cone
launcher 335
includes an upper portion having an upper outer diameter, an intermediate
portion that
mates with the expansion cone 315 and the over-expansion insert 330, an a
lower portion
having a lower outer diameter. The lower outer diameter is greater than the
upper outer
diameter. A shoe 340 defuiirig a valveable passage 345 is coupled to the lower
portion of
the expansion cone launcher 335. In a preferred embodiment, the valveable
passage 345
may be controllably closed in order to fluidicly isolate a region 350 below
the expansion
cone 315 and bounded by the lower portion of the expansion cone launcher 335
and the
shoe 340 from the region outside of the apparatus 300.
In a preferred embodiment, as illustrated in Fig. 3, the over-expansion insert
330
includes a plurality of spaced-apart arcuate inserts 330a, 330b, 330c and 330d
that are
positioned between the outer conical surface 325 of the expansion cone 315 and
the inner
surface of the intermediate portion of the expansion cone launcher 335. In
this manner,
the relative axial displacement of the expansion cone 315 and the expansion
cone launcher
335 will cause the expansion cone to over-expand the intermediate portion of
the
expansion cone launcher. In this manner, a recess may be formed in the
radially expanded
expansion cone launcher 335. In several alternative embodiments, the inserts
330a, 330b,
330c, and 330d fall out of the recess and/or are removed from the recess using
a
conventional retrieval tool upon the completion of the radial expansion
process.
In an alternative embodiment, as illustrated in Fig. 3a, the over expansion
insert
330 further includes intermediate resilient members 331a, 331b, 331c, and 331d
for
resiliently coupling the inserts 330a, 330b, 330c, and 330d. In this manner,
upon the
completion of the radial expansion process, the resilient force exerted by the
resilient
members 331 causes the over-expansion insert to collapse in the radial
direction and
thereby fall out of the recess.
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CA 02595540 2007-08-15
An expandable tubular member 355 is coupled to the upper portion of the
expansion cone launcher 335. One or more sealing members 360a and 360b are
coupled
to the exterior of the upper portion of the expandable tubular member 355. In
several
alternative embodiments, the sealing members 360a and 360b may include
elastomeric
elements and/or metallic elements and/or composite elements. In several
alternative
embodiments, one or more anchoring elements may substituted for, or used in
addition to,
the sealing members 360a and 360b.
In a preferred embodiment, the support member 305, the expansion cone 315, the
expansion cone launcher 335, the shoe 340, and the expandable tubular member
355 are
provided substantially as disclosed in one or more of the following: U.S.
Patent
Nos. 6,557,460; 6,604,763; 6,575,240; 6,966,370; 6,712,154; 6,640,903;
6,725,919;
6,892,819; 6,328,113; 6,823,937; 6,568,471; 6,739,392; 6,745,845; 6,758,278;
6,857,473;
6,497,289; 7,011,161; 7,021,390; 6,604,763; 6,564,875; 6,695,012; 7,048,067;
7,100,684;
and WO 01/04535.
As illustrated in Fig. 2b, in a preferred embodiment, during placement of the
apparatus 300 within the wellbore 10, fluidic materials 365 within the
wellbore 10 are
conveyed through the apparatus 300 through the passages 310, 320 and 345 to a
location
above the apparatus 300. In this manner, surge pressures during placement of
the
apparatus 300 within the wellbore 10 are reduced. In a preferred embodiment,
the
apparatus 300 is initially positioned within the wellbore 10 such that the top
portion of the
tubular member 355 overlaps with the preexisting casing 15. In this manner,
the upper
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CA 02595540 2007-08-15
portion of the expandable tubular member 355 may be radially expanded into
contact with
and coupled to the preexisting casing 15. As will be recognized by persons
having
-ordinary-skill in the art,-the-preeise initial position-of-the-e-xpandable--
tubular member 355
will vary as a function of the amount of radial expansion, the amount of axial
shrinkage
during radial expansion, and the material properties of the expandable tubular
member.
As illustrated in Fig. 2c, a fluidic materia1370 may then be injected through
the
apparatus 300 through the passages 310, 320, and 345 in order to test the
proper operation
of these passages.
As illustrated in Fig. 2d, a hardenable fluidic sealing materia1375 may then
be
injected through the apparatus 300 through the passages 310, 320 and 345 into
the annulus
between the apparatus and the wellbore 10. In this manner, an annular barrier
to fluid
migration into and out of the wellbore 10 may be formed around the radially
expanded
expansion cone launcher 335 and expandable tubular member 355. The hardenable
fluidic
sealing material may include, for example, a cement mixture. In several
alternative
embodiments, the injection of the hardenable fluidic sealing materia1375 maybe
omitted.
In several alternative embodiments, the hardenable fluidic sealing material
375 is
compressible, before, during andlor after, the curing process.
As illustrated in Fig. 2e, a non-hardenable fluidic materia1380 may then be
injected into the apparatus through the passages 310 and 320. A ball plug 385,
or other
similar device, may then be injected with the fluidic material 380 to thereby
seal off the
passage 345. In this manner, the region 350 maybe pressurized by the continued
injection
of the fluidic materia1380 into the apparatus 300.
As illustrated in Fig. 2f, the continued injection of the fluidic materia1380
into the
apparatus 300 causes the expansion cone launcher 335 to be plastically
deformed and
radially expanded off of the over-expansion insert 330. In this manner, the
expansion cone
315 is displaced relative to the expansion cone launcher 335 and expandable
tubular
member 355 in the axial direction.
Once the radial expansion process has progressed beyond the over-expansion
insert
330, the radial expansion of the expansion cone launcher 335 and expandable
tubular
member 355 is provided solely by the outer conical surface 325 of the
expansion cone 315.
Note that the amount of radial expansion provided by the outer conical surface
325 of
expansion cone 315 is less than the amount of radial expansion provided by the
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CA 02595540 2007-08-15
combination of the over-expansion insert 330 and the expansion cone 315. In
this manner,
as illustrated in Fig. 2g, a recess 390 is formed in the radially expanded
tubular member
355.
In several alternative embodiments, the over-expansion insert 330 is removed
from
the recess 390 by falling out and/or removal using a conventional retrieval
tool. In an
alternative embodiment, the resilient force provided by the resilient members
33 la, 331b,
331c, and 331d cause the insert 330 to collapse in the radial direction and
thereby fall out
of the recess 390. In an alternative embodiment, as illustrated in Fig. 4, one
or more
resilient hooks 395a and 395b are coupled to the bottom of the expansion cone
315 for
retrieving the over-expansion insert 330 during or after the completion of the
radial
expansion process.
After completing the plastic deformation and radial expansion of the tubular
member 355, the hardenable fluidic sealing material is allowed to cure to
thereby form an
-annular body 400 that provides a barrier to fluid flow into or out of the
wellbore 10.
Referring to Fig. 2h, the shoe 340 may then removed by drilling out the shoe
using
a conventional drilling device. A new section of the wellbore 10 may also be
drilled out in
order to permit additional expandable tubular members to be coupled to the
bottom portion
of the plastically deformed and radially expanded tubular member 355.
Referring to Fig. 2j, a tubular member 405 may then be plastically deformed
and.
radially expanded using any number of conventional methods of radially
expanding a
tubular member. In a preferred embodiment, the upper portion of the radially
expanded
tubular member 405 overlaps with and mates with the recessed portion 390 of
the tubular
member 355. Tn a preferred embodiment, one or more sealing members 410 are
coupled to
the exterior surface of the upper portion of the tubular member 405. In a
preferred
embodiment, the sealing members 410 seal the interface between the upper
portion of the
tubular member 405 and the recessed portion 390 of the tubular member 355. In
several
alternative embodiments, the sealing members 410 may include elastomeric
elements
and/or metallic elements and/or composite elements. In several alternative
embodiments,
one or more anchoring elements may substituted for, or used in addition to,
the sealing
members 410. In a preferred embodiment, an annular body 415 of a hardenable
fluidic
sealing material is also formed around the tubular member 405 using one or
more
conventional methods.
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CA 02595540 2007-08-15
In a preferred embodiment, the tubular member 405 is plastically deformed and
radially expanded, and the annular body 415 is formed using one or more of the
apparatus
and methods disclosed in the following: U.S. Patent Nos. 6,557,460; 6,604,763;
6,575,240; 6,966,370; 6,712,154; 6,640,903; 6,725,919; 6,892,819; 6,328,113;
6,823,937;
6,568,471; 6,739,392; 6,745,845; 6,758,278; 6,857,473; 6,497,289; 7,011,161;
7,021,390;
6,604,763; 6,564,875; 6,695,012; 7,048,067; 7,100,684; and WO 01/04535.
In an alternative embodiment, the annular body 415 may be omitted. In several
alternative embodiments, the annular body 415 may be radially compressed
before,
during and/or after curing.
Referring to Fig. 2j, an expansion cone 420 may then be driven in a downward
direction by fluid pressure and/or by a support member 425 to plastically
deform and
-radia.}ly-expand th.e-t-ubularmernber-4-05-such that-the-inteor-diameterof
the tubular
members 355 and 405 are substantially equal. In this.manner, as illustrated in
Fig. 2k, a
mono-diameter wellbore casing may be formed.
Referring to Figs 5a-5b, in an alternative embodiment, a tubular member 500
having a shoe 505 may be plastically deformed and radially expanded and
thereby coupled
to the preexisting section of wellbore casing 15 using any number of
conventional
methods. An annular body of a fluidic sealing materia1510 may also be formed
around the
tubular member 500 using any number of conventional methods. In a preferred
embodiment, the tubular member 500 is plastically deformed and radially
expanded and
the annular body 510 is formed using one or more of the methods and apparatus
disclosed
in one or more of the following: -
U.S. Patent Nos. 6,557,460; 6,604,763; 6,575,240; 6,966,370; 6,712,154;
6,640,903; 6,725,919; 6,892,819; 6,328,113; 6,823,937; 6,568,471; 6,739,392;
6,745,845;
6,758,278; 6,857,473; 6,497,289; 7,011,161; 7,021,390; 6,604,763; 6,564,875;
6,695,012;
7,048,067; 7,100,684; and WO 01/04535.
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CA 02595540 2007-08-15
In several alternative embodiments, the annular body 510 may be omitted or may
be compressible before, during, or after curing.
Referring to Figs. 5c and 5d, a conventional inflatable bladder 515 may then
be
positioned within the tubular member 500 and inflated to a sufficient
operating pressure to
plastically deform and radially expand a portion of the tubular member to
thereby form a
recess 520 in the tubular member.
Referring to Figs. 5e and 5f, the inflatable bladder 515 may then be removed
and
the shoe 505 drilled out using a conventional drilling device.
Referring to Fig. 5g, an additional tubular member 525 may then be plastically
deformed and radially expanded in a conventional manner and/or by using one or
more of
the methods and apparatus described above in order to form a mono-diameter
wellbore
casing. Before, during or after the radial expansion of the tubular member
525, an annular
body 530 of a fluidic sealing material may be formed around the tubular member
in a
conventional manner and/or by using one or more of the methods and apparatus
described
above.
In several alternative embodiments, the inflatable bladder 515 may be coupled
to
the bottom of an expansion cone in order to permit the over-expansion process
to be
performed during the radial expansion process implemented using the expansion
cone.
Referring to Figs 6a-6b, in an alternative embodiment, a tubular member 600
having a shoe 605 may be plastically deformed and radially expanded and
thereby coupled
to the preexisting section of wellbore casing 15 using any number of
conventional
methods. An annular body of a fluidic sealing material 610 may also be formed
around the
tubular member 600 using any number of conventional methods. In a preferred
embodiment, the tubular member 600 is plastically deformed and radially
expanded and
the annular body 610 is formed using one or more of the methods and apparatus
disclosed
in one or more of the following:
U.S. Patent Nos. 6,557,460; 6,604,763; 6,575,240; 6,966,370; 6,712,154;
6,640,903; 6,725,919; 6,892,819; 6,328,113; 6,823,937; 6,568,471; 6,739,392;
6,745,845;
6,758,278; 6,857,473; 6,497,289; 7,011,161; 7,021,390; 6,604,763; 6,564,875;
6,695,012;
7,048,067; 7,100,684; and WO 01/04535.
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CA 02595540 2007-08-15
In several alternative embodiments, the annular body 610 may be omitted or may
be compressible before, during, or after curing.
Referring to Figs. 6c and 6d, a conventional roller expansion device 615 may
then
be positioned within the tubular member 600 and operated in a conventional
manner apply
a radial force to the interior surface of the tubular member 600 to
plastically deform and
radially expand a portion of the tubular member to thereby form a recess 620
in the tubular
member. As will be recognized by persons having ordinary slcill in the art, a
roller
expansion device typically utilizes one or more rollers that, through rotation
of the device,
apply a radial force to the interior surfaces of a tubular member. In several
alternative
-embodiments; the roller expansion device-615-may include eccentric rollers
such as, for
example, as disclosed in U.S. Pat. Nos. 5,014,779 and 5,083,608.
Referring to Figs. 6d and 6e, the roller expansion device 615 may then be
removed
and the shoe 605 drilled out using a conventional drilling device.
Referring to Fig. 6f, an additional tubular member 625 may then be plastically
deformed and radially expanded in a conventional manner andlor by using one or
more of
the methods and apparatus described above in order to fonn a mono-diameter
wellbore
casing. Before, during or after the radial expansion of the tubular member
625, an annular
body 630 of a fluidic sealing material maybe formed around the tubular member
in a
conventional manner and/or by using one or more of the methods and apparatus
described
above.
In several alternative embodiments, the roller expansion device 615 may be
coupled to the bottom of an expansion cone in order to permit the over-
expansion process
to be performed during the radial expansion process implemented using the
expansion
cone.
Referring initially to Fig. 7a, a wellbore 10 includes a preexisting wellbore
casing
15. The wellbore 10 may be oriented in any orientation from the vertical to
the horizontal.
The preexisting wellbore casing 15 may be coupled to the upper portion of the
wellbore 10
using any number of conventional methods. In a preferred embodiment, the
wellbore
casing 15 is coupled to the upper portion of the wellbore 10 using one or more
of the
methods and apparatus disclosed in one or more of the following:
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CA 02595540 2007-08-15
U.S. Patent Nos. 6,557,460; 6,604,763; 6,575,240; 6,966,370; 6,712,154;
6,640,903; 6,725,919; 6,892,819; 6,328,113; 6,823,937; 6,568,471; 6,739,392;
6,745,845;
6,758,278; 6,857,473; 6,497,289; 7,011,161; 7,021,390; 6,604,763; 6,564,875;
6,695,012;
7,048,067; 7,100,684; and WO 01/04535.
More generally, the preexisting wellbore casing 15 may be coupled to another
preexisting wellbore casing and/or may include one or more concentrically
positioned
tubular members.
Referring to Fig. 7b, an apparatus 700 for radially expanding a tubular member
may then be positioned within the wellbore 10. The apparatus 700 includes a
tubular
support member 705 defuiing a passage 710 for conveying fluidic materials. An
expansion cone 715 defining a passage 720 and having an outer conical surface
725 for
radially expanding tubular members is coupled to an end of the tubular support
member
705.
An expansion cone launcher 735 is movably coupled to and supported by the
expansion cone 715. The expansion cone launcher 735 includes an upper portion
735a
having an upper outer diameter, an intermediate portion 735b that niates with
the
expansion cone 715, and a lower portion 735c having a lower outer diameter.
The lower
outer diameter is greater than the upper outer diameter. The expansion cone
launcher 735
further includes a recessed portion 735d having an outer diameter that is less
than the
lower outer diameter.
A-shoe 740--dofining-a-valveable-passage 745-is-coupled--to the-lowerportion
of the
expansion cone launcher 735. In a preferred embodiment, the valveable passage
745 may
be controllably closed in order to fluidicly isolate a region 750 below the
expansion cone
715 and bounded by the lower portion 735c of the expansion cone launcher 735
and the
shoe 740 from the region outside of the apparatus 700.
An expandable tubular member 755 is coupled to the upper portion 735a of the
expansion cone launcher 735. One or more sealing members 760a and 760b may be
coupled to the exterior of the upper portion of the expandable tubular member
755. In
several altemative embodiments, the sealing members 760a and 760b may include
elastomeric elements and/or metallic elements and/or composite elemerits. In
several
alternative embodiments, one or more anchoring elements may substituted for,
or used in
addition to, the sealing members 760a and 760b.
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CA 02595540 2007-08-15
In a preferred embodiment, the support member 705, the expansion cone 715, the
expansion cone launcher 735, the shoe 740, and the expandable tubular member
755 are
provided substantially as disclosed in one or more of the following: U.S.
Patent
Nos. 6,557,460; 6,604,763; 6,575,240; 6,966,370; 6,712,154; 6,640,903;
6,725,919;
6,892,819; 6,328,113; 6,823,937; 6,568,471; 6,739,392; 6,745,845; 6,758,278;
6,857,473;
6,497,289; 7,011,161; 7,021,390; 6,604,763; 6,564,875; 6,695,012; 7,048,067;
7,100,6H4;
and WO 01/04535.
As illustrated in Fig. 7b, in a preferred embodiment, during placement of the
apparatus 700 within the wellbore 10, fluidic materials 765 within the
wellbore 10 are
conveyed through the apparatus 700 through the passages 710, 720 and 745 to a
location
above the apparatus 700. In this manner, surge pressures during placement of
the
apparatus 700 within the wellbore 10 are reduced. In a preferred embodiment,
the
apparatus 700 is initially positioned within the wellbore 10 such that the top
portion of the
tubular member 755 overlaps with the preexisting casing 15. In this manner,
the upper
portion of the expandable tubular member 755 may be radially expanded into
contact with
and coupled to the preexisting casing 15. As will be recognized by persons
having
ordinary skill in the art, the precise initial position of the expandable
tubular member 755
will vary as a function of the amount of radial expansion, the amount of axial
shrinkage
during radial expansion, and the material properties of the expandable tubular
member.
As illustrated in Fig. 7c, a fluidic materia1770 may then be injected through
the
apparatus 700 through the passages 710, 720, and 745 in order to test the
proper operation
of these passages.
As illustrated in Fig. 7d, a hardenable fluidic sealing material 775 may then
be
injected through the apparatus 700 through the passages 710, 720 and 745 into
the annulus
between the apparatus and the wellbore 10. In this manner, an annular barrier
to fluid
migration into and out of the wellbore 10 may be formed around the radially
expanded
expansion cone launcher 735 and expandable tubular member 755. The hardenable
fluidic
sealing material may include, for example, a cement mixture. In several
alternative
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CA 02595540 2007-08-15
embodiments, the injection of the hardenable fluidic sealing material 775 may
be omitted.
In several altemative embodiments, the hardenable fluidic sealing material 775
is
compressible, before, during and/or after, the curing process.
As illustrated in Fig. 7e, a non-hardenable fluidic material 780 may then be
injected into the apparatus through the passages 710 and 720. A ball plug 785,
or other
similar device, may then be injected with the fluidic material 780 to thereby
seal off the
passage 745. In this manner, the region 750 may be pressurized by the
continued injection
of the fluidic material 780 into the apparatus 700.
As illustrated in Figs. 7f and 7g, the continued injection of the fluidic
materia1780
into the apparatus 700 causes the expansion cone launcher 735 and expandable
tubular
member 755 to be plastically deformed and radially expanded off of the
expansion cone
715. The resulting structure includes a lip 790.
After completing the plastic deformation and radial expansion of the tubular
member 755, the hardenable fluidic sealing material is allowed to cure to
thereby form an
annular body 795 that provides a barrier to fluid flow into or out of the
wellbore 10.
Referring to Fig. 7h, the shoe 740 may then removed by drilling out the shoe
using
a conventional drilling device. A new section of the wellbore 10 may also be
drilled out in
order to permit additional expandable tubular members to be coupled to the
bottom portion
of the plastically deformed and radially expanded tubular member 755.
Referring to Fig. 7i, an additional tubular member 800 may then be plastically
deformed and radially expanded in a conventional manner and/or by using one or
more of
the methods and apparatus described above in order to form a mono-diameter
wellbore
casing. Before, during or after the radial expansion of the tubular member
800, an annular
body 805 of a fluidic sealing material may be formed around the tubular member
in a
conventional manner andlor by using one or more of the methods and apparatus
described
above, In a preferred embodiment, the lip 790 facilitates the coupling of the
tubular
member 800 to the tubular member 755 by providing a region on which the
tubular
member 800 may be easily coupled onto.
Referring to Fig. 8a, in an alternative embodiment, a wellbore 10 includes a
preexisting section of wellbore casing 15 and 900. The wellbore casing 900
includes
sealing members 905a and 905b and a recess 910. An annular body 915 of a
fluidic
sealing material may also be provided around the casing 900. The casing 900
and annular
- 23 -
CA 02595540 2007-08-15
body 915 may be provided using any number of conventional methods, the methods
described above, and/or using one or more of the methods disclosed in the
following:
U.S. Patent Nos. 6,557,460; 6,604,763; 6,575,240; 6,966,370; 6,712,154;
6,640,903;
6,725,919; 6,892,819; 6,328,113; 6,823,937; 6,568,471; 6,739,392; 6,745,845;
6,758,278;
6,857,473; 6,497,289; 7,011,161; 7,021,390; 6,604,763; 6,564,875; 6,695,012;
7,048,067;
7,100,684; and WO 01/04535.
Referring to Fig. 8b, an apparatus 1000 for radially expanding a tubular
member is
then positioned within the wellbore 10 that includes a tubular support member
1005 that
defines a passage 1010 for conveying fluidic materials. A hydraulic locking
device 1015
that defines a passage 1020 for conveying fluidic materials that is fluidicly
coupled to the
-24-
CA 02595540 2007-08-15
passage 1010. The locking device 1015 further includes inlet passages, 1020a
and 1020b,
actuating chambers, 1025a and 1025b, and locking members, 1030a and 1030b.
During
-operatiun; the inj-ectiorl-offluidic materials-into-the-actuating chambers,
1025a and 1025b,
causes the locking members, 1030a and 1030b, to be displaced outwardly in the
radial
direction. In this manner, the locking device 1015 may be controllably coupled
to a
tubular member to thereby maintain the tubular member in a substantially
stationary
position. As will be recognized by persons having ordinary skill in the art,
the operating
pressures and physical shape of the inlet passages 1020, actuating chambers
1025, and
locking members 1030 will determine the maximum amount of holding force
provided by
the locking device 1015. In several alternative embodiments, fluidic
rnaterials may be
injected into the locking device 1015 using a dedicated fluid passage in order
to provide
precise control of the locking device. In several alternative embodiments, the
locking
device 1015 may be omitted and the tubular support member 1005 coupled
directly to the
tubular support member 1035.
One end of a tubular support member 1035 that defines a passage 1040 is
coupled
to the locking device 1015. The passage 1040 is fluidicly coupled to the
passage 1020.
An expansion cone 1045 that defines a passage 1050 and includes an outer
conical surface
1055 is coupled to another end of the tubular support member 1035. An
expansion cone
launcher 1060 is movably coupled to and supported by the expansion cone 1045.
The
expansion cone launcher 1060 includes an upper portion 1060a having an upper
outside
diameter, an intermediate portion 1060b that mates with the expansion cone
1045, and a
lower portion 1060c having a lower outside diameter. The lower outside
diameter is
greater than the upper outside diameter.
A shoe 1065 that defines a valveable passage 1070 is coupled to the lower
portion
1060c of the expansion cone launcher 1060. In this manner, a region 1075 below
the
expansion cone 1045 and bounded by the expansion cone launcher 1060 and the
shoe 1065
may be pressurized and fluidicly isolated from the annular region between the
apparatus
1000 and the wellbore 10.
An expandable tubular member 1080 is coupled to the upper portion of the
expansion cone launcher 1060. In several alternative embodiments, one or more
sealing
members are coupled to the exterior of the upper portion of the expandable
tubular
member 1080. In several alternative embodiments, the sealing members may
include
- 25 -
CA 02595540 2007-08-15
elastomeric elements and/or metallic elements and/or composite elements. In
several
alternative embodiments, one or more anchoring elements may be substituted
for, or used
in addition to, the sealing members.
An expansion cone 1085 defining a passage 1090 for receiving the tubular
support
member 1005 includes an outer conical surface 1095. A tubular support member
1100
defining a passage 1105 for receiving the tubular support member 1005 is
coupled to the
bottom of the expansion cone 1085 for supporting and actuating the expansion
cone.
In a preferred embodiment, the support member 1005 and 1035, the expansion
cone 1045, the expansion cone launcher 1060, the shoe 1065, and the expandable
tubular
member 1080 are provided substantially as disclosed in one or more of the
following:
U.S. Patent Nos. 6,557,460; 6,604,763; 6,575,240; 6,966,370; 6,712,154;
6,640,903;
6,725,919; 6,892,819; 6,328,113; 6,823,937; 6,568,471; 6,739,392; 6,745,845;
6,758,278;
6,857,473; 6,497,289; 7,011,161; 7,021,390; 6,604,763; 6,564,875; 6,695,012;
7,048,067;
7,100,684; and WO 01/04535.
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CA 02595540 2007-08-15
As illustrated in Fig. 8b, in a preferred embodiment, during placement of the
apparatus 1000 within the wellbore 10, fluidic materials 1110 within the
wellbore 10 are
conveyed through the apparatus 1000 through the passages 1010, 1020, 1040 and
1070 to a
location above the apparatus 1000. In this manner, surge pressures during
placement of
the apparatus 1000 within the wellbore 10 are reduced. In a preferred
embodiment, the
apparatus 1000 is initially positioned within the wellbore 10 such that the
top portion of
the tubular member 1080 overlaps with the recess 910 of the preexisting casing
900. In
this manner, the upper portion of the expandable tubular member 1080 may be
radially
expanded into contact with and coupled to the recess 910 of the preexisting
casing 900.
As illustrated in Fig. 8c, a fluidic material 1115 may then be injected
through the
apparatus 1000 through the passages 1010, 1020, 1040, and 1070 in order to
test the
proper operation of these passages.
As illustrated in Fig. 8d, a hardenable fluidic sealing material 1120 may then
be
injected through the apparatus 1000 through the passages 1010, 1020, 1040, and
1070 into
the annulus between the apparatus and the wellbore 10. In this manner, an
annular barrier
to fluid migration into and out of the wellbore 10 may be formed around the
radially
expanded expansion cone launcher 1060 and expandable tubular member 1080. The
hardenable fluidic sealing material may include, for example, a cement
mixture. In several
altemative embodiments, the injection of the hardenable fluidic sealing
material 1120 may
be omitted. In several alternative embodiments, the hardenable fluidic sealing
material
1120 is compressible, before, during and/or after, the curing process.
As illustrated in Fig. 8e, a non-hardenable fluidic material 1125 may then be
injected into the apparatus 1000 through the passages 1010, 1020 and 1040. A
ball plug
1130, or other similar device, may then be injected with the fluidic material
1125 to
thereby seal off the passage 1070. In this manner, the region 1075 may be
pressurized by
the continued injection of the fluidic material 1125 into the apparatus 1000.
Furthermore,
in this manner, the actuating chambers, 1025a and 1025b, of the loclcing
device 1015 may
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CA 02595540 2007-08-15
be pressurized. In this manner, the tubular member 1080 may be held in a
substantially
stationary position by the locking device 1015.
As-THustrated-hrFig. 8-f,--the expansion cone 1085-may-then-be actuated in the
downward direction by a direct application of axial force using the support
member 1100
and/or through the application of fluid force. The axial displacement of the
expansion
cone 1085 may plastically deform and radially expand the upper portion of the
expandable
tubular member 1080. In this manner, the upper portion of the expandable
tubular
member 1080 may be precisely coupled to the recess 910 of the preexisting
casing 900.
During the downward actuation of the expansion cone 1085, the locking member
1015 preferably prevents axial displacement of the tubular member 1080. In a
preferred
embodiment, the locking member 1015 is positioned proximate the upper portion
of the
tubular member 1080 in order to prevent buckling of the tubular member 1080
during the
radial expansion of the upper portion of the tubular member. In an alternative
embodiment, the locking member-1015 is omitted and the interference between
the
intermediate portion 1060b of the expansion cone launcher 1060 and the
expansion cone
1045 prevents the axial displacement of the tubular member 1080 during the
radial
expansion of the upper portion of the tubular member.
As illustrated in Fig. 8g, the expansion cone 1085 and 1100 may then be raised
out
of the wellbore 10.
As illustrated in Fig. 8h, the continued injection of the fluidic material
1125 into
the apparatus 1000 may then cause the expansion cone launcher 1060 and the
expandable
tubular member 1080 to be plastically deformed and radially expanded off of
the
expansion cone 1045. In this manner, the expansion cone 1045 is displaced
relative to the
expansion cone launcher 1060 and expandable tubular member 1080 in the axial
direction.
In a preferred embodiment, the axial forces created during the radial
expansion process are
greater than the axial forces generated by the locking device 1015. As will be
recognized
by persons having ordinary skill in the art, the precise relationship between
these axial
forces will vary as a function of the operating characteristics of the locking
device 1015
and the metallurgical properties of the expansion cone launcher 1060 and
expandable
tubular 1080. In an alternative embodiment, the operating pressures of the
actuating
chambers, 1025a and 1025b, and the region 1075 are separately controllable by
providing
separate and dedicated fluid passages for pressurizing each.
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CA 02595540 2007-08-15
As illustrated in Fig. 8i, after completing the plastic deformation and radial
expansion of the tubular member 1080, the hardenable fluidic sealing material
is allowed
to cure to thereby form an annular body 1130 that provides a barrier to fluid
flow into or
out of the wellbore 10. The shoe 1065 may then removed by drilling out the
shoe using a
conventional drilling device. A new section of the wellbore 10 may also be
drilled out in
order to permit additional expandable tubular members to be coupled to the
bottom portion
of the plastically deformed and radially expanded tubular member 1080.
In an alternative embodiment, the annular body 1130 may be omitted. In several
alternative embodiments, the annular body 1130 may be radially compressed
before,
during and/or after curing.
Referring to Fig. 8j, the tubular member 1080 may be radially expanded again
using one or more of the methods described above to provide an mono-diameter
wellbore
casing.
Referring to Fig. 9a, a wellbore 1200 includes an upper preexisting casing
1205
and a lower preexisting casing 1210. The casings, 1205 and 1210, may fu.rther
include
outer annular layers of fluidic sealing materials such as, for example,
cement. The ends of
the casings, 1205 and 1210, are separated by a gap 1215.
Referring to Fig. 9b, a tubular member 1220 may then be coupled to the
opposing
ends of the casings, 1205 and 1210, to thereby bridge the gap 1215. In a
preferred
embodiment, the tubular member 1220 is coupled to the opposing ends of the
casings,
1205 and 1210, by plastically deforming and radially expanding the tubular
member 1220
using one or more of the methods and apparatus described and referenced above.
Referring to Fig. 9c, a radial expansion device 1225 may then be positioned
within
the tubular member 1220. In a preferred embodiment, the length of the radial
expansion
device 1225 is greater than or equal to the axial length of the tubular member
1220. In
several alternative embodiments, the radial expansion device 1225 may be any
number of
conventional radial expansion devices such as, for example, expansion cones
actuated by
hydraulic and/or direct axial force, roller expansion devices, andlor
expandable hydraulic
bladders.
Referring to Figs. 9d and 9e, after actuation and subsequent de-actuation and
removal of the radial expansion device 1225, the inside diameters of the
casings, 1205 and
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CA 02595540 2007-08-15
1210, are substantially equal to the inside diameter of the tubular member
1220. In this
manner, a mono-diameter wellbore casing may be formed.
Referringto-Fig.40, a wel}bere-1300 ineludes-an-outer-tubular-member 1305 and
an inner tubular member 1310. In a preferred embodiment, the tubular members,
1305 and
1310, are plastically deformed and radially expanded using one or more of the
methods
and apparatus described and referenced above. In this manner, a wellbore
casing maybe
provided whose burst and collapse strength may be precisely controlled by
varying the
number, thickness, and/or material properties of the tubular members, 1305 and
1310.
Referring to Fig. 11 a, a wellbore 1400 includes a casing 1405 that is coupled
to a
preexisting casing 1410. In a preferred embodiment, one or more sealing
members 1415
are coupled to the exterior of the upper portion of the tubular member 1405 in
order to
optimally seal the interface between the tubular member 1405 and the
preexisting casing
1410. In a preferred embodiment, the tubular member 1405 is plastically
deformed and
radially expanded using conventional methods and/or one or more of the methods
and
apparatus described and referenced above. In an exemplary embodiment, the
outside
diatneter of the tubular member 1405 prior to the radial expansion process is
ODo, the wall
thickness of the tubular member 1405 prior to the radial expansion process is
to, the
outside diameter of the tubular member following the radial expansion process
is OD1, and
the wall thickness of the tubular member following the radial expansion
process is t,.
Referring to Fig. 11b, a tubular member 1420 may then be coupled to the lower
portion of the tubular member 1405 by plastically deforming and radially
expanding the
tubular member 1420 using conventional methods and/or one or more of the
methods and
apparatus described and referenced above. In a preferred embodiment, the
exterior surface
of the upper portion of the tubular member 1420 includes one or more sealing
members for
sealing the interface between the tubular member 1420 and the tubular member
1405.
Referring to Fig. 11 c, lower portion of the tubular member 1405 and the
tubular
member 1420 may be radially expanded again to provide a mono-diameter wellbore
casing. The additional radial expatision may be provided using conventional
methods
and/or one or more of the methods and apparatus described and referenced
above. In an
exemplary embodiment, the outside diameter and wall thickness of the lower
portion of
the tubular member 1405 after the additional radial expansion process are ODZ
and t~.
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CA 02595540 2007-08-15
The radial expansion process of Figs. 11b-1 lc can then be repeated to provide
a
mono-diameter wellbore casing of virtually unlimited length.
in-several-alternat-ive-embodiments; the-or-der-ing-o-f-t-he-radial-ex-
pansions of the
tubular members, 1405 and 1420, may be changed. For example, the first tubular
member
1405 may be plastically deformed and radially expanded to provide a lower
portion having
the outside diameter ODZ and the remaining portion having the outside diameter
ODI. The
tubular member 1420 may then be plastically deformed and radially expanded one
or more
times until the inside diameters of the tubular members, 1405 and 1420, are
substantially
equal. The plastic deformations and radial expansions of the tubular members,
1405 and
1420, may be provided using conventional methods and/or one or more of the
methods and
apparatus described and referenced above.
In an exemplary embodiment, the total expansion strain E of the tubular member
1405 may be expressed by the following equation:
E = (ODZ - ODo ) / ODo (1)
where ODo = original outside diameter;
OD1 = outside diameter affter ls' radial expansion; and
OD2 = outside diameter after 2"d radial expansion.
Furthermore, in an exemplary embodiment, where: (1) the exterior surface of
the
upper portion of the tubular member 1420 includes sealing members, and (2) the
radial
spacing between the tubular member 1405 and the wellbore 1400 prior to the
first radial
expansion is equal to d, the outside diameters, OD1 and OD2, of the tubular
member 1405
following the first and second radial expansions may be expressed as:
ODl = ODo + 2d + 2t, (2)
OD2 = OD1 + 2R + 2t2 (3)
where ODo = the original outside diameter of the tubular member 1405;
OD, = the outside diameter of the tubular member 1405
following the first radial expansion;
OD2 = the outside diameter of the tubular member 1405
following the second radial expansion;
d = the radial spacing between the tubular member 1405
and the wellbore prior to the first radial expansion;
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CA 02595540 2007-08-15
tl = the wall thickness of the tubular member 1405 after
the first radial expansion;
t2 -ffie-w-all- thi-elcnessof-the-4ubufar-member 1405 after
the second radial expansion; and
R = the thickness of sealing member provided on the
exterior surface of the tubular member 1420.
Furthermore, in an exemplary embodiment, for d approximately equal to 0.25
inches and R approximately equal to 0.1 inches, equation (1) can be
approximated as:
E _ (0.7"+ 3.70 / ODo (4)
where to = the original wall thickness of the tubular member
1405.
In an exemplary embodiment, the total expansion strain of the tubular member
1405 should be less than or equalto0.3 in order to maximize the burst and
collapse
strength of the expandable tubular member. Therefore, from equation (4) the
ratio of the
original outside diameter to the original wall thickness (ODo/to) may be
expressed as:
ODo I to >_ 3.8/(0.3- 0.7/ODo) (5)
Thus, in a preferred embodiment, for ODo less than 10 inches, the optimal
ratio of
the original outside diameter to the original wall thickness (ODo/to) may be
expressed as:
ODo l to >_ 16 (6)
In this manner, for typical tubular members, the burst and collapse strength
of the
tubular members following one or more radial expansions are maximized when the
relationship in equation (6) is satisfied. Furthermore, the relationships
expressed in
equations (1) through (6) are valid regardless of the order or type of the
radial expansions
of the tubular member 1405. More generally, the relationships expressed in
equations (1)
through (6) may be applied to the radial expansion of structures having a wide
range of
profiles such as, for example, triangular, rectangular, and oval.
An apparatus for plastically deforming and radially expanding a tubular member
has been described that includes means for plastically deforming and radially
expanding a
first portion of the tubular member to a first outside diameter, and means for
plastically
deforming and radially expanding a second portion of the tubular member to a
second
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CA 02595540 2007-08-15
outside diameter. In a preferred embodiment, the first outside diameter is
greater than the
second outside diameter. In a preferred embodiment, the means for plastically
deforming
and rad3alfy-e-xpancling-the-frn-t--portion-of the tubul-ar-member to-the-fir-
st-outside diameter
is removable. In a preferred embodiment, the means for plastically deforming
and radially
expanding the first portion of the tubular member to the first outside
diameter is frangible.
In a preferred embodiment, the means for plastically deforming and radially
expanding the
first portion of the tubular member to the first outside diameter is elastic.
In a preferred
embodiment, the means for plastically deforming and radially expanding the
first portion
of the tubular member to the first outside diameter includes means for
applying a radial
force to the first portion of the tubular member. In a preferred embodiment,
the means for
plastically deforming and radially expanding the first portion of the tubular
member to the
first outside diameter is inflatable. In a preferred embodiment, the means for
plastically
deforming and radially expanding the first portion of the tubular member to
the first
outside diameter includes rolling means for applying radial pressure to the
first portion of
the tubular member.
An apparatus for plastically deforming and radially expanding a tubular member
has also been described that includes a tubular support member including a
first fluid
passage, an expansion cone coupled to the tubular support member having a
second fluid
passage fluidicly coupled to the first fluid passage and an outer conical
surface, a
removable annular conical sleeve coupled to the outer conical surface of the
expansion
cone, an annular expansion cone launcher coupled to the conical sleeve and a
lower
portion of the tubular member, and a shoe having a valveable passage coupled
to an end of
the expansion cone launcher. In a preferred embodiment, the conical sleeve is
frangible.
In a preferred embodiment, the conical sleeve is elastic. In a preferred
embodiment, the
conical sleeve includes a plurality of arcuate elements.
A method of plastically deforming and radially expanding a tubular member has
also been described that includes plastically deforming and radially expanding
a portion of
the tubular member to a first outside diameter, and plastically deforming and
radially
expanding another portion of the tubular member to a second outside diameter.
In a
preferred embodiment, the first diameter is greater than the second diameter.
In a
preferred embodiment, plastically deforming and radially expanding the portion
of the
tubular member includes applying a radial force to the portion of the tubular
member using
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CA 02595540 2007-08-15
a conical sleeve. In a preferred embodiment, conical sleeve is frangible. In a
preferred
embodiment, the conical sleeve is elastic. In a preferred embodiment, the
conical sleeve
-includes--a-pluraWof arcuate-elements,-In-apreferred embodiment, plastically
deforming
and radially expanding the portion of the tubular member includes applying a
radial force
to the portion of the tubular meinber using an inflatable bladder. In a
preferred
embodiment, plastically deforming and radially expanding the portion of the
tubular
member includes applying a radial force to the portion of the tubular member
using a roller
expansion device.
A method of coupling a first tubular member to a second tubular member has
also
been described that includes plastically deforming and radially expanding a
first portion of
the first tubular member to a first outside diameter, plastically deforming
and radially
expanding another portion of the first tubular member to a second outside
diameter,
positioning the second tubular member inside the first tubular member in
overlapping
relation to the first portion of the first tubular member, plastically
deforming and radially
expanding the second tubular member to a third outside diameter, and
plastically
deforming and radially expanding the second tubular member to a fourth outside
diameter.
The inside diameters of the first and second tubular members after the plastic
deformations
and radial expansions are substantially equal. In a preferred embodiment, the
first outside
diameter is greater than the second outside diameter. In a preferred
embodiment,
plastically deforming and radially expanding the first portion of the first
tubular member
includes applying a radial force to the portion of the tubular member using a
conical
sleeve. In a preferred embodiment, the conical sleeve is frangible. In a
preferred
embodiment, the conical sleeve is elastic. In a preferred embodiment, the
conical sleeve
includes a plurality of arcuate elements. In a preferred embodiment,
plastically deforming
and radially expanding the first portion of the first tubular member includes
applying a
radial force to the first portion of the first tubular member using an
inflatable bladder. In a
preferred embodiment, plastically deforming and radially expanding the first
portion of the
first tubular meinber includes applying a radial force to the first portion of
the first tubular
member using a roller expansion device.
An apparatus for coupling a first tubular member to a second tubular member
has
also been described that includes means for plastically deforming and radially
expanding a
first portion of the first tubular member to a first outside diameter, means
for plastically
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CA 02595540 2007-08-15
deforming and radially expanding another portion of the first tubular member
to a second
outside diameter, means for positioning the second tubular member inside the
first tubular
member in overlapping relation to the first portion of the first tubular
member, means for
plastically deforming and radially expanding the second tubular member to a
third outside
diameter, and means for plastically deforming and radially expanding the
second tubular
member to a fourth outside diameter. The inside diameters of the first and
second tubular
members after the plastic deformations and radial expansions are substantially
equal. In a
preferred embodiment, the first outside diameter is greater than the second
outside
diameter. In a preferred embodiment, the means for plastically deforming and
radially
expanding the first portion of the first tubular member includes means for
applying a radial
force to the portion of the tubular member using a conical sleeve. In a
preferred
embodiment, the conical sleeve is frangible. In a preferred embodiment, the
conical sleeve
is elastic. In a preferred embodiment, the conical sleeve includes a plurality
of arcuate
elements. In a preferred embodiment, the means for plastically deforming and
radially
expanding the first portion of the first tubular member includes means for
applying a radial
force to the first portion of the first tubular member using an inflatable
bladder. In a
preferred embodiment, the means for plastically deforming and radially
expanding the first
portion of the first tubular member includes means for applying a radial force
to the first
portion of the first tubular member using a roller expansion device.
An apparatus for forming a wellbore casing within a wellbore has also been
described that includes means for supporting a tubular member within the
wellbore, means
for plastically deforming and radially expanding a first portion of the
tubular member to a
first outside diameter, and means for plastically deforming and radially
expanding a
second portion of the tubular member to a second outside diameter. In a
preferred
embodiment, the first outside diameter is greater than the second outside
diameter. In a
preferred embodiment, the means for plastically deforming and radially
expanding the first
portion of the tubular member to the first outside diameter is removable. In a
preferred
embodiment, the means for plastically deforming and radially expanding the
first portion
of the tubular member to the first outside diameter is frangible. In a
preferred
embodiment, the means for plastically deforming and radially expanding the
first portion
of the tubular member to the first outside diameter is elastic. In a preferred
embodiment,
the means for plastically deforming and radially expanding the first portion
of the tubular
-35-
CA 02595540 2007-08-15
member to the first outside dianieter includes means for applying a radial
force to the first
portion of the tubular member. In a preferred embodiment, the means for
plastically
3-eforming-and-radiafly-expazid-ing-the-first portian-o-f-thefiubular-mer-nber
to the first
outside diameter is inflatable. In a preferred embodiment, the means for
plastically
deforming and radially expanding the first portion of the tubular member to
the first
outside diameter includes rolling means for applying radial pressure to the
first portion of
the tubular member. In a preferred embodiment, the apparatus fin-ther includes
means for
forming an annular body of a fluidic sealing material within an annulus
between the
tubular member and the wellbore.
- An apparatus for formirig a wellbore casing withiti a wellbore has also been
described that includes a tubular support member including a first fluid
passage, an
expansion cone coupled to the tubular support member having a second fluid
passage
fluidicly coupled to the first fluid passage and an outer conical surface, a
removable
annular conical sleeve coupled to the outer conical surface of the expansion
cone, an
annular expansion cone launcher coupled to the conical sleeve and a lower
portion of the
tubular member, and a shoe having a valveable passage coupled to an end of the
expansion
cone launcher. In a preferred embodiment, the conical sleeve is frangible. In
a preferred
embodiment, the conical sleeve is elastic. In a preferred embodiment, the
conical sleeve
includes a plurality of arcuate elements.
A method of forming a wellbore casing within a wellbore has also been
described
that includes supporting a tubular member within a wellbore, plastically
deforming and
radially expanding a portion of the tubular member to a first outside
diameter, and
plastically defonning and radially expanding another portion of the tubular
member to a
second outside diameter. In a preferred embodiment, the first diameter is
greater than the
second diarneter. In a preferred embodiment, plastically deforming and
radially expanding
the portion of the tubular member includes applying a radial force to the
portion of the
tubular member using a conical sleeve. In a preferred embodiment, the conical
sleeve is
frangible. In a preferred embodiment, the conical sleeve is elastic. In a
preferred
embodiment, the conical sleeve includes a plurality of arcuate elements. In a
preferred
embodiment, plastically deforming and radially expanding the portion of the
tubular
member includes applying a radial force to the portion of the tubular member
using an
inflatable bladder. In a preferred embodiment, plastically deforming and
radially
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CA 02595540 2007-08-15
expanding the portion of the tubular member includes applying a radial force
to the portion
of the tubular member using a roller expansion device. In a preferred
embodiment, the
method further includes injecting an-annular-body of-a-ha-r-denable fluidic
sealing material
into an annulus between the tubular member and the wellbore. In a preferred
embodiment,
the method further includes curing the annular body of hardenable fluidic
sealing material.
A method of forming a mono-diameter wellbore casing within a wellbore has also
been described that includes supporting a first tubular member within the
wellbore,
plastically deforming and radially expanding a first portion of the first
tubular member to a
first outside diameter, plastically deforming and radially expanding another
portion of the
first tubular member to a second outside diameter, positioning the second
tubular member
inside the first tubular member in overlapping relation to the first portion
of the first
tubular member, plastically deforming and radially expanding the second
tubular member
to a third outside diameter, and plastically deforming and radially expanding
the second
tubular member to a fourth outside diameter. The inside diameters of the first
and second
tubular members after the plastic deformations and radial expansions are
substantially
equal. In a preferred embodiment, the first outside diameter is greater than
the second
outside diameter. In a preferred embodiment, plastically deforming and
radially expanding
the first portion of the first tubular member includes applying a radial force
to the portion
of the tubular member using a conical sleeve. In a preferred embodiment, the
conical
sleeve is frangible. In a preferred embodiment, the conical sleeve is elastic.
In a preferred
embodiment, the conical sleeve includes a plurality of arcuate elements. In a
preferred
embodiment, plastically deforming and radially expanding the first portion of
the first
tubular member includes applying a radial force to the first portion of the
first tubular
member using an inflatable bladder. In a preferred embodiment, plastically
deforrning and
radially expanding the first portion of the first tubular member includes
applying a radial
force to the first portion of the first tubular member using a roller
expansion device. In a
preferred embodiment, the method further includes injecting an annular body of
a
hardenable fluidic sealing material into an annulus between the first tubular
member and
the wellbore. In a preferred embodiment, the method further includes curing
the annular
body of hardenable fluidic sealing material. In a preferred embodiment, the
method
further includes injecting an annular body of a hardenable fluidic sealing
material into an
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CA 02595540 2007-08-15
annulus between the second tubular member and the wellbore. ln a preferred
embodiment,
the method further includes curing the annular body of hardenable fluidic
sealing material.
An-appar~ttts~c3r-eaupling~~ -st tubular-r-nember to a-second-tubular member
has
also been described that includes means for plastically deforming and radially
expanding a
first portion of the first tubular member to a first outside diameter, means
for plastically
deforming and radially expanding another portion of the first tubular member
to a second
outside diameter, means for positioning the second tubular member inside the
first tubular
member in overlapping relation to the first portion of the first tubular
member, means for
plastically deforming and radially expanding the second tubular member to a
third outside
diameter, and means for plastically deforming and radially expanding the
second tubular
member to a fourth outside diameter. The inside diameters of the first and
second tubular
members after the plastic deformations and radial expansions are substantially
equal. In a
preferred embodiment, the first outside diameter is greater than the second
outside
diameter. In a preferred embodiment, the means for plastically deforming and
radially
expanding the first portion of the first tubular member includes means for
applying a radial
force to the portion of the tubular member using a conical sleeve. In a
preferred
embodiment, the conical sleeve is frangible. In a preferred embodiment, the
conical sleeve
is elastic. In a preferred embodiment, the conical sleeve includes a plurality
of arcuate
elements. In a preferred embodiment, the means for plastically deforming and
radially
expanding the first portion of the first tubular member includes means for
applying a radial
force to the first portion of the first tubular member using an inflatable
bladder. In a
preferred embodiment, the means for plastically deforming and radially
expanding the first
portion of the first tubular member includes means for applying a radial force
to the first
portion of the first tubular member using a roller expansion device. In a
preferred
embodiment, the apparatus further includes means for injecting an annular body
of a
hardenable fluidic sealing material into an annulus between the first tubular
member and
the wellbore. In a preferred embodiment, the apparatus further includes means
for curing
the annular body of hardenable fluidic sealing material. In a preferred
embodiment, the
apparatus further includes means for injecting an annular body of a hardenable
fluidic
sealing material into an annulus between the second tubular member and the
wellbore. In
a preferred embodiment, the apparatus further includes means for curing the
annular body
of hardenable fluidic sealing material,
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CA 02595540 2007-08-15
An apparatus for plastically deforming and radially expanding a tubular member
has also been described that includes means for providing a lipped portion in
a portion of
th- e-tubular-member,-ancl-m-eans-fer-plastiea11y-defo-nni-ngai}d -r-adial-ly-
expanding another
portion of the tubular member.
An apparatus for plastically deforming and radially expanding a tubular member
has also been described that includes a tubular support member including a
first fluid
passage, an expansion cone coupled to the tubular support member having a
second fluid
passage fluidicly coupled to the first fluid passage and an outer conical
surface, an annular
expansion cone launcher including: a first annular portion coupled to a lower
portion of
the tubular member, a second annular portion coupled to the first annular
portion that
mates with the outer conical surface of the expansion cone, a third annular
portion coupled
to the second annular portion having a first outside diameter, and a fourth
annular portion
coupled to the third annular portion having a second outside diameter, wherein
the second
outside diameter is less than the first outside diameter, and a-shoe having a
valveable
passage coupled to fourth annular portion of the expansion cone launcher.
A method of plastically deforming and radially expanding a tubular member has
also been described that includes providing a lipped portion in a portion of
the tubular
member, and plastically deforming and radially expanding another portion of
the tubular
member.
A method of coupling a first tubular member to a second tubular member has
also
been described that includes providing a lipped portion in a portion of the
first tubular
member, plastically deforming and radially expanding another portion of the
first tubular
member, positioning the second tubular member inside the first tubular member
in
overlapping relation to the lipped portion of the first tubular member, and
plastically
deforming and radially expanding the second tubular member. The inside
diameters of the
first and second tubular members after the plastic deformations and radial
expansions are
substantially equal.
An apparatus for coupling a first tubular member to a second tubiular member
has
also been described that includes means for providing a lipped portion in the
first tubular
member, means for plastically deforming and radially expanding another portion
of the
first tubular member, means for positioning the second tubular member inside
the first
tubular member in overlapping relation to the lipped portion of the first
tubular member,
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CA 02595540 2007-08-15
and means for plastically deforming and radially expanding the second tubular
member.
The inside diameters of the first and second tubular members after the plastic
deformations
-md-radial-expansions -are-sttbstantiallreqrtal:
An apparatus for forming a wellbore casing within a wellbore has also been
described that includes means for supporting a tubular member within the
wellbore, means
for providing a lipped portion in the tubular member, and means for
plastically deforming
and radially expanding another portion of the tubular member to a second
outside
diameter.
An apparatus for forming a wellbore casing within a wellbore has also been
described that includes a tubular support member including a first fluid
passage, an
expansion cone coupled to the tubular support member having a second fluid
passage
fluidicly coupled to the first fluid passage and an outer conical surface, an
annular
expansion cone launcher including: a first amlular portion coupled to a lower
portion of
the tubular member, a second annular portion coupled to the first annular
portion that
mates with the outer conical surface of the expansion cone, a third annular
portion coupled
to the second annular portion having a first outside diameter, and a fourth
annular portion
coupled to the third annular portion having a second outside diameter, wherein
the second
outside diameter is less than the first outside diameter, and a shoe having a
valveable
passage coupled to fourth annular portion of the expansion cone launcher.
A method of forming a wellbore casing in a wellbore has also been described
that
includes supporting a tubular member within the wellbore, providing a lipped
portion in a
portion of the tubular member, and plastically defomiing and radially
expanding another
portion of the tubular member. In a preferred embodiment, the method further
includes
injecting a hardenable fluidic sealing material in an annulus between the
tubular member
and the wellbore. In a preferred embodiment, the method further includes
curing the
fluidic sealing material.
A method of forming a mono-diameter wellbore casing within a wellbore has also
been described that includes supporting a first tubular member within the
welibore,
providing a lipped portion in a portion of the first tubular member,
plastically deforming
and radially expanding another portion of the first tubular member,
positioning the second
tubular member inside the first tubular member in overlapping relation to the
lipped
portion of the first tubular member, and plastically deforming and radially
expanding the
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CA 02595540 2007-08-15
second tubular, member. The inside diameters of the first and second tubular
members
after the plastic deformations and radial expansions are substantially equal.
In a preferred
embodiment, the method further includes injecting a hardenable fluidic sealing
material in
an annulus between the first tubular member and the wellbore. In a preferred
embodiment,
the method further includes curing the fluidic sealing material. In a
preferred embodiment,
the method further includes injecting a hardenable fluidic sealing material in
an annulus
between the second tubular member and the wellbore. In a preferred embodiment,
the
method further includes curing the fluidic sealing material.
An apparatus for forming a mono-diameter wellbore casing within a wellbore has
also been described that includes means for providing a lipped portion in the
first tubular
member, means for plastically deforming and radially expanding another portion
of the
first tubular member, means for positioning the second tubular member inside
the first
tubular member in overlapping relation to the lipped portion of the first
tubular member,
and means for plastically deforming and radially expanding the second tubular
member.
The inside diameters of the first and second tubular members after the plastic
deformations
and radial expansions are substantially equal. In a preferred embodiment, the
apparatus
further includes means for injecting a hardenable fluidic sealing material in
an annulus
between the first tubular member and the wellbore. In a preferred embodiment,
the
apparatus further includes means for curing the fluidic sealing material. In a
preferred
embodiment, the apparatus further includes means for injecting a hardenable
fluidic
sealing material in an annulus between the second tubular member and the
wellbore. In a
preferred embodiment, the apparatus further includes means for curing the
fluidic sealing
material.
An apparatus for plastically defonning and radially expanding a tubular member
has also been described that includes means for plastically deforming and
radially
expanding a first end of the tubular member, and means for plastically
deforming and
radially expanding a second end of the tubular member. In a preferred
embodiment, the
apparatus further includes means for anchoring the tubular member during the
radial
expansion.
An apparatus for plastically deforming and radially expanding a tubular member
has also been described that includes a tubular support member including a
first passage,
an expansion cone coupled to the tubular support having a second passage
fluidicly
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CA 02595540 2007-08-15
coupled to the first passage and an outer conical surface, an annular
expansion cone
launcher movably coupled to outer conical surface of the expansion cone, an
expandable
tubular member coupled to an end of the annular expansion cone launcher, a
shoe coupled
to another end of the annular expansion cone launcher having a valveable fluid
passage,
and another annular expansion cone movably coupled to the tubular support
member. The
annular expansion cones are positioned in opposite orientations. In a
preferred
embodiment, the annular expansion cone is adapted to plastically deform and
radially
expand a first end of the expandable tubular member and the other annular
expansion cone
is adapted to plastically deform and radially expand a second end of the
expandable
tubular member. In a preferred embodiment, the apparatus further includes an
anchoring
member coupled to the tubular support member adapted to hold the expandable
tabular.
A method of plastically deforming and radially expanding a tubular member has
also been described that includes plastically deforming and radially expanding
a first end
of the tubular member, and plastically deforming and radially expanding a
second end of
the tubular member. In a preferred embodiment, the method further includes
anchoring
the tubular member during the radial expansion. In a preferred embodiment, the
first end
of the tubular member is plastically deformed and radially expanded before the
second
end. In a preferred embodiment, plastically deforming and radially expanding
the second
end of the tubular member includes injecting a fluidic material into the
tubular member.
A method of coupling a first tubular member to a second tubular member has
also
been described that includes positioning the second tubular member inside the
first tubular
member in an overlapping relationship, plastically deforming and radially
expanding the
end of the second tubular member that overlaps with the first tubular member,
and
plastically deforming and radially expanding the remaining portion of the
second tubular
member. In a preferred embodiment, the method further includes plastically
deforming
and radially expanding at least a portion of the second tubular member. In a
preferred
embodiment, the inside diameters of the first and second tubular members are
substantially
equal after the radial expansions.
An apparatus for coupling a first tubular member to a second tubular member
has
also been described that includes means for positioning the second tubular
member inside
the first tubular member in an overlapping relationship, means for plastically
deforming
and radially expanding the end of the second tubular member that overlaps with
the first
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CA 02595540 2007-08-15
tubular member; and means for plastically deforming and radially expanding the
remaining
portion of the second tubular member. In a preferred embodiment, the apparatus
further
inciudes-Yneans for plastiealfy-deforsning and-radialfy-ex4aa-nding at least-a-
portion of the
second tubular member. In a preferred embodiment, the inside diameters of the
first and
second tubular members are substantially equal after the radial expansions.
An apparatus for forrning a wellbore casing within a wellbore has also been
described that includes means for supporting a tubular member within the
wellbore, means
for plastically deforming and radially expanding a first end of the tubular
member, and
means for plastically deforming and radially expanding a second end of the
tubular
member. In a preferred embodiment, the apparatus further includes means for
anchoring
the tubular member during the radial expansion. In a preferred embodiment, the
apparatus
fiuther includes means for injecting a hardenable fluidic sealing material
into an annulus
between the tubular member and the welibore.
An apparatus for forming a wellbore casing within a wellbore has also been
described that includes a tubular support member including a first passage, an
expansion
cone coupled to the tubular support having a second passage fluidicly coupled
to the first
passage and an outer conical surface, an annular expansion cone launcher
movably
coupled to outer conical surface of the expansion cone, an expandable tubular
member
coupled to an end of the annular expansion cone launcher, a shoe coupled to
another end
of the annular expansion cone launcher having a valveable fluid passage, and
another
annular expansion cone movably coupled to the tubular support member. The
annular
expansion cones are positioned in opposite orientations. In a preferred
embodiment, the
annular expansion cone is adapted to plastically deform and radially expand a
first end of
the expandable tubular member and the other annular expansion cone is adapted
to
plastically deform and radially expand a second end of the expandable tubular
member. In
a preferred embodiment, the apparatus fiuther includes an anchoring member
coupled to
the tubular support member adapted to hold the expandable tubular.
A method of forming a wellbore casing within a wellbore has also been
described
that includes plastically deforming and radially expanding a first end of the
tubular
member, and plastically defonning and radially expanding a second end of the
tubular
member. In a preferred embodiment, the method further includes anchoring the
tubular
member during the radial expansion. In a preferred embodiment, the first end
of the
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CA 02595540 2007-08-15
tubular member is plastically deformed and radially expanded before the second
end. In a
preferred embodiment, plastically deforming and radially expanding the second
end of the
-tubuiar-member-includes-inj-ecting-a-fiui-die- -nater-i-al-in-to-#he #ubul-ar-
member. In a -
preferred embodiment, the method further includes injecting a hardenable
fluidic sealing
material into an annulus between the tubular member and the wellbore.
A method of fomiing a wellbore casing within a wellbore has also been
described
that includes plastically deforming and radially expanding a first tubular
member within
the wellbore, positioning a second tubular member inside the first tubular
member in an
overlapping relationship, plastically deforming and radially expanding the end
of the
second tubular member that overlaps with the first tubular member, plastically
defonning
and radially expanding the remaining portion of the second tubular member. In
a preferred
embodiment, the method further includes plastically deforming and radially
expanding at
least a portion of the second tubular member. In a preferred embodiment, the
inside
diameters of the first and second tubular members are substantially equal
after the radial
expansions. In a preferred embodiment, the method further includes injecting a
hardenable
fluidic sealing material into an annulus between the first tubular member and
the wellbore.
In a preferred embodiment, the method further includes injecting a hardenable
fluidic
sealing material into an annulus between the second tubular member and the
wellbore.
An apparatus for forming a wellbore casing within a wellbore has also been
described that includes means for plastically deforming and radially expanding
a first
tubular member within the welibore, means for positioning the second tubular
member
inside the first tubular member in an overlapping relationship, means for
plastically
deforming and radially expanding the end of the second tubular member that
overlaps with
the first tubular member, means for plastically deforming and radially
expanding the
remaining portion of the second tubular member. In a preferred embodiment, the
apparatus ftu-ther includes means for plastically deforming and radially
expanding at least
a portion of the second tubular member. In a preferred embodiment, the inside
diameters
of the first and second tubular members are substantially equal after the
radial expansions.
In a preferred embodiment, the apparatus further includes means for injecting
a
hardenable fluidic sealing material into an annulus between the first tubular
member and
the welibore. In a preferred embodiment, the apparatus further includes means
for
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CA 02595540 2007-08-15
injecting a hardenable fluidic sealing material into an annulus between the
second tubular
member and the wellbore.
An-apparatus- for-bridging-an a-xinl-gap-betwee-n-opposing-pai-rs -of wellbore
casing
within a wellbore has also been described that includes means for supporting a
tubular
member in overlapping relation to the opposing ends of the wellbore casings,
means for
plastically deforming and radially expanding the tubular member, and means for
plastically
deforming and radially expanding the tubular member and the opposing ends of
the
wellbore casings.
A method of bridging an axial gap between opposing pairs of wellbore casing
within a wellbore has also been described that includes supporting a tubular
member in
overlapping relation to the opposing ends of the wellbore casings, plastically
deforming
and radially expanding the tubular member, and
plastically deforming and radially expanding the tubular member and the
opposing ends of
the wellbore casings.
A method of forming a structure having desired strength characteristics has
also
been described that includes providing a first tubular member, and plastically
deforming
and radially expanding additional tubular members onto the interior surface of
the first
tubular member until the desired strength characteristics are achieved. .
A method of forming a wellbore casing within a wellbore having desired
strength
characteristics has also been described that includes plastically deforming
and radially
expanding a first tubular member within the wellbore, and plastically
deforming and
radially expanding additional tubular members onto the interior surface of the
first tubular
member until the desired strength characteristics are achieved.
A method of coupling a first tubular member to a second tubular member, the
first
tubular member having an original outside diameter ODo and an original wall
thickness to,
has also been described that includes plastically deforming and radially
expanding a first
portion of the first tubular member to a first outside diameter, plastically
deforming and
radially expanding another portion of the first tubular member to a second
outside
diameter, positioning the second tubular member inside the first tubular
member in
overlapping relation to the first portion of the first tubular member,
plastically deforming
and radially expanding the second tubular member to a third outside diameter,
and
plastically deformi.ng and radially expanding the second tubular member to a
fourth
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CA 02595540 2007-08-15
outside diameter, wherein the inside diameters of the first and second tubular
members
after the plastic deformations and radial expansions are substantially equal,
and
wherein-the -rati-o-of-the$riginal-otttside-di-ameter-ODo of-tl.ie first-
tubular-rnember to the
original wall thickness tfl of the first tubular member is greater than or
equal to 16.
A method of forming a mono-diameter wellbore casing has also been described
that includes positioning a first tubular member within a wellbore, the first
tubular member
having an original outside diameter ODo and an original wall thickness to,
plastically
deforming and radially expanding a first portion of the first tubular member
to a first
outside diameter, plastically deforming and radially expanding another portion
of the first
tubular member to a second outside diameter, positioning the second tubular
member
inside the first tubular member in overlapping relation to the first portion
of the first
tubular member, plastically defonning and radially expanding the second
tubular member
to a third outside diameter, and plastically deforming and radially expanding
the second
tubular member to a fourth outside diameter. The inside diameters of the first
and second
tubular members after the plastic deformations and radial expansions are
substantially
equal, and wherein the ratio of the original outside diameter ODo of the first
tubular
member to the original wall thickness to of the first tubular member is
greater than or equal
to 16.
An apparatus has also been described that includes a plastically deformed and
radially expanded tubular member having a first portion having a first outside
diameter
and a remaining portion having a second outside diameter, wherein the ratio of
the original
outside diameter ODo of the first tubular member to the original wall
thickness to of the
first tubular member is greater than or equal to 16.
An apparatus has also been described that includes a plastically deformed and
radially expanded first tubular member having a first portion having a first
outside
diameter and a remaining portion having a second outside diameter, and a
plastically
deformed and radially expanded second tubular member coupled to the first
portion of the
first tubular member. The ratio of the original outside diameter ODo of the
first tubular
member to the original wall thickness to of the first tubular member is
greater than or equal
to 16. In a preferred embodiment, the inside diameters of the first and second
tubular
members are substantially equal.
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CA 02595540 2007-08-15
A wellbore casing formed in a wellbore has also been described that includes a
plastically deformed and radially expanded first tubular member having a first
portion
having a first outside diameter and a remaining portion having a second
outside diameter,
and a plastically deformed and radially expanded second tubular member coupled
to the
first portion of the first tubular member. The ratio of the original outside
diameter ODo of
the first tubular member to the original wall thickness to of the first
tubular member is
greater than or equal to 16. In a preferred embodiment, the inside diameters
of the first
and second tubular members are substantially equal.
An apparatus has also been described that includes a plastically deformed and
radially expanded tubular member. In a preferred embodiment, the ratio of the
original
outside diameter ODo of the tubular member to the original wall thickness to
of the tubular
member is greater than or equal to 16.
In several alternative embodiments, the methods and apparatus described and
referenced above may be used to form or repair wellbore casings, pipelines,
and structural
supports.
Although this detailed description has shown and described illustrative
embodiments of the invention, this description contemplates a wide range of
modifications, changes, and substitutions. In some instances, one may employ
some
features of the present invention without a corresponding use of the other
features.
Accordingly, it is appropriate that readers should construe the appended
claims broadly,
and in a manner consistent with the scope of the invention.
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