APPAREIL ET PROCEDE SERVANT A DECOUPER UN ELEMENT TUBULAIRE

APPARATUS AND METHOD FOR CUTTING A TUBULAR

Abrégé français

La présente invention concerne un appareil qui permet l'expansion radiale et la déformation plastique d'un élément tubulaire.

Abrégé anglais

An apparatus for radially expanding and plastically deforming a tubular member.

Revendications

Claims
1. An apparatus for cutting a tubular member, comprising:
an upper cam assembly having a plurality of arms, each upper cam
arm having a cam surface;
a plurality of upper segments coupled to the upper cam assembly,
each upper segment having a cutting element coupled thereto;
a lower cam assembly having a plurality of arms interleaved among the
arms of the upper cam assembly, each lower cam arm having a cam surface;
and
a plurality of lower segments interleaved among the upper segments,
each lower segment having a cutting element coupled thereto;
wherein the lower cam assembly is displaceable relative to the upper
cam assembly, whereby the upper cutting elements slide over the lower cam
surfaces and the lower cutting elements slide over the upper cam surfaces,
whereby the upper and lower cutting elements rotate into engagement with
the tubular member.
2. The apparatus of claim 1, further comprising:
an actuator coupled to the upper cam assembly and the lower cam
assembly for moving the cutting elements between a first position and a
second position;
wherein in the first position, the cutting elements do not engage the
tubular member; and
wherein in the second position, the cutting elements engage the tubular
member.
3. The apparatus of claim 2, further comprising:
a sensor coupled to the upper cam assembly and the lower cam
assembly for sensing the internal diameter of the tubular member.
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4. The apparatus of claim 3, wherein the sensor prevents the cutting
elements from being moved to the second position if the internal diameter of
the tubular member is less than a predetermined value.
5. The apparatus of claim 2, wherein the cutting elements of the plurality
of upper segments are interleaved with the cutting elements of the plurality
of
lower segments.
6. The apparatus of claim 5, wherein in the first position, the cutting
elements of the plurality of upper segments are not axially aligned with the
cutting elements of the plurality of lower segments.
7. The apparatus of claim 5, wherein in the second position, the cutting
elements of the plurality of upper segments are axially aligned with the
cutting
elements of the plurality of lower segments.
8. A method of cutting a tubular member, comprising:
positioning a plurality of cutting elements within the tubular member;
positioning a second plurality of cutting elements within the tubular
member and axially displaced relative to the first plurality; and
translating the first plurality of cutting elements relative to the second
plurality of cutting elements, whereby the first and second pluralities of
cutting
elements rotate simultaneously into engagement with the tubular member.
9. The method of claim 8, wherein the plurality of cutting elements are
interleaved with the plurality of cutting elements.
10. The method of claim 8, wherein the cutting elements are rotated about
a common axis.
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11. The method of claim 8, further comprising:
preventing the cutting elements from coming into engagement with the
tubular member if the inside diameter of the tubular member is less than a
predetermined value.
12. The method of claim 11, wherein preventing the cutting elements from
coming into engagement with the tubular member if the inside diameter of the
tubular member is less than a predetermined value comprises:
sensing the inside diameter of the tubular member.
13. A system for cutting a tubular member, comprising:
means for positioning a plurality of cutting elements within the tubular
member; and
means for translating some of the plurality of cutting elements relative
to the others, whereby the cutting elements rotate into engagement with the
tubular member.
122

Description

CA 02522918 2009-03-02
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APPARATUS AND METHOD FOR CUTTING A TUBULAR
Background of the Invention
[0004] This invention relates generally to oil and gas exploration, and in
particular to
forming and repairing weilbore casings to facilitate oil and gas exploration.
Sumrnary OS The Invention
[0005] According to one aspect of the present invention, an apparatus for
radially
expanding and plastically deforming an expandable tubular member is provided
that includes
a supporl member, a cutling device for cutting the tubular member coupled to
the support
member, and an expansion device for radially expanding and plastically
deforming the
tubular member coupled to the support member.
[0006] According to another aspect of the present invention, an apparatus for
radially
expanding and plastically deforming an expandable tubular member is provided
that includes
a support member, an expansion device for radially expanding and plastically
deforming the
tubular member coupled to the support member, and an actuator coupled to the
support
member for displacing the expansion device relative to the support member.
[0007] According to another aspect of the present invention, an apparatus for
radially
expanding and plastically deforming an expandable tubular member is provided
that includes
a_ support member; an expansion device for radially expanding and plastically
deforming the
tubular member coupled to the support member; and a sealing assembly for
sealing an
annulus defined between the support member and the tubular member.
[0008] According to another aspect of the present invention, an apparatus for
radially
expanding and plastically deforming an expandable tubular member is provided
that includes
a support member a first expansion device for radially expanding and
plastically deforming
the tubular member coupled to the support member; and a second expansion
device for
radially expanding and plastically deforming the tubular member coupled to the
support
member.
[0009] According to another aspect of the present invention, an apparatus for
radially
expanding and plastically deforming an expandable tubular member is provided
that includes
a support member; an expansion device for radially expanding and plastically
deforming the
tubular member coupled to the support member; and a packer coupled to the
support
member.
[0010] According to another aspect of the present invention, an apparatus for
radially
expanding and plastically deforming an expandable tubular member is provided
that includes
a support member; a cutting device for cutting the tubular member coupled to
the support
member; a gripping device for gripping the tubular member coupled to the
support member;
a sealing device for sealing an interface with the tubular member coupled to
the support
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member; a locking device for locking the position of the tubular member
relative to the
support member, a first adjustable expansion device for radially expanding and
plastically
deforming the tubular member coupled to the support member; a second
adjustable
expansion device for radially expanding and plastically deforming the tubular
member
coupled to the support member; a packer coupled to the support member, and an
actuator
for displacing one or more of the sealing assembly, first and second
adjustable expansion
devices, and packer relative to the support member.
[0011] According to another aspect of the present invention, an apparatus for
cutting a
tubular member is provided that includes a support member; and a plurality of
movable
cutting elements coupled to the support member.
[0012] According to another aspect of the present invention, an apparatus for
engaging
a tubular member is provided that includes a support member; and a plurality
of movable
elements coupled to the support member.
[0013] According to another aspect of the present invention, an apparatus for
gripping a
tubular member is provided that includes a plurality of movable gripping
elements.
[0014] According to another aspect of the present invention, an actuator is
provided that
includes a tubular housing; a tubular piston rod movably coupled to and at
least partially
positioned within the housing; a plurality of annular piston chambers defined
by the tubular
housing and the tubular piston rod; and a plurality of tubular pistons coupled
to the tubular
piston rod, each tubular piston movably positioned within a corresponding
annular piston
chamber.
[0015] According to another aspect of the present invention, an apparatus for
controlling
a packer is provided that includes a tubular support member; one or more drag
blocks
releasably coupled to the tubular support member; and a tubular stinger
coupled to the
tubular support member for engaging the packer.
[0016] According to another aspect of the present invention, a packer is
provided that
includes a support member defining a passage; a shoe comprising a float valve
coupled to
an end of the support member; one or more compressible packer elements movably
coupled
to the support member; and a sliding sleeve valve movably positioned within
the passage of
the support member.
[0017] According to another aspect of the present invention, a method of
radially
expanding and plastically deforming an expandable tubular member within a
borehole
having a preexisting wellbore casing is provided that includes positioning the
tubular
member within the borehole in overlapping relation to the wellbore casing;
radially expanding
and plastically deforming a portion of the tubular member to form a bell
section; and radially
expanding and plastically deforming a portion of the tubular member above the
bell section
comprising a portion of the tubular member that overlaps with the welibore
casing; wherein
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the inside diameter of the bell section is greater than the inside diameter of
the radially
expanded and plastically deformed portion of the tubular member above the bell
section.
[0018] According to another aspect of the present invention, a method for
forming a
mono diameter wellbore casing is provided that includes positioning an
adjustable expansion
device within a first expandable tubular member; supporting the first
expandable tubular
member and the adjustable expansion device within a borehole; lowering the
adjustable
expansion device out of the first expandable tubular member; increasing the
outside
dimension of the adjustable expansion device; displacing the adjustable
expansion device
upwardiy reiative to the first expandabie tubular member m times to radially
expand and
plastically deform m portions of the first expandable tubular member within
the borehole;
positioning the adjustable expansion device within a second expandable tubular
member;
supporting the second expandable tubular member and the adjustable expansion
device
within the borehole in overlapping relation to the first expandable tubular
member; lowering
the adjustable expansion device out of the second expandable tubular member;
increasing
the outside dimension of the adjustable expansion device; and displacing the
adjustable
expansion device upwardly relative to the second expandable tubular member n
times to
radially expand and plastically deform n portions of the second expandable
tubular member
within the borehole.
[0019] According to another aspect of the present invention, a method for
radially
expanding and plastically deforming an expandable tubular member within a
borehole is
provided that includes positioning an adjustable expansion device within the
expandable
tubular member, supporting the expandable tubular member and the adjustable
expansion
device within the borehole; lowering the adjustable expansion device out of
the expandable
tubular member; increasing the outside dimension of the adjustable expansion
device;
displacing the adjustable expansion mandrel upwardly relative to the
expandable tubular
member n times to radially expand and plastically deform n portions of the
expandable
tubular member within the borehole; and pressurizing an interior region of the
expandable
tubular member above the adjustable expansion device during the radial
expansion and
plastic deformation of the expandable tubular member within the borehole.
[0020] According to another aspect of the present invention, a method for
forming a
mono diameter wellbore casing is provided that includes positioning an
adjustable expansion
device within a first expandable tubular member; supporting the first
expandable tubular
member and the adjustable expansion device within a borehole; lowering the
adjustable
expansion device out of the first expandable tubular member; increasing the
outside
dimension of the adjustable expansion device; displacing the adjustable
expansion device
upwardly relative to the first expandable tubular member m times to radially
expand and
plastically deform m portions of the first expandable tubular member within
the borehole;
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pressurizing an interior region of the first expandable tubular member above
the adjustable
expansion device during the radial expansion and plastic deformation of the
first expandable
tubular member within the borehole; positioning the adjustable expansion
mandrel within a
second expandable tubular member; supporting the second expandable tubular
member and
the adjustable expansion mandrel within the borehole in overlapping relation
to the first
expandable tubular member; lowering the adjustable expansion mandrel out of
the second
expandable tubular member; increasing the outside dimension of the adjustable
expansion
mandrel; displacing the adjustable expansion mandrel upwardly relative to the
second
expandable tubular member n times to radially expand and plastically deform n
portions of
the second expandable tubular member within the borehole; and pressurizing an
interior
region of the second expandable tubular member above the adjustable expansion
mandrel
during the radial expansion and plastic deformation of the second expandable
tubular
member within the borehole.
[0021] According to another aspect of the present invention, a method for
radially
expanding and plastically deforming an expandable tubular member within a
borehole is
provided that includes positioning first and second adjustable expansion
devices within the
expandable tubular member; supporting the expandable tubular member and the
first and
second adjustable expansion devices within the borehole; lowering the first
adjustable
expansion device out of the expandable tubular member, increasing the outside
dimension
of the first adjustable expansion device; displacing the first adjustable
expansion device
upwardly relative to the expandable tubular member to radially expand and
plastically
deform a lower portion of the expandable tubular member; displacing the first
adjustable
expansion device and the second adjustable expansion device downwardly
relative to the
expandable tubular member; decreasing the outside dimension of the first
adjustable
expansion device and increasing the outside dimension of the second adjustable
expansion
device; displacing the second adjustable expansion device upwardly relative to
the
expandable tubular member to radially expand and plastically deform portions
of the
expandable tubular member above the lower portion of the expandable tubular
member,
wherein the outside dimension of the first adjustable expansion device is
greater than the
outside dimension of the second adjustable expansion device.
[0022] According to another aspect of the present invention, a method for
forming a
mono diameter wellbore casing is provided that includes positioning first and
second
adjustable expansion devices within a first expandable tubular member;
supporting the first
expandable tubular member and the first and second adjustable expansion
devices within a
borehole; lowering the first adjustable expansion device out of the first
expandable tubular
member; increasing the outside dimension of the first adjustable expansion
device;
displacing the first adjustable expansion device upwardly relative to the
first expandable
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tubular member to radially expand and plastically deform a lower portion of
the first
expandable tubular member; displacing the first adjustable expansion device
and the second
adjustable expansion device downwardly relative to the first expandable
tubular member,
decreasing the outside dimension of the first adjustable expansion device and
increasing the
outside dimension of the second adjustable expansion device; displacing the
second
adjustable expansion device upwardly relative to the first expandable tubular
member to
radially expand and plastically deform portions of the first expandable
tubular member above
the lower portion of the expandable tubular member; positioning first and
second adjustable
expansion devices within a second expandable tubular member, supporting the
first
expandable tubular member and the first and second adjustable expansion
devices within
the borehole in overlapping relation to the first expandable tubular member;
lowering the first
adjustable expansion device out of the second expandable tubular member;
increasing the
outside dimension of the first adjustable expansion device; displacing the
first adjustable
expansion device upwardly relative to the second expandable tubular member to
radially
expand and plastically deform a lower portion of the second expandable tubular
member;
displacing the first adjustable expansion device and the second adjustable
expansion device
downwardly relative to the second expandable tubular member; decreasing the
outside
dimension of the first adjustable expansion device and increasing the outside
dimension of
the second adjustable expansion device; and displacing the second adjustable
expansion
device upwardly relative to the second expandable tubular member to radially
expand and
plastically deform portions of the second expandable tubular member above the
lower
portion of the second expandable tubular member; wherein the outside dimension
of the first
adjustable expansion device is greater than the outside dimension of the
second adjustable
expansion device.
[0023] According to another aspect of the present invention, a method for
radially
expanding and plastically deforming an expandable tubular member within a
borehole is
provided that includes positioning first and second adjustable expansion
devices within the
expandable tubular member; supporting the expandabie tubular member and the
first and
second adjustable expansion devices within the borehole; lowering the first
adjustable
expansion device out of the expandable tubular member; increasing the outside
dimension
of the first adjustable expansion device; displacing the first adjustable
expansion device
upwardly relative to the expandable tubular member to radially expand and
plastically
deform a lower portion of the expandable tubular member; pressurizing an
interior region of
the expandable tubular member above the first adjustable expansion device
during the radial
expansion of the lower portion of the expandable tubular member by the first
adjustable
expansion device; displacing the first adjustable expansion device and the
second
adjustable expansion device downwardly relative to the expandable tubular
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decreasing the outside dimension of the first adjustable expansion device and
increasing the
outside dimension of the second adjustable expansion device; displacing the
second
-adjustable expansion device upwardly relative to the expandable tubular
member to radially
expand and plastically deform portions of the expandable tubular member above
the lower
portion of the expandable tubular member; and pressurizing an interior region
of the
expandable tubular member above the second adjustable expansion device during
the radial
expansion of the portions of the expandable tubular member above the lower
portion of the
expandable tubular member by the second adjustable expansion device; wherein
the outside
dimension of the first adjustable expansion device is greater than the outside
dimension of
the second adjustable expansion device.
[0024] According to another aspect of the present invention, a method for
forming a
mono diameter wellbore casing is provided that includes positioning first and
second
adjustable expansion' devices within a first expandable tubular member;
supporting the first
expandable tubular member and the first and second adjustable expansion
devices within a
borehole; lowering the first adjustable expansion device out of the first
expandable tubular
member; increasing the outside dimension of the first adjustable expansion
device;
displacing the first adjustable expansion device upwardly relative to the
first expandable
tubular member to radially expand and plastically deform a lower portion of
the first
expandable tubular member; pressurizing an interior region of the first
expandable tubular
member above the first adjustable expansion device during the radial expansion
of the lower
portion of the first expandable tubular member by the first adjustable
expansion device;
displacing the first adjustable expansion device and the second adjustable
expansion device
downwardly relative to the first expandable tubular member, decreasing the
outside
dimension of the first adjustable expansion device and increasing the outside
dimension of
the second adjustable expansion device; displacing the second adjustable
expansion device
upwardly relative to the first expandable tubular member to radially expand
and plastically
deform portions of the first expandable tubular member above the lower portion
of the
expandable tubular member, pressurizing an interior region of the first
expandable tubular
member above the second adjustable expansion device during the radial
expansion of the
portions of the first expandable tubular member above the lower portion of the
first
expandable tubular member by the second adjustable expansion device;
positioning first and
second adjustable expansion devices within a second expandable tubular member;
supporting the first expandable tubular member and the first and second
adjustable
expansion devices within the borehole in overlapping relation to the first
expandable tubular
member; lowering the first adjustable expansion device out of the second
expandable
tubular member; increasing the outside dimension of the first adjustable
expansion device;
displacing the first adjustable expansion device upwardly relative to the
second expandable
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tubular member to radially expand and plastically deform a lower portion of
the second
expandable tubular member; pressurizing an interior region of the second
expandable
tubular member above the first adjustable expansion device during the radial
expansion of
the lower portion of the second expandable tubular member by the first
adjustable expansion
device; displacing the first adjustable expansion device and the second
adjustable
expansion device downwardly relative to the second expandable tubular member;
decreasing the outside dimension of the first adjustable expansion device and
increasing the
outside dimension of the second adjustable expansion device; displacing the
second
adjustable expansion device upwardly relative to the second expandable tubular
member to
radially expand and plastically deform portions of the second expandable
tubular member
above the lower portion of the second expandable tubular member; and
pressurizing an
interior region of the second expandable tubular member above the second
adjustable
expansion device during the radial expansion of the portions of the second
expandable
tubular member above the lower portion of the second expandable tubular member
by the
second adjustable expansion device; wherein the outside dimension of the first
adjustable
expansion device is greater than the outside dimension of the second
adjustable expansion
device.
[0025] According to. another aspect of the present invention, a method for
radially
expanding and plastically deforming an expandable tubular member within a
borehole is
provided that includes supporting the expandable tubular member, an hydraulic
actuator,
and an adjustable expansion device within the borehole; increasing the size of
the adjustable
expansion device; and displacing the adjustable expansion device upwardly
relative to the
expandable tubular member using the hydraulic actuator to radially expand and
plastically
deform a portion of the expandable tubular member.
[0026] According to another aspect of the present invention, a method for
forming a
mono diameter wellbore casing within a borehole that includes a preexisting
wellbore casing
is provided that includes supporting the expandable tubular member, an
hydraulic actuator,
and an adjustable expansion device within the borehole; increasing the size of
the adjustable
expansion device; displacing the adjustable expansion device upwardly relative
to the
expandable tubular member using the hydraulic actuator to radially expand and
plastically
deform a portion of the expandable tubular member; and displacing the
adjustable
expansion device upwardly relative to the expandable tubular member to
radially expand
and plastically deform the remaining portion of the expandable tubular member
and a portion
of the preexisting wellbore casing that overlaps with an end of the remaining
portion of the
expandable tubular member.
[0027] According to another aspect of the present invention, a method of
radially
expanding and plastically deforming a tubular member is provided that includes
positioning
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the tubular member within a preexisting structure; radially expanding and
plastically
deforming a lower portion of the tubular member to form a bell section; and
radially
expanding and plastically deforming a portion of the tubular member above the
bell section.
[0028] According to another aspect of the present invention, a method of
radially
expanding and plastically deforming a tubular member is provided that includes
applying
internal pressure to the inside surface of the tubular member at a plurality
of discrete location
separated from one another.
[0029] According to another aspect of the present invention, a system for
radially
expanding and plastically deforming an expandable tubular member within a
borehole
having a preexisting wellbore casing is provided that includes means for
positioning the
tubular member within the borehole in overlapping relation to the wellbore
casing; means for
radially expanding and plastically deforming a portion of the tubular member
to form a bell
section; and means for radially expanding and plastically deforming a portion
of the tubular
member above the bell section comprising a portion of the tubular member that
overlaps with
the wellbore casing; wherein the inside diameter of the bell section is
greater than the inside
diameter of the radially expanded and plastically deformed portion of the
tubular member
above the bell section.
[0030] According to another aspect of the present invention, a system for
forming a
mono diameter wellbore casing is provided that includes means for positioning
an adjustable
expansion device within a first expandable tubular member; means for
supporting the first
expandable tubular member and the adjustable expansion device within a
borehole; means
for lowering the adjustable expansion device out of the first expandable
tubular member;
means for increasing the outside dimension of the adjustable expansion device;
means for
displacing the adjustable expansion device upwardly relative to the first
expandable tubular
member m times to radially expand and plastically deform m portions of the
first expandable
tubular member within the borehole; means for positioning the adjustable
expansion device
within a second expandable tubular member; means for supporting the second
expandable
tubular member and the adjustable expansion device within the borehole in
overlapping
relation to the first expandable tubular member; means for lowering the
adjustable expansion
device out of the second expandable tubular member; means for increasing the
outside
dimension of the adjustable expansion device; and means for displacing the
adjustable
expansion device upwardly relative to the second expandable tubular member n
times to
radially expand and plastically deform n portions of the second expandable
tubular member
within the borehole.
[0039] According to another aspect of the present invention, a system for
radially
expanding and plastically deforming an expandable tubular member within a
borehole is
provided that includes means for positioning an adjustable expansion device
within the
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expandable tubular member, means for supporting the expandable tubular member
and the
adjustable expansion device within the borehole; means for lowering the
adjustable
expansion device out of the expandable tubular member; means for increasing
the outside
dimension of the adjustable expansion device; means for displacing the
adjustable
expansion mandrel upwardly relative to the expandable tubular member n times
to radially
expand and plastically deform n portions of the expandable tubular member
within the
borehole; and means for pressurizing an interior region of the expandable
tubular member
above the adjustable expansion device during the radial expansion and plastic
deformation
of the expandable tubular member within the borehole.
[0032] According to another aspect of the present invention, a system for
forming a
mono diameter welibore casing is provided that includes means for positioning
an adjustable
expansion device within a first expandable tubular member; means for
supporting the first
expandable tubular member and the adjustable expansion device within a
borehole; means
for lowering the adjustable expansion device out of the first expandable
tubular member,
means for increasing the outside dimension of the adjustable expansion device;
means for
displacing the adjustable expansion device upwardly relative to the first
expandable tubular
member m times to radially expand and plastically deform m portions of the
first expandable
tubular member within the borehole; means for pressurizing an interior region
of the first
expandable tubular member above the adjustable expansion device during the
radial
expansion and plastic deformation of the first expandable tubular member
within the
borehole; means for positioning the adjustable expansion mandrel within a
second
expandable tubular member; means for supporting the second expandable tubular
member
and the adjustable expansion mandrel within the borehole in overlapping
relation to the first
expandable tubular member; means for lowering the adjustable expansion mandrel
out of
the second expandable tubular member, means for increasing the outside
dimension of the
adjustable expansion mandrel; means for displacing the adjustable expansion
mandrel
upwardly relative to the second expandable tubular member n times to radially
expand and
plastically deform n portions of the second expandable tubular member within
the borehole;
and means for pressurizing an interior region of the second expandable tubular
member
above the adjustable expansion mandrel during the radial expansion and plastic
deformation
of the second expandable tubular member within the borehole.
[0033] According to another aspect of the present invention, a system for
radially
expanding and plastically deforming an expandable tubular member within a
borehole is
provided that includes means for positioning first and second adjustable
expansion devices
within the expandable tubular member; means for supporting the expandable
tubular
member and the first and second adjustable expansion devices within the
borehole; means
for lowering the first adjustable expansion device out of the expandable
tubular member;
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means for increasing the outside dimension of the first adjustable expansion
device; means
for displacing the first adjustable expansion device upwardly relative to the
expandable
tubular member to radially expand and plastically deform a lower portion of
the expandable
tubular member; means for displacing the first adjustable expansion device and
the second
adjustable expansion device downwardly relative to the expandable tubular
member; means
for decreasing the outside dimension of the first adjustable expansion device
and increasing
the outside dimension of the second adjustable expansion device; means for
displacing the
second adjustable expansion device upwardly relative to the expandable tubular
member to
radially expand and plastically deform portions of the expandable tubular
member above the
lower portion of the expandable tubular member; wherein the outside dimension
of the first
adjustable expansion device is greater than the outside dimension of the
second adjustable
expansion device.
[0034] According to another aspect of the present invention, a system for
forming a
mono diameter wellbore casing is provided that includes means for positioning
first and
second adjustable expansion devices within a first expandable tubular member;
means for
supporting the first expandable tubular member and the first and second
adjustable
expansion devices within a borehole; means for lowering the first adjustable
expansion
device out of the first expandable tubular member, means for increasing the
outside
dimension of the first adjustable expansion device; displacing the first
adjustable expansion
device upwardly relative to the first expandable tubular member to radially
expand and
plasticaily deform a lower portion of the first expandable tubular member;
means for
displacing the first adjustable expansion device and the second adjustable
expansion device
downwardly relative to the first expandable tubular member; means for
decreasing the
outside dimension of the first adjustable expansion device and increasing the
outside
dimension of the second adjustable expansion device; means for displacing the
second
adjustable expansion device upwardly relative to the first expandable tubular
member to
radially expand and plastically deform portions of the first expandable
tubular member above
the lower portion of the expandable tubular member; means for positioning
first and second
adjustable expansion devices within a second expandable tubular member; means
for
supporting the first expandable tubular member and the first and second
adjustable
expansion devices within the borehole in overlapping relation to the first
expandable tubular
member; means for lowering the first adjustable expansion device out of the
second
expandable tubular member; means for increasing the outside dimension of the
first
adjustable expansion device; means for displacing the adjustable expansion
device
upwardly relative to the second expandable tubular member to radially expand
and
plastically deform a lower portion of the second expandable tubular member;
means for
displacing the first adjustable expansion device and the second adjustable
expansion device
to

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downwardly relative to the second expandable tubular member, means for
decreasing the
outside dimension of the first adjustable expansion device and increasing the
outside
dimension of the second adjustable expansion device; and means for displacing
the second
adjustable expansion device upwardly relative to the second expandable tubular
member to
radially expand and plastically deform portions of the second expandable
tubular member
above the lower portion of the second expandable tubular member; wherein the
outside
dimension of the first adjustable expansion device is greater than the outside
dimension of
the second adjustable expansion device.
[0036] Rccording to another aspect of the present invention, a system for
radially
expanding and plastically deforming an expandable tubular member within a
borehole is
provided that includes means for positioning first and second adjustable
expansion devices
within the expandable tubular member; means for supporting the expandable
tubular
member and the first and second adjustable expansion devices within the
borehole; means
for lowering the first adjustable expansion device out of the expandable
tubular member;
means for increasing the outside dimension of the first adjustable expansion
device; means
for displacing the first adjustable expansion device upwardly relative to the
expandable
tubular member to radially expand and plastically deform a lower portion of
the expandable
tubular member; means for pressurizing an interior region of the expandable
tubular member
above the first adjustable expansion device during the radial expansion of the
lower portion
of the expandable tubular member by the first adjustable expansion device;
means for
displacing the first adjustable expansion device and the second adjustable
expansion device
downwardly relative to the expandable tubular member, means for decreasing the
outside
dimension of the first adjustable expansion device and increasing the outside
dimension of
the second adjustable expansion device; means for displacing the second
adjustable
expansion device upwardly relative to the expandable tubular member to
radially expand
and plastically deform portions of the expandable tubular member above the
lower portion of
the expandable tubular member; and means for pressurizing an interior region
of the
expandable tubular member above the second adjustable expansion device during
the radial
expansion of the portions of the expandable tubular member above the lower
portion of the
expandable tubular member by the second adjustable expansion device; wherein
the outside
dimension of the first adjustable expansion device is greater than the outside
dimension of
the second adjustable expansion device.
[0036] According to another aspect of the present invention, a system for
forming a
mono diameter wellbore casing is provided that includes means for positioning
first and
second adjustable expansion devices within a first expandable tubular member;
means for
supporting the first expandable tubular member and the first and second
adjustable
expansion devices within a borehole; means for lowering the first adjustable
expansion
11

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device out of the first expandable tubular member, means for increasing the
outside
dimension of the first adjustable expansion device; means for displacing the
first adjustable
expansion device upwardly relative to the first expandable tubular member to
radially expand
and plastically deform a lower portion of the first expandable tubular member,
means for
pressurizing an interior region of the first expandable tubular member above
the first
adjustable expansion device during the radial expansion of the lower portion
of the first
expandable tubular member by the first adjustable expansion device; means for
displacing
the first adjustable expansion device and the second adjustable expansion
device
downwardly relative to the first expandable tubular member; means for
decreasing the
outside dimension of the first adjustable expansion device and increasing the
outside
dimension of the second adjustable expansion device; means for displacing the
second
adjustable expansion device upwardly relative to the first expandable tubular
member to
radially expand and plastically deform portions of the first expandable
tubular member above
the lower portion of the expandable tubular member; means for pressurizing an
interior
region of the first expandable tubular member above the second adjustable
expansion
device during the radial expansion of the portions of the first expandable
tubular member
above the lower portion of the first expandable tubular member by the second
adjustable
expansion device; means for positioning first and second adjustable expansion
devices
within a second expandable tubular member; means for supporting the first
expandable
tubular member and the first and second adjustable expansion devices within
the borehole in
overlapping relation to the first expandable tubular member; means for
lowering the first
adjustable expansion device out of the second expandable tubular member, means
for
increasing the outside dimension of the first adjustable expansion device;
means for
displacing the first adjustable expansion device upwardly relative to the
second expandable
tubular member to radially expand and plastically deform a lower portion of
the second
expandable tubular member; means for pressurizing an interior region of the
second
expandable tubular member above the first adjustable expansion device during
the radial
expansion of the lower portion of the second expandable tubular member by the
first
adjustable expansion device; means for displacing the first adjustable
expansion device and
the second adjustable expansion device downwardly relative to the second
expandable
tubular member; means for decreasing the outside dimension of the first
adjustable
expansion device and increasing the outside dimension of the second adjustable
expansion
device; means for displacing the second adjustable expansion device upwardly
relative to
the second expandable tubular member to radially expand and plastically deform
portions of
the second expandable tubular member above the lower portion of the second
expandable
tubular member; and means for pressurizing an interior region of the second
expandable
tubular member above the second adjustable expansion device during the radial
expansion
12

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of the portions of the second expandable tubular member above the lower
portion of the
second expandable tubular member by the second adjustable expansion device;
wherein the
outside dimension of the first adjustable expansion device is greater than the
outside
dimension of the second adjustable expansion device.
(0037] According to another aspect of the present invention, a system for
radially
expanding and plastically deforming an expandable tubular member within a
borehole is
provided that includes means for supporting the expandable tubular member, an
hydraulic
actuator, and an adjustable expansion device within the borehole; means for
increasing the
size of the adjustable expansion device; and means for displacing the
adjustable expansion
device upwardly relative to the expandable tubular member using the hydraulic
actuator to
radially expand and plastically deform a portion of the expandable tubular
member.
[0038] According to another aspect of the present invention, a system for
forming a
mono diameter wel(bore casing within a borehole that includes a preexisting
welibore casing
is provided that includes means for supporting the expandable tubular member,
an hydraulic
actuator, and an adjustable expansion device within the borehole; means for
increasing the
size of the adjustable expansion device; means for displacing the adjustable
expansion
device upwardly relative to the expandable tubular member using the hydraulic
actuator to
radially expand and plastically deform a portion of the expandable tubular
member; and
means for displacing the adjustable expansion device upwardly relative to the
expandable
tubular member to radially expand and plastically deform the remaining portion
of the
expandable tubular member and a portion of the preexisting weilbore casing
that overlaps
with an end of the remaining portion of the expandable tubular member.
[0039] According to another aspect of the present invention, a system for
radially
expanding and plastically deforming a tubular member is provided that includes
means for
positioning the tubular member within a preexisting structure; means for
radially expanding
and plastically deforming a lower portion of the tubular member to form a bell
section; and
means for radially expanding and plastically deforming a portion of the
tubular member
above the bell section.
[0040] According to another aspect of the present invention, a system of
radially
expanding and plastically deforming a tubular member is provided that includes
a support
member; and means for applying internal pressure to the inside surface of the
tubular
member at a plurality of discrete location separated from one another coupled
to the support
member.
[0041] According to another aspect of the present invention, a method of
cutting a
tubular member is provided that includes positioning a plurality of cutting
elements within the
tubular member; and bringing the cutting elements into engagement with the
tubular
member.
13

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[0042] According to another aspect of the present invention, a method of
gripping a
tubular member is provided that includes positioning a plurality of gripping
elements within
the tubular member; bringing the gripping elements into engagement with the
tubular
member. In an exemplary embodiment, bringing the gripping elements into
engagement
with the tubular member includes displacing the gripping elements in an axial
direction; and
displacing the gripping elements in a radial direction.
[0043] According to another aspect of the present invention, a method of
operating an
actuator is provided that includes pressurizing a plurality of pressure
chamber.
[0044] According to another aspect of the present invention, a method of
injecting a
hardenable fluidic sealing material into an annulus between a tubular member
and a
preexisting structure is provided that includes positioning the tubular member
into the
preexisting structure; sealing off an end of the tubular member; operating a
valve within the
end of the tubular member; and injecting a hardenabte fluidic sealing material
through the
valve into the annulus between the tubular member and the preexisting
structure.
[0045] According to another aspect of the present invention, a system for
cutting a
tubular member is provided that includes means for positioning a plurality of
cutting elements
within the tubular member; and means for bringing the cutting elements into
engagement
with the tubular member.
[0046] According to another aspect of the present invention, a system for
gripping a
tubular member is provided that includes means for positioning a plurality of
gripping
elements within the tubular member; and means for bringing the gripping
elements into
engagement with the tubular member.
[0047] According to another aspect of the present invention, an actuator
system is
provided that includes a support member; and means for pressurizing a
plurality of pressure
chambers coupled to the support member. In an exemplary embodiment, the system
further
includes means for transmitting torsional loads.
[0048] According to another aspect of the present invention, a system for
injecting a
hardenable fluidic sealing material into an annulus between a tubular member
and a
preexisting structure is provided that includes means for positioning the
tubular member into
the preexisting structure; means for sealing off an end of the tubular member;
means for
operating a valve within the end of the tubular member; and means for
injecting a
hardenable fluidic sealing material through the valve into the annulus between
the tubular
member and the preexisting structure.
[0049] According to another aspect of the present invention, a method of
engaging a
tubular member is provided that includes positioning a plurality of elements
within the tubular
member; and bringing the elements into engagement with the tubular member.
14

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[0050] According to another aspect of the present invention, a system for
engaging a
tubular member is provided that includes means for positioning a plurality of
elements within
the tubular member, and means for bringing the elements into engagement with
the tubular
member. In an exemplary embodiment, the elements include a first group of
elements; and
a second group of elements; wherein the first group of elements are
interleaved with the
second group of elements.
Brief Description of the ratuingis
[0051] Fig. 1 is a fragmentary cross-sectional illustration of an embodiment
of a system
for radially expanding and plastically deforming wellbore casing, including a
tubular support
member, a casing cutter, a ball gripper for gripping a wellbore casing, a
force multiplier
tension actuator, a safety sub, a cup sub, a casing lock, an extension
actuator, a bell section
adjustable expansion cone assembly, a casing section adjustable expansion cone
assembly,
a packer setting tool, a packer, a stinger, and an expandable welibore casing,
during the
placement of the system within a wellbore.
[0052] Fig. 2 is a fragmentary cross-sectional illustration of the system of
Fig. 1 during
the subsequent displacement of the bell section adjustable expansion cone
assembly, the
casing section adjustable expansion cone assembly, the packer setting tool,
the packer, and
the stinger downwardly out of the end of the expandable wellbore casing and
the expansion
of the size of the bell section adjustable expansion cone assembly and the
casing section
adjustable expansion cone assembly.
[0053] Fig. 3 is a fragmentary cross-sectional illustration of the system of
Fig. 2 during
the subsequent operation of the tension actuator to displace the bell section
adjustable
expansion cone assembly upwardly into the end of the expandable wellbore
casing to form a
bell section in the end of the expandable wellbore casing.
[0054] Fig. 4 is a fragmentary cross-sectional illustration of the system of
Fig. 3 during
the subsequent reduction of the bell section adjustable expansion cone
assembly.
[0055] Fig. 5 is a fragmentary cross-sectional illustration of the system of
Fig. 4 during
the subsequent upward displacement of the expanded casing section adjustable
expansion
cone assembly to radially expand the expandable wellbore casing.
[0056] Fig. 6 is a fragmentary cross-sectional illustration of the system of
Fig. 5 during
the subsequent lowering of the tubular support member, casing cutter, bail
gripper, a force
multiplier tension actuator, safety sub, cup sub, casing lock, extension
actuator, bell section
adjustable expansion cone assembly, casing section adjustable expansion cone
assembly,
packer setting tool, packer, and stinger and subsequent setting of the packer
within the
expandable wellbore casing above the bell section.
[0057] Fig. 7 is a fragmentary cross-sectional illustration of the system of
Fig. 6 during
the subsequent injection of fluidic materials into the system to displace the
expanded casing

CA 02522918 2007-08-27
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section adjustable expansion cone assembly upwardly through the expandable
wellbore
casing to radially expand and plastically deform the expandable weilbore
casing.
[0058] Fig. 8 is a fragmentary cross-sectional illustration of the system of
Fig. 7 during
the subsequent injection of fluidic materials into the system to displace the
expanded casing
section adjustable expansion cone assembly upwardly through the expandable
wellbore
casing and a surrounding preexisting wellbore casing to radially expand and
plastically
deform the overlapping expandable wellbore casing and the surrounding
preexisting
wellbore casing.
[0058] Fig. 9 is a fragmentary cross-sectional illustration of the system of
Fig. 8 during
the subsequent operation of the casing cutter to cut off an end of the
expandable wellbore
casing.
[0060] Fig. 10 is a fragmentary cross-sectional illustration of the system of
Fig. 9 during
the subsequent removal of the cut off end of the expandable wellbore casing.
[0061] Figs. 11-1 and 11-2, 11A1 to 11A2, 11131 to 1162, 11C, 11D, 11E, 11F,
11G,
11H,111,11j,11K,11L,11M,11N,110,11P,11Q,11R,11S,11T,11U,11V,11W,11X,
11Y, 11Z1 to 11Z4, 11AA1 to 11AA4, 11AB1 to 11AB4, 11AC1 to 11AC4, 11AD, and
11AE
are fragmentary cross-sectional and perspective illustrations of an exemplary
embodiment of
a casing cutter assembly.
[0062] Figs. 12A1 to 12A4 and 12C1 to 12C4 are fragmentary cross-sectional
iltustrations of an exemplary embodiment of a ball gripper assembly.
[0063] Fig. 12B is a top view of a portion of the ball gripper assembly of
Figs. 12A1 to
12A4 and 12C1 to 12C4.
[0064] Figs. 13A1 to 13A8 and 13B1 to 13B7 are fragmentary cross-sectional
illustrations of an exemplary embodiment of a tension actuator assembly.
[0065] Fig. 14A is a fragmentary cross-sectional illustrations of an exemplary
embodiment of a safety sub assembly.
[0066] Figs. 14A, 14B and 14C are fragmentary cross-sectional and perspective
illustrations of an exemplary embodiment of a cup seal assembly.
[0067] Figs. 15-1 and 15-2, 15A1 to 15A2, 15B1 to 15B2, 15C, 15D, 15E, 15F,
15G,
15H, 151, 15j, 15K, 15L, 15M, 15N, 150, 15P, 15R, 15S, 15T, 15U, 15V, 15W,
15X, 15Y,
15Z1 to 15Z4, 15AA1 to 15AA4, 15AB1 to 15AB4, 15AC1 to 15AC4, 15AD, and 15AE
are
fragmentary cross-sectional and perspective illustrations of an exemplary
embodiment of an
adjustable bell section expansion cone assembly.
[0068] Figs. 16-1 and 16-2, 16A1 to 16A2, 16B1 to 16B2, 16C, 16D, 16E, 16F,
16G,
16H, 161, 16j, 16K, 16L, 16M, 16N, 160, 16P, 16R, 16S, 16T, 16U, 16V, 16W,
16X, 16Y,
16Z1-16Z4, 16AA1 to 16AA4, 16AB1 to 16AB4, 16AC1 to 16AC4, 16AD, and 16AE are
16

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WO 2004/085790 PCT/US2004/009434
fragmentary cross-sectional and perspective illustrations of an exemplary
embodiment of an
adjustable casing expansion cone assembly.
[0069] Figs. 17A to 17C is a fragmentary cross-sectional illustration of an
exemplary
embodiment of a packer setting tool assembly.
[0070] Figs. 18-1 to 18-5 is a fragmentary cross-sectional illustration of an
exemplary
embodiment of a paci:er assembly.
[0079] Figs. 19A1 to 19A5, 1961 to 19135, 19C1 to 19C5, 19D1 to 19D5, 19E1 to
19E6,
19F1 to 19F6, 19G1 to 19G6, and 19H1 to 19H5, are fragmentary cross-sectional
illustrations of an exemplary embodiment of the operation of the packer
setting tool and the
packer assembly of Figs. 17A to 17C and 18-1 to 18-5.
Detailed Description of the Illustrative Embodiments
[0072] Referring initially to Figs. 1-10, an exemplary embodiment of a system
10 for
radially expanding and plastically deforming a wellbore casing includes a
conventional
tubular support 12 having an end that is coupled to an end of a casing cutter
assembly 14.
In an exemplary embodiment, the casing cutter assembly 14 may be, or may
include
elements, of one or more conventional commercially available casing cutters
for cutting
wellbore casing, or equivalents thereof.
[0073] An end of a ball gripper assembly 16 is coupled to another end of the
casing
cutter assembly 14. In an exemplary embodiment, the ball gripper assembly 14
may be, or
may include elements, of one or more conventional commercially available ball
grippers, or
other types of gripping devices, for gripping weilbore casing, or equivalents
thereof.
[0074] An end of a tension actuator assembly 18 is coupled to another end of
the ball
gripper assembly 16. In an exemplary embodiment, the tension actuator assembly
18 may
be, or may include elements, of one or more conventional commercially
actuators, or
equivalents thereof.
[0075] An end of a safety sub assembly 20 is coupled to another end of the
tension
actuator assembly 18. In an exemplary embodiment, the safety sub assembly 20
may be, or
may include elements, of one or more conventional apparatus that provide quick
connection
and/or disconnection of tubular members, or equivalents thereof.
[0076] An end of a sealing cup assembly 22 is coupled to another end of the
safety sub
assembly 20. In an exemplary embodiment, the sealing cup assembly 22 may be,
or may
include elements, of one or more conventional sealing cup assemblies, or other
types of
sealing assemblies, that sealingly engage the interior surfaces of surrounding
tubular
members, or equivalents thereof.
[0077] An end of a casing lock assembly 24 is coupled to another end of the
sealing cup
assembly 22. In an exemplary embodiment, the casing lock assembly 24 may be,
or may
include elements, of one or more conventional casing lock assemblies that lock
the position
17

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of wellbore casing, or equivalents thereof.
[0078] An end of an extension actuator assembly 26 is coupled to another end
of the
casing lock assembly 24. In an exemplary embodiment, the extension actuator
assembly 26
may be, or may include elements, of one or more conventional actuators, or
equivalents
thereof.
[0078] An end of an adjustable bell section expansion cone assembly 28 is
coupled to
another end of the extension actuator assembly 26. In an exemplary embodiment,
the
adjustable bell section expansion cone assembly 28 may be, or may include
elements, of
one or more conventional adjustable expansion devices for radially expanding
and plastically
deforming weilbore casing, or equivalents thereof.
[0080] An end of an adjustable casing expansion cone assembly 30 is coupled to
another end of the adjustable bell section expansion cone assembly 28. In an
exemplary
embodiment, the adjustable casing expansion cone assembly 30 may be, or may
include
elements, of one or more conventional adjustable expansion devices for
radially expanding
and plastically deforming wellbore casing, or equivalents thereof.
[0081] An end of a packer setting tool assembly 32 is coupled to another end
of the
adjustable casing expansion cone assembly 30. In an exemplary embodiment, the
packer
setting tool assembly 32 may be, or may include elements, of one or more
conventional
adjustable expansion devices for controlling the operation of a conventional
packer, or
equivalents thereof.
[0082] An end of a stinger assembly 34 is coupled to another end of the packer
setting
tool assembly 32. In an exemplary embodiment, the stinger assembly 34 may be,
or may
include elements, of one or more conventional devices for engaging a
conventional packer,
or equivalents thereof.
[0083] An end of a packer assembly 36 is coupled to another end of the stinger
assembly 34. In an exemplary embodiment, the packer assembly 36 may be, or may
include elements, of one or more conventional packers.
[0084] As illustrated in Fig. 1, in an exemplary embodiment, during operation
of the
system 10, an expandable wellbore casing 100 is coupled to and supported by
the casing
lock assembly 24 of the system. The system 10 is then positioned within a
wellbore 102 that
traverses a subterranean formation 104 and includes a preexisting wellbore
casing 106.
[0085] As illustrated in Fig. 2, in an exemplary embodiment, the extension
actuator
assembly 26 is then operated to move the adjustable bell section expansion
cone assembly
28, adjustable casing expansion cone assembly 30, packer setting tool assembly
32, stinger
assembly 34, packer assembly 36 downwardly in a direction 108 and out of an
end of the
expandable wellbore casing 100. After the adjustable bell section expansion
cone assembly
28 and adjustable casing expansion cone assembly 30 have been moved to a
position out of
18

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the end of the expandable welibore casing 100, the adjustable bell section
expansion cone
assembly and adjustable casing expansion cone assembly are then operated to
increase the
outside diameters of the expansion cone assemblies. In an exemplary
embodiment, the
increased outside diameter of the adjustable bell section expansion cone
assembly 28 is
greater than the increased outside diameter of the adjustable casing expansion
cone
assembly 30.
[0086] As illustrated in Fig. 3, in an exemplary embodiment, the ball gri.pper
assembly 16
is then operated to engage and hold the position of the expandable tubular
member 100
stationary relative to the tubular support member 12. The tension actuator
assembly 18 is
then operated to move the adjustable bell section expansion cone assembly 28,
adjustable
casing expansion cone assembly 30, packer setting tool assembly 32, stinger
assembly 34,
packer assembly 36 upwardly in a direction 110 into and through the end of the
expandable
wellbore casing 100. As a result, the end of the expandable wellbore casing
100 is radially
expanded and plastically deformed by the adjustable bell section expansion
cone assembly
28 to form a bell section 112. In an exemplary embodiment, during the
operation of the
system 10 described above with reference to Fig. 3, the casing lock assembly
24 may or
may not be coupled to the expandable wellbore casing 100.
[0087] In an exemplary embodiment, the length of the end of the expandable
welibore
casing 100 that is radially expanded and plastically deformed by the
adjustable bell section
expansion cone assembly 28 is limited by the stroke length of the tension
actuator assembly
18. In an exemplary embodiment, once the tension actuator assembly 18
completes a
stroke, the ball gripper assembly 16 is operated to release the expandable
tubular member
100, and the tubular support 12 is moved upwardly to permit the tension
actuator assembly
to be re-set. In this manner, the length of the bell section 112 can be
further extended by
continuing to stroke and then re-set the position of the tension actuator
assembly 18. Note,
that, during the upward movement of the tubular support 12 to re-set the
position of the
tension actuator assembly 18, the expandable tubular wellbore casing 100 is
supported by
the expansion surfaces of the adjustable bell section expansion cone assembly
28.
[0088] As illustrated in Fig. 4, in an exemplary embodiment, the casing lock
assembly 24
is then operated to engage and maintain the position of the expandable
wellbore casing 100
stationary relative to the tubular support 12. The adjustable bell section
expansion cone
assembly 28, adjustable casing expansion cone assembly 30, packer setting tool
assembly
32, stinger assembly 34, and packer assembly 36 are displaced downwardly into
the bell
section 112 in a direction 114 relative to the expandable wellbore casing 100
by operating
the extension actuator 26 and/or by dispiacing the system 10 downwardly in the
direction
114 relative to the expandable wellbore casing. After the adjustable bell
section expansion
cone assembly 28 and adjustable casing expansion cone assembly 30 have been
moved
19

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downwardiy in the direction 114 into the bell section 112 of the expandable
wellbore casing
100, the adjustable bell section expansion cone assembly is then operated to
decrease the
outside diameter of the adjustable bell section expansion cone assembly. In an
exemplary
embodiment, the decreased outside diameter of the adjustable bell section
expansion cone
assembly 28 is less than the increased outside diameter of the adjustable
casing expansion
cone assembly 30. In an exemplary embodiment, during the operation or'the
system
illustrated and described above with reference to Fig. 4, the ball gripper 16
may or may not
be operated to engage the expandable wellbore casing 100.
[00E2] As illustrated in Fig. 5, in an exemplary embodiment, the casing lock
assembly 24
is then disengaged from the expandable wellbore casing 100 and fluidic
material 116 is then
injected into the system 10 through the tubular support 12 to thereby
pressurize an annulus
118 defined within the expandable wellbore casing below the cup sub assembly
22. As a
result, a pressure differential is created across the cup seal assembly 22
that causes the cup
seal assembly to apply a tensile force in the direction 120 to the system 10.
As a result, the
system 10 is displaced upwardly in the direction 120 relative to the
expandable wellbore
casing 100 thereby pulling the adjustable casing expansion cone assembly 30
upwardly in
the direction 120 through the expandable wellbore casing thereby radially
expanding and
plastically deforming the expandable wellbore casing.
[0090] In an exemplary embodiment, the tension actuator assembly 16 may also
be
operated during the injection of the fluidic material 116 to displace the
adjustable casing
expansion cone assembly 30 upwardly relative to the tubular support 12. As a
result,
additional expansion forces may be applied to the expandable wellbore casing
100.
[0091] As illustrated in Fig. 6, in an exemplary embodiment, the radial
expansion and
plastic deformation of the expandable wellbore casing using the adjustable
casing expansion
cone assembly 30 continues until the packer assembly 36 is positioned within a
portion of
the expandable tubular member above the bell section 112. The packer assembly
36 may
then be operated to engage the interior surface of the expandable wellbore
casing 100
above the bell section 112.
[0092] In an exemplary embodiment, after the packer assembly 36 is operated to
engage the interior surface of the expandable wellbore casing 100 above the
bell section
112, a hardenable fluidic sealing material 122 may then be injected into the
system 10
through the tubular support 12 and then out of the system through the packer
assembly to
thereby permit the annulus between the expandable wellbore casing and the
wellbore 102 to
be filled with the hardenable fluidic sealing material. The hardenable fluidic
sealing material
122 may then be allowed to cure to form a fluid tight annulus between the
expandable
wellbore casing 100 and the wellbore 102, before, during, or after the
completion of the
radial expansion and plastic deformation of the expandable wellbore casing.

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[0093] As illustrated in Fig. 7, in an exemplary embodiment, the fluidic
material 116 is
then re-injected into the system 10 through the tubular support 12 to thereby
re-pressurize
the annulus 118 defined within the expandable wellbore casing below the cup
sub assembly
22. As a resuft, a pressure differential is once again created across the cup
seal assembly
22 that causes the cup seal assembly to once again apply a tensile force in
the direction 120
to the system 10. As a result, the system 10 is displaced upwardly in the
direction 120
relative to the expandable wellbore casing 100 thereby pulling the adjustable
casing
expansion cone assembly 30 upwardly in the direction 120 through the
expandable wellbore
casing thereby radially expanding and plastically deforming the expandable
wellbore casing
and disengaging the stinger assembly 34 from the pacl:er assembly 36. in an
exemplary
embodiment, during this operational mode, the packer assembly 36 prevents the
flow of
fluidic materials out of the expandable wellbore casing 100. As a result, the
pressurization of
the annulus 118 is rapid and efficient thereby enhancing the operational
efficiency of the
subsequent radial expansion and plastic deformation of the expandable wellbore
casing 100.
[0094] In an exemplary embodiment, the tension actuator assembly 16 may also
be
operated during the re-injection of the fluidic material 116 to displace the
adjustable casing
expansion cone assembly 30 upwardly relative to the tubular support 12. As a
result,
additional expansion forces may be applied to the expandable wellbore casing
100_
[0095] As illustrated in Fig. 8, in an exemplary embodiment, the radial
expansion and
plastic deformation of the expandable wellbore casing using the adjustable
casing expansion
cone assembly 30 continues until the adjustable casing expansion cone assembly
30
reaches the portion 124 of the expandable wellbore casing 100 that over(aps
with the
preexisting welibore casing 106. At which point, the system 10 may radially
expand the
portion 124 of the expandable wellbore casing 100 that overlaps with the
preexisting
wellbore casing 106 and the surrounding portion of the preexisting wellbore
casing.
Consequently, in an exemplary embodiment, during the radial expansion of the
portion 124
of the expandable welibore casing 100 that overlaps with the preexisting
wellbore casing
106, the tension actuator assembly 16 is also operated to displace the
adjustable casing
expansion cone assembly 30 upwardly relative to the tubular support 12. As a
result,
additional expansion forces may be applied to the expandable wellbore casing
100 and the
preexisting wellbore casing 106 during the radial expansion of the portion 124
of the
expandable weilbore casing that overlaps with the preexisting wellbore casing.
[0096] As illustrated in Fig. 9, in an exemplary embodiment, the entire length
of the
portion 124 of the expandable wellbore casing 100 that overlaps with the
preexisting
wellbore casing 106 is not radially expanded and plastically deformed. Rather,
only part of
the portion 124 of the expandable wellbore casing 100 that overlaps with the
preexisting
wellbore casing 106 is radially expanded and plastically deformed. The
remaining part of the
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WO 2004/085790 PCT/US2004/009434
portion 124 of the expandable wellbore casing 100 that overlaps with the
preexisting
wellbore casing 106 is then cut away by operating the casing cutter assembly
14.
[0097] As illustrated in Fig. 10, the remaining part of the portion 124 of the
expandable
wellbore casing 100 that overlaps with the preexisting wellbore casing 106
that is cut away
by operating the casing cutter assembly 14 is then also carried out of the
wellbore 102 using
the casing cutter assembly.
[009E) Furthermore, in an exemplary embodiment, the inside diameter of the
expandable
weilbore casing 100 above the bell section 112 is equal to the inside diameter
of the portion
of the preexisting wellbore casing 106 that does not overlap with the
expandable wellbore
casing 100. As a result, a wellbore casing is constructed that includes
overlapping wellbore
casings that together define an internal passage having a constant cross-
sectional area.
[00010] In several exemplary embodiments, the system 10 includes one or more
of the methods and apparatus disclose in one or more of the following: U.S.
Patent
Nos. 6,550,821; 6,968,618; 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; 7,172,024; 7,185,710; 7,100,685; 6,470,966; 6,521,227;
6,631,760;
7,240,728; 6,634,431; 6,705,395; 6,631,759; 6,631,769; 7,063,142; 6,684,947;
7,055,608;
7,044,221; 7,040,396; 7,048,062; 7,086,475; 7,077,213; 7,036,582; 7,044,218;
7,159,665;
7,108,061; 7,108,072; 7,121,352; 6,550,821; U.S. Publication Nos.
2004/0244968;
2002/0100595; 2003/0107217; 2004/0123988; 2003/0192705; 2003/0222455; and
WO 01/04535; WO 02/66783; WO 03/23178; WO 03/16669; WO 03/29607;
WO 03/04819; WO 03/23179; WO 03/58022; WO 03/71086; WO 03/42486;
WO 03/42487; WO 03/102365; WO 04/03337; WO 03/086675; WO 03/078785;
WO 03/089161; WO 04/010039; WO 03/093623; WO 03/059549; WO 03/104601;
WO 03/106130; WO 04/11776; WO 04/09950; WO 04/20895.
[0099] In an exemplary embodiment, the casing cutter assembly 14 is provided
and
operates substantially, at least in part, as disclosed in WO 04/02720.
[00100] In an exemplary embodiment, as illustrated in Figs. 11-1 and 11-2,
11A1 to 11A2,
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WO 2000085790 PCT/[TS2004/009434
11 B1 to 11132, 11 C, 11 D, 11 E, 11 F, 11 G, 11 H, Ill, 11 j, 11 K,11 L, 11M,
11 N, 110, 11 P,
11Q, 11R, 11S, 11T, IIU, 11V, 11W, 11X, 91Y, 11Z1 to 11Z4, 11AA1 to 11AA4,
IIABI to
11AB4, 11AC1 to 11AC4, 11AD, and 11AE, the casing cutter assembly 14 includes
an upper
tubular tool joint 14002 that defines a longitudinal passage 14002a and
mounting holes,
14002b and 14002c, and includes an intemal threaded connection 14002d, an
inner annular
recess 14002e, an inner annular recess 14002f, and an internal threaded
connection
14002g. A tubular torque plate 14004 that defines a longitudinal passage
14004a and
includes circumferentially spaced apart teeth 14004b is received within, mates
with, and is
coupled to the intemal annular recess 14002e of the upper tubular tool joint
14002.
[00102] Circumferentially spaced apart teeth 14006a of an end of a tubular
lower mandrel
14006 that defines a longitudinal passage 14006b, a radial passage 14006ba,
and a radial
passage 14006bb and includes an external threaded connection 14006c, an
external flange
14006d, an external annular recess 14006e having a step 14006f at one end, an
extemal
annular recess 14006g, external teeth 14006h, an external threaded connection
140061, and
an extemal annular recess 14006j engage the circumferentially spaced apart
teeth 14004b
of the tubular torque plate 14004. An internal threaded connection 14008a of
an end of a
tubular toggle bushing 14008 that defines a longitudinal passage 14008b, an
upper
longitudinal slot 14008c, a lower longitudinal slot 14008d, mounting holes,
14008e, 14008f,
14008g, 14008h, 14008i, 14008j, 14008k, 140081, 14008m, 14008n, 14008o,
14008p,
14008q, 14008r, 14008s, 14008t, 14008u, 14008v, 14008w, 14008x, 14008xa, and
14008xb, and includes an extemal annular recess 14008y, internal annular
recess 14008z,
external annular recess 14008aa, and an extemal annular recess 14008ab
receives and is
coupled to the external threaded connection 14006c of the tubular lower
mandrel 14006.
[0100] A sealing element 14010 is received within the extemal annular recess
14008y of
the tubular toggle bushing 14008 for sealing the interface between the tubular
toggle
bushing and the upper tubular tool joint 14002. A sealing element 14012 is
received within
the intemal annular recess 14008z of the tubular toggle bushing 14008 for
sealing the
interface between the tubular toggle bushing and the tubular lower mandrel
14006.
[0101] Mounting screws, 14014a and 14014b, mounted within and coupled to the
mounting holes, 14008w and 14008x, respectively, of the tubular toggle bushing
14008 are
also received within the mounting holes, 14002b and 14002c, of the upper
tubular tool joint
14002. Mounting pins, 14016a, 14016b, 14016c, 14016d, and 14016e, are mounted
within
the mounting holes, 14008e, 14008fi, 94008g, 14008h, and 14008i, respectively.
Mounting
pins, 14018a, 14018b, 14018c, 14018d, and 14018e, are mounted within the
mounting
holes, 14008t, 14008s, 14008r, 14008q, and 14008p, respectively. Mounting
screws,
14020a and 14020b, are mounted within the mounting holes, 14008u and 14008v,
respectively.
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WO 2004/085790 PCT[US2004/009434
[0102] A first upper toggle link 14022 defines mounting holes, 14022a and
14022b, for
receiving the mounting pins, 14016a and 14016b, and includes a mounting pin
14022c at
~'one end. A first lower toggle link 14024 defines mounting holes, 14024a,
14024b, and
14024c, for receiving the mounting pins, 14022c, 14016c, and 14016d,
respectively and
includes an engagement arm 14024d. A first trigger 14026 defines a mounting
hole 14026a
for receiving the mounting pin 14016e and includes an engagement arm 14026b at
one end,
an engagement member 14026c, and an engagement arm 14026d at another end.
10103] A second upper toggle link 14028 defines mounting holes, 14028a and
14028b,
for receiving the mounting pins, 14018a and 14018b, and includes a mounting
pin 14028c at
one end. A second lower toggle link 14030 defines mounting holes, '14030a,
14030b, and
14030c, for receiving the mounting pins, 14028c, 14018c, and 14018d,
respectively and
includes an engagement arm 14030d. A second trigger 14032 defines a mounting
hole
14032a for receiving the mounting pin 14018e and includes an engagement arm
14032b at
one end, an engagement member 14032c, and an engagement arm 14032d at another
end.
[0104] An end of a tubular spring housing 14034 that defines a longitudinal
passage
14034a, mounting holes, 14034b and 14034c, and mounting holes, 14034ba and
14034ca,
and includes an internal flange 14034d and an internal annular recess 14034e
at one end,
and an internal flange 14034f, an internal annular recess 14034g, an intemal
annular recess
14034h, and an extemal threaded connection 14034i at another end receives and
mates
with the end of the tubular toggle bushing 14008. Mounting screws, 14035a and
14035b,
are mounted within and coupled to the mounting holes, 14008xb and 14008xa,
respectively,
of the tubular toggle bushing 14008 and are received within the mounting
holes, 14034ba
and 14034ca, respectively, of the tubular spring housing 14034.
[0105] A tubular retracting spring ring 14036 that defines mounting holes,
14036a and
14036b, receives and mates with a portion of the tubular lower mandrel 14006
and is
received within and mates with a portion of the tubular spring housing 14034.
Mounting
screws, 14038a and 14038b, are mounted within and coupled to the mounting
holes, 14036a
and 14036b, respectively, of the tubular retracting spring ring 14036 and
extend into the
mounting holes, 14034b and 14034c, respectively, of the tubular spring housing
14034.
[0106] Casing diameter sensor springs, 14040a and 14040b, are positioned
within the
.longitudinal slots, 14008c and 1408d, respectively, of the tubular toggle
bushing 14008 that
engage the engagement members, 14026c and 14032c, and engagement arms,14026d
and
14032d, of the first and second triggers, 14026 and 14032, respectively. An
inner flange
14042a of an end of a tubular spring washer 14042 mates with and receives a
portion of the
tubular lower mandrel 14006 and an end face of the inner flange of the tubular
spring washer
is positioned proximate and end face of the external flange 14006d of the
tubular lower
mandrel. The tubular spring washer 14042 is further received within the
longitudinal
24

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WO 2004/085790 PCT/US2004/009434
passage 14034a of the tubular spring housing 14034.
[0107] An end of a retracting spring 14044 that receives the tubular lower
mandrel
14006 is positioned within the tubular spring washer 14042 in contact with the
intemal flange
14042a of the tubular spring washer and the other end of the retracting spring
is positioned
in contact with an end face of the tubular retracting spring ring 14036.
[0`li 0E] A sealing element 14046 is received within the extemal annular
recess 14006j of
the tubular lower mandrel 14006 for sealing the interface between the tubular
lower mandrel
and the tubular spring housing 14034. A sealing element 14048 is received
within the
internal annular recess 14034h of the tubular spring housing 14034 for sealing
the interface
between the tubular spring housing and the tubular lower mandrel 14006.
[0109] An internal threaded connection 14050a of an end of a tubular upper
hinge
sleeve 14050 that includes an intemal flange 14050b and an internal pivot
14050c receives
and is coupled to the extemal threaded connection 14034i of the end of the
tubular spring
housing 14034.
[0110] An external flange 14052a of a base member 14052b of an upper cam
assembly
14052, that is mounted upon and receives the lower tubular mandrel 14006, that
includes an
internal flange 14052c that is received within the external annular recess
14006e of the
lower tubular mandrel 14006 and a plurality of circumferentially spaced apart
cam arms
14052d extending from the base member mates with and is received within the
tubular upper
hinge sleeve 14050. The base member 14052b of the upper cam assembly 14052
further
includes a plurality of circumferentially spaced apart teeth 14052f that mate
with and are
received within a plurality of circumferentially spaced apart teeth 14034j
provided on the end
face of the tubular spring housing 14034 and an end face of the external
flange 14052a of
the base member of the upper cam assembly is positioned in opposing relation
to an end
face of the internal flange 14050b of the tubular upper hinge sleeve 14050.
Each of the
cam arms 14052d of the upper cam assembly 14052 include external cam surfaces
14052e.
In an exemplary embodiment, the teeth 14052f of the base member 14052b of the
upper
cam assembly 14052 and the teeth 14034j provided on the end face of the
tubular spring
housing 14034 permit torsional loads to be transmitted between the tubular
spring housing
and the upper cam assembly.
[0111] A plurality of circumferentially spaced apart upper casing cutter
segments 14054
are mounted upon and receive the lower tubular mandrel 14006 and each include
an
external pivot recess 14054a for mating with and receiving the internal pivot
14050c of the
tubular upper hinge sleeve 14050 and an external flange 14054b and are
pivotally mounted
within the tubular upper hinge sleeve and are interleaved with the
circumferentially spaced
apart cam arms 14052d of the upper cam assembly 14052. A casing cutter element
14056
is coupled to and supported by the upper surface of each upper casing cutter
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CA 02522918 2007-08-27
WO 2004/085790 PCT/US2004/009434
14054 proximate the external flange 14054b.
[0112] A plurality of circumferentially spaced apart lower casing cutter
segments 14058
are mounted upon and receive the lower tubular mandrel 14006, are interleaved
among the
upper casing cutter segments 14054, are oriented in the opposite direction to
the upper
casing cutter segments 14054, each include an external pivot recess 14058a,
and are
positioned in opposing relation to corresponding circumferentially spaced
apart cam anns
14052d of the upper cam assembly 14052.
[0113] A lower cam assembly 14060 is mounted upon and receives the lower
tubular
mandrel 14006 that includes a base member 14060a having an external flange
14060b, a
plurality of circumferentially spaced apart cam arms 14060d that extend from
the base
member that each include external cam surfaces 14060e and define mounting
holes 14060f
and 14060g. The base member 14060a of the lower cam assembly 14060 further
includes a
plurality of circumferentially spaced apart teeth 14060h. The
circumferentially spaced apart
cam arms 14060d of the lower cam assembly 14060 are interleaved among the
lower casing
cutter segments 14058 and the circumferentially spaced apart cam arms 14052d
of the
upper cam assembly 14052 and positioned in opposing relation to corresponding
upper
casing cutter segments 14054.
[0114] Mounting screws, 14062a, 14062b, 14062c, and 14062e, are mounted within
the
corresponding mounting holes, 14060f and 14060g, of the lower cam assembly
14060 and
are received within the external annular recess 14006g of the lower cam
assembly 14060.
[0115] A tubular lower hinge sleeve 14064 that receives the lower casing
cutter
segments 14058 and the lower cam assembly 14060 includes an intemal flange
14064a for
engaging the external flange 14060b of the base member of the lower cam
assembly 14060,
an internal pivot 14064b for engaging and receiving the extemal pivot recess
14058a of the
lower casing cutter segments 14058 thereby pivotally mounting the lower casing
cutter
segments within the tubular lower hinge sleeve, and an internal threaded
connection
14064c.
[0116] An external threaded connection 14066a of an end of a tubular sleeve
14066 that
defines mounting holes, 14066b and 14066c, and includes an intemal annular
recess
14066d having a shoulder 14066e, an intemal flange 14066f, and an internal
threaded
connection 14066g at another end is received within and coupled to the intemal
threaded
connection 14064c of the tubular lower hinge sleeve 14064. An external
threaded
connection 14068a of an end of a tubular member 14068 that defines a
longitudinal passage
14068b and mounting holes, 14068c and 14068d, and includes an external annular
recess
14068e, and an extemal threaded connection 14068f at another end is received
within and is
coupled to the internal threaded connection 14066g of the tubular sleeve
14066.
[0117] Mounting screws, 14070a and 14070b, are mounted in and coupled to the
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WO 2004/085790 PCT/US2004/009434
mounting holes, 14068c and 14068d, respectively, of the tubular member 14068
that also
extend into the mounting holes, 14066b and 14066c, respectively, of the
tubular sleeve
.14066. A sealing element 14072 is received within the extemal annular recess
14068e of
the tubular member 14068 for sealing the interface between the tubular member
and the
tubular sleeve 14066.
[0118] An internal threaded connection 14074a of a tubular retracting piston
14074 that
defines a longitudinal passage 14074b and includes an intemal annular recess
14074c and
an external annular recess 14074d receives and is coupled to the external
threaded
connection 14006i of the tubular lower mandrel 14006. A sealing element 14076
is received
within the external annular recess 14074d of the tubular retracting piston
14074 for sealing
the interface between the tubular retracting piston and the tubular sleeve
14066. A sealing
element 14078 is received within the internal annular recess 14074c of the
tubular retracting
piston 14074 for sealing the interface between the tubular retracting piston
and the tubular
lower mandrel 14006.
[0119] Locking dogs 14080 mate with and receive the external teeth 14006h of
the
tubular lower mandrel 14006. A spacer ring 14082 is positioned between an end
face of the
locking dogs 14080 and an end face of the lower cam assembly 14060. A release
piston
14084 mounted upon the tubular lower mandrel 14006 defines a radial passage
14084a for
mounting a burst disk 14086 includes sealing elements, 14084b, 14084c, and
14084d. The
sealing elements, 14084b and 14084d, sealing the interface between the release
piston
14084 and the tubular lower mandrel 14006. An end face of the release piston
14084 is
positioned in opposing relation to an end face of the locking dogs 14080.
[0120] A release sleeve 14088 that receives and is mounted upon the locking
dogs
14080 and the release piston 14084 includes an intemal flange 14088a at one
end that
sealingly engages the tubular lower mandrel 14006. A bypass sleeve 14090 that
receives
and is mounted upon the release sleeve 14088 includes an internal flange
14090a at one
end.
[0121] In an exemplary embodiment, during operation of the casing cutter
assembly 14,
the retracting spring 14044 is compressed and thereby applies a biasing spring
force in a
direction 14092 from the lower tubular mandrel 14006 to the tubular spring
housing 14034
that, in the absence of other forces, moves and/or maintains the upper cam
assembly 14052
and the upper casing cutter segments 14054 out of engagement with the lower
casing cutter
segments 14058 and the lower cam assembly 14060. In an exemplary embodiment,
during
operation of the casing cutter assembly 14, an external threaded connection
12a of an end
of the tubular support member 12 is coupled to the internal threaded
connection 14002d of
the upper tubular tool joint 14002 and an internal threaded connection 16a of
an end of the
ball gripper assembly 16 is coupled to the external threaded connection 14068f
of the tubular
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CA 02522918 2007-08-27
WO 2004/085790 PCT/US2004/009434
member 14068.
[0122] The upper cam assembly 14052 and the upper casing cutter segments 14054
may be brought into engagement with the lower casing cutter segments 14058 and
the
lower cam assembly 14060 by pressurizing an annulus 14094 defined between the
lower
tubular mandrel 14006 and the tubular spring housing 14034. In particular,
injection of fluidic
materials into the cam cutter assembly 14 through the longitudinal passage
14006b or'the
lower tubular mandrel 14006 and into the radial passage 14006ba may pressurize
the
annulus 14094 thereby creating sufficient operating pressure to generate a
force in a
direction 14096 sufficient to overcome the biasing force of the retracting
spring 14044. As a
result, the spring housing 14034 may be displaced in the direction 14096
relative to the
lower tubular mandrel 14006 thereby displacing the tubular upper hinge sleeve
14050, upper
cam assembly 14052 , and upper casing cutter segments 14054 in the direction
14096.
[0123] In an exemplary embodiment, as illustrated in Figs. 11P, 11Q and 11R,
the
displacement of the upper cam assembly 14052 and upper casing cutter segments
14054 in
the direction 14096 will cause the lower casing cutter segments 14058 to ride
up the cam
surfaces of the cam arms of the upper cam assembly 14052 while also pivoting
about the
lower tubular hinge segment 14064, and will also cause the upper casing cutter
segments
14054 to ride up the cam surfaces of the cam arms of the lower cam assembly
14060 while
also pivoting about the upper tubular hinge segment 14050.
[0124] In an exemplary embodiment, during the operation of the casing cutter
assembly
14, when the upper and lower casing cutter segments, 14054 and 14058, brought
into axial
alignment in a radially expanded position, the casing cutter elements of the
casing cutter
segments are brought into intimate contact with the interior surface of a pre-
selected portion
of the expandable wellbore casing 100. The casing cutter assembly 14 may then
be rotated
to thereby cause the casing cutter elements to cut through the expandable
wellbore casing.
The portion of the expandable wellbore casing 100 cut away from the remaining
portion on
the expandable wellbore casing may then be carried out of the wellbore 102
with the cut
away portion of the expandable wellbore casing supported by the casing cutter
elements.
[0125] In an exemplary embodiment, the upper cam assembly 14052 and the upper
casing cutter segments 14054 may be moved out of engagement with the lower
casing
cutter segments 14058 and the lower cam assembly 14060 by reducing the
operating
pressure within the annulus 14094.
[0126] In an alternative embodiment, as illustrated in Figs. 11S, 11T, 11U and
11V,
during operation of the casing cutter assembly 14, the upper cam assembly
14052 and the
upper casing cutter segments 14054 may also be moved out of engagement with
the lower
casing cutter segments 14058 and the lower cam assembly 14060 by sensing the
operating
pressure within the longitudinal passage 14006b of the lower tubular mandrel
14006. In
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particutar, as illustrated in Fig. 11T, if the operating pressure within the
longitudinal passage
14006b and radial passage 14006bb of the lower tubular mandrel 14006 exceeds a
'predetermined value, the burst disc 14086 will open the passage 14084a
thereby
pressurizing the interior of the tubular release sleeve 14088 thereby
displacing the tubular
release sleeve 14088 downwardly in a direction 14092 away from engagement with
the
locking dogs 14080.
[0927] As a result, as illustrated in Fig. 11 U, the locking dogs 14080 are
displaced
outwardly in the radial directed and thereby released from engagement with the
lower
tubular mandrel 14006 thereby permitting the lower casing cutter segments
14058 and the
lower cam assembly 14060 to be displaced downwardly relative to the lower
tubular
mandrel.
[0128] As a result, as illustrated in Fig. 11V, the operating pressure within
the lower
tubular mandrei 14066 may then cause the lower tubular mandrel to be displaced
downwardly in the direction 14094 relative to the tubular lower mandrel 14006
and the
retracting piston 14074. As a result, the lower tubular mandrel 14066, the
lower casing
cutter segments 14058, the lower cam assembly 14060, and tubular lower hinge
sleeve
14064 are displaced downwardly in the direction 14094 relative to the tubular
spring housing
14034 thereby moving the lower casing cutter segments 14058 and the lower cam
assembly
14060 out of engagement with the upper cam assembly 14052 and the upper casing
cutter
segments 14054.
[0129] In an exemplary embodiment, as illustrated in Figs. 11W, 11X, and 11Y,
during
operation of the casing cutter assembly 14, the casing cutter assembly 14
senses the
diameter of the expandable wellbore casing 100 using the upper toggle links,
14022 and
14028, lower toggle links, 14024 and 14030, and triggers, 14026 and 14032, and
then
prevents the engagement of the upper cam assembly 14052 and the upper casing
cutter
segments 14054 with the lower casing cutter segments 14058 and the lower cam
assembly
14060.
[0130] In particular, as illustrated in Fig. 11W, anytime the upper toggle
links, 14022 and
14028, and lower toggle links, 14024 and 14030, are positioned within a
portion of the
expandable welibore casing 100 that has been radially expanded and plastically
deformed
by the system 10, the triggers, 14026 and 14032, will be pivoted by the
engagement arms,
14024d and 14030d, of the lower toggle links, 14024 and 14030, to a position
in which the
triggers will no )onger engage the internal flange 14034d of the end of the
tubular spring
housing 14034 thereby permitting the displacement of the tubular spring
housing in the
direction 14096. As a result, the upper cam assembly 14052 and the upper
casing cutter
segments 14054 can be brought into engagement with the lower casing cutter
segments
14058 and the lower cam assembly 14060. In an exemplary embodiment, the upper
toggle
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CA 02522918 2007-08-27
WO 2004/085790 PCT/US2004/009434
links, 14022 and 14028, and the lower toggle links, 14024 and 14030, are
spring biased
towards the position illustrated in Fig. 11W.
[0131] Conversely, as illustrated in Fig. 11X, anytime the upper toggle links,
14022 and
14028, and lower toggle links, 14024 and 14030, are positioned within a
portion of the
expandable vtjellbore casing 100 that has not been radially expanded and
plastically
deformed by the system 10, the triggers, 14026 and 14032, will be maintained
in a position
in which the triggers will engage the internal flange 14034d of the end of the
tubular spring
housing 14034 thereby preventing the displacement of the tubular spring
housing in the
direction 14096. As a result, the upper cam assembly 14052 and the upper
casing cutter
segments 14054 cannot be brought into engagement with the lower casing cutter
segments
14058 and the lower cam assembly 14060. In an exemplary embodiment, the
triggers,
14026 and 14032, are spring biased towards the position illustrated in Fig.
11X.
[0132] In an exemplary embodiment, as illustrated in Fig. 11 Y, the tubular
spring
housing 14034 may be displaced upwardly in the direction 14098 even if the
upper toggle
links, 14022 and 14028, and lower toggle links, 14024 and 14030, are
positioned within a
portion of the expandable wellbore casing 100 that has not been radially
expanded and
plastically deformed by the system 10.
[0133] In an exemplary embodiment, as illustrated in Figs. 11Z1 to 11Z4, 11AA1
to
11AA4, 11AB1 to 11AB4, 11AC1 to 11AC4, 11AD, and 11AE, the tubular spring
housing
14034 of the casing cutter assembly 14 defines intemal annular recesses 14034k
and
140341, spaced apart by an internal flange 14034m, the tubular toggle bushing
14008
defines an external annular recess 14008ac, and the casing cutter assembly
further includes
pins, 14100a and 14100b and 14102a and 14102b, mounted in holes 14008j and
14008o
and 14008k and 14008n, respectively, of the tubular toggle bushing, and a one-
shot
deactivation device 14104 mounted on the tubular toggle bushing between the
pins, 14100a
and 14100b and 14102a and 14102b.
[0134] The one-shot deactivation device 14104 includes a tubular body 14104a
that
defines radial holes, 14104b and 14014c, and includes an external annular
recess 14104d at
one end, a centrally positioned extemal flange 14104e, a centrally positioned
intemal
annular recess 14104f, and an extemal annular recess 14104g at another end. An
engagement member 14106 that includes a base member 14106a having a tapered
end
14106b and a key member 14106c having a tapered end 14106d is received within
a portion
of the internal annular recess 14104f of the tubular body 14104a and an
engagement
member 14108 that includes a base member 14108a having a tapered end 14108b
and a
key member 14108c having a tapered end 14108d is received within an opposite
portion of
the internal annular recess 14104f of the tubular body 14104a. Spring members,
14110 and
14112, are received within the annular recess 14104f of the tubular body
14104a for biasing

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the base members, base member 14106a and 14108a, of the engagement members,
14106
and 14108, respectively, radially inwardly relative to the tubular body
14104a.
.[0135] In an exemplary embodiment, during operation of the casing cutter
assembly
14, as illustrated in Figs. 11Z1 to 11Z4, the one-shot deactivation device
14104 are
positioned proximate and in intimate contact with the pins, 14102a and 141
02b, with the
tapered ends, 14106b and 14108b, of the base members, 141 06a and 14108a, of
the
engagement members, 14106 and 14108, received within the extemal annular
recess
14008ac of the tubular toggle bushing 14008. When the one-shot deactivation
device 14104
is positioned as illustrated in Fig.11Z, the extemai annular recess 14104d of
the tubular
body 14104a of the one-shot deactivation device is moved out of engagement
with the
engagement arms, 14026d and 14032d, of the triggers, 14026 and 14032,
respectively. As
a result, the triggers, 14026 and 14032, may operate normally as described
above with
reference to Figs. 11W, 11X, and 11Y.
[0136] Conversely, in an exemplary embodiment, during operation of the casing
cutter
assembly 14, as illustrated in Figs. 11AA1 to 11AA4, the one-shot deactivation
device 14104
are positioned proximate and in intimate contact with the pins, 14100a and
14100b, with the
tapered ends, 14106b and 14108b, of the base members, 14106a and 14108a, of
the
engagement members, 14106 and 14108, not received within the external annular
recess
14008ac of the tubular toggle bushing 14008. When the one-shot deactivation
device 14104
is positioned as illustrated in Figs. 11AA1 to 11AA4, the extemal annular
recess 14104d of
the tubular body 14104a of the one-shot deactivation device is moved into
engagement with
the engagement arms, 14026d and 14032d, of the triggers, 14026 and 14032,
respectively.
As a result, the triggers, 14026 and 14032, are deactivated and may not
operate normally as
described above with reference to Figs. 11W, 11X, and 11Y.
[0137] In an alternative embodiment, the eiements of the casing cutter
assembly 14 that
sense the diameter of the expandable weilbore casing 100 may be disabled or
omitted or
adjusted to sense any pre-selected internal diameter of the expandable
wellbore casing.
[0138] In an exemplary embodiment, the ball gripper assembly 16 is provided
and
operates substantially, at least in part, as disclosed in one or more of the
following:
WO 04/02720; WO 03/093623.
[0139] In an exemplary embodiment, as illustrated in Figs. 12A1 to 12A4, 12B
and 12C1
to 12C4, the ball gripper assembly 16 includes an upper mandrel 1602 that
defines a
longitudinal passage 1602a and a radial passage 1602b and includes an internal
threaded
31

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WO 2004/085790 PCT/US2004/009434
connection 1602c at one end, an external flange 1602d at an intermediate
portion that
includes an extemal annular recess 1602e having a shoulder 1602f and an
extemal radial
hole 1602g, an extemal annular recess 1602h, an external annular recess 1602i,
an external
annular recess 1602j having a tapered end 1602k including an extemal annular
recess
1602ka, an external annular recess 16021, and an external annular recess
1602m, and an
extemal annular recess 1602n, an external radial hole 1602o, an external
annular recess
1602p, and an external annular recess 1602q at another end.
[0140] An upper tubular bushing 1604 defines an internally threaded radial
opening
1604a and includes an external flange 1604b having an external annular recess
1604c and
an internal annular recess 1604d mates with and receives the external flange
1602d of the
upper mandrel 1602. In particular, the internal annular recess 1604d of the
upper tubular
bushing 1604 mates with the shoulder 1602f of the external annular recess
1602e of the
upper mandrel 1602. A screw 1606 that is threadably coupled to the internally
threaded
radial opening 1604a of the upper tubular bushing 1604 extends into the
external radial hole
1602g of the external flange 1602d of the upper mandrel 1602.
[0141] A deactivation tubular sleeve 1608 defines a radial passage 1608a and
includes
an internal annular recess 1608b that mates with and receives an end of the
extemal
annular recess 1604c of the external flange 1604b of the upper tubular bushing
1604, an
intemal annular recess 1608c that mates with and receives the extemal flange
1602d of the
upper mandrel 1602, an internal annular recess 1608d, an internal annular
recess 1608e,
and an internal annular recess 1608f. A deactivation spring 1610 is received
within an
annulus 1612 defined between the internal annular recess 1608b of the
deactivation tubular
sleeve 1608, an end face of the external annular recess 1604c of the external
flange 1604b
of the upper tubular bushing 1604, and the external annular recess 1602h of
the external
flange 1602d of the upper mandrel 1602.
[0142] A sealing member 1614 is received with the extemal annular recess 1602i
of the
external flange 1602d of the upper mandrel 1602 for sealing the interface
between the upper
mandrel and the deactivation tubular sleeve 1608. An annular spacer element
1616 is
received within the extemal annular recess 1602ka of the tapered end 1602k of
the external
annular recess 1602j of the upper mandrel 1602.
[0143] One or more inner engagement elements 1618a of a tubular coglet 1618
engage
and are received within the external annular recess 1602ka of the tapered end
1602k of the
extemal annular recess 1602j of the upper mandrel 1602 and one or more outer
engagement elements 1618b of the cogiet engage and are received within the
internal
annular recess 1608d of the deactivation tubular sleeve 1608.
[0144] An external annular recess 1620a of an end of a tubular coglet prop
1620 that
includes an inner flange 1620b receives and mates with the inner surfaces of
the outer
32

CA 02522918 2007-08-27
WO 2004/085790 PCT/US2004/009434
engagement elements 1618b of the coglet 1618. The end of the tubular cogiet
prop 1620
further receives and mates with the externat annular recess 1602j of the
extemal flange
1602d of the upper mandrel 1602. A sealing element 1622 is received within the
extemal
annular recess 16021 of the upper mandre11602 for sealing the interface
between the upper
mandrel and the tubular coglet prop 1620.
[0145] An end of a tubular bumper sleeve 1624 that includes intemai and
extemai
flanges, 1624a and 1624b, and a hole 1624c at another end mates with and
receives the
external annular recess 1602m of the external flange 1602d of the upper
mandrel 1602. A
coglet spring 1626 is received within an annulus 1628 defined between the
extemal annular
recess 1602m of the external flange 1602d of the upper mandrel 1602, the
tubular cogiet
prop 1620, the inner flange 1620b of the tubular cogiet prop, an end face of
the tubular
bumper sleeve 1624, and the internal annular recess 1608c of the deactivation
tubular
sleeve 1608.
[0146] A tubular ball race 1628 that defines a plurality of tapered annular
recesses
1628a and an internally threaded radial opening 1628b and includes one or more
axial
engagement elements 1628c at one end and one or more axial engagement elements
1628d at another end receives and mates with the other end of the upper
mandrel 1602. In
an exemplary embodiment, the axial engagement elements 1628c of the tubular
ball race
1628 are received within and are coupled to the hole 1624c of the tubular
bumper sleeve
1624. An end of a tubular activation sleeve 1630 that defines a plurality of
radial openings
1630a, a radial opening 1630b, a radial opening 1630c, and inciudes an
internal annular
recess 1630d receives and mates with the tubular ball race 1628. In an
exemplary
embodiment, an end face of an end of the tubular activation sleeve 1630 is
positioned
proximate and in opposing relation to an end face of an end of the
deactivation sleeve 1608.
In an exemplary embodiment, the radial openings 1630a are aligned with and
positioned in
opposing relation to corresponding of tapered annular recesses 1628a of the
tubular ball
race 1628, and the radial openings are also narrowed in cross section in the
radial direction
for reasons to be described.
[0147] Balls 1632 are received within each of the of tapered annular recesses
1628a
and corresponding radial openings 1630a of the tubular ball race 1628 and
tubular activation
sleeve 1630, respectively. In an exemplary embodiment, the narrowed cross
sections of the
radial openings 1630a of the tubular activation sleeve 1630 will permit the
balls 1632 to be
displaced outwardly in the radial direction until at least a portion of the
balls exiends beyond
the outer perimeter of the tubular activation sleeve to thereby permit
engagement of the balls
with an outer structure such as, for example, a wellbore casing.
[0148] A lower mandrel 1634 that defines a longitudinal passage 1634a and an
internally
threaded radial passage 1634b at one end and includes internal annular
recesses, 1634c
33

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WO 2004/085790 PCT/1JS2004/009434
and 1634d, for receiving and mating with the extemal annular recesses, 1602p
and 1602q,
of the upper mandrel 1602, an intemal annular recess 1634e, an extemai flange
1634f, and
an externally threaded connection 1634g at another end. In an exemplary
embodiment, as
illustrated in Fig. 12B, the end of the lower mandrel 1634 further includes
longitudinal
recesses 1634h for receiving and mating with corresponding axial engagement
elements
1628d of the tubular ball race 1628. A sealing element 1635 is received within
the internal
annular recess 1634d of the lower mandrel 1634 for sealing an interface
between the lower
mandrel and the external annular recess 1602p of the upper mandrel 1602.
[0149] A tubular spring retainer 1636 that defines a radial passage 1636a and
includes
an external annular recess 1636b at one end mates with and receives the end of
the lower
mandrel 1634 and is positioned proximate an end face of the external flange
1634f of the
lower mandrel. A tubular spring retainer 1638 receives and mates with the end
of the lower
mandrel 1634 and is received and mates with the internal annular recess 1630d
of the
tubular activation sleeve 1630.
[0150] An activation spring 1640 is received within an annulus 1642 defined an
end face
of the tubular spring retainer 1638, an end face of the spring retainer 1636,
the internal
annular recess 1630d of the tubular activation sleeve 1630, and the end of the
lower
mandrel 1634. A retainer screw 1642 is received within and is threadably
coupled to the
internally threaded radial opening 1634b of the lower mandrel 1634 that also
extends into
the extemal radial hole 1602o of the upper mandrel 1602.
[0151] During operation of the ball gripper assembly 16, in an exemplary
embodiment,
as illustrated in Figs. 12A1 to 12A4, the ball gripper assembly may be
positioned within the
expandable wellbore casing 100 and the intemally threaded connection 1602c of
the upper
mandrel 1602 may be coupled to an externally threaded connection 14a of an end
of the
casing cutter assembly 14 and the externally threaded connection 1634g of the
lower
mandrel 1634 may be coupled to an intemaliy threaded connection 18a of an end
of the
tension actuator assembly 18.
[0152] In an alternative embodiment, the intemally threaded connection 1602c
of the
upper mandrel 1602 may be coupled to an externally threaded connection of an
end of the
tension actuator assembly 18 and the extemally threaded connection 1634g of
the lower
mandrel 1634 may be coupled to an intemally threaded connection of an end of
casing
cutter assembly 14.
[0153] In an exemplary embodiment, the deactivation spring 1610 has a greater
spring
rate than the activation spring 1640. As a result, in an initial operating
mode, as illustrated in
Figs. 12A1 to 12A4, a biasing spring force is applied to the deactivation
sleeve 1608 and
activation sleeve 1630 in a direction 1644 that maintains the activation
sleeve in a position
relative to the tubular ball race 1628 that maintains the balls 1632 within
the radially inward
34

CA 02522918 2007-08-27
WO 2004/085790 PCT/US2004/009434
portions of the corresponding tapered annular recesses 1628a of the tubular
ball race such
that the balls do not extend beyond the perimeter of the activation sleeve to
engage the
expandable wellbore casing 100.
[0154] As illustrated in Figs. 12C1 to 12C4, in an exemplary embodiment, the
ball
gripper 16 may be operated to engage the interior surface of the expandable
wellbore casing
100 by injecting a fluidic material 1650 into the ball gripper assembly
through the longitudinal
passages 1602a and 1634aa, of the upper and lower mandrels, 1602 and 1634,
respectively.
[0155] In particular, when the longitudinal and radial passages, 1602a and
1602b,
respectively, of the upper mandrel 1602 are pressurized by the injection of
the fluidic
material 1650, the internal annular recess 1608c of the deactivation tubular
sleeve 1608 is
pressurized. When the operating pressure of the fluidic material 1650 within
the intemal
annular recess 1608c of the deactivation tubular sleeve 1608 is sufficient to
overcome the
biasing spring force of the deactivation spring 1610, the deactivation tubular
sleeve is
displaced in a direction 1652. As a result, the spring force provided by the
activation spring
1640 then may displace the activation tubular sleeve 1630 in the direction
1652 thereby
moving the balls 1632 on the corresponding tapered annular recesses 1628a of
the tubular
ball race 1628 outwardly in a radial direction into engagement with the
interior surface of the
expandable wellbore casing 100. In an exemplary embodiment, the operating
pressure of
the fluidic material 1650 sufficient to overcome the biasing spring force of
the deactivation
spring 1610 was about 100 psi.
[0156] In an exemplary embodiment, when the operating pressure of the fluidic
material
1650 is reduced, the operating pressure of the fluidic material 1650 within
the internal
annular recess 1608c of the deactivation tubular sleeve 1608 is no longer
sufficient to
overcome the biasing spring force of the deactivation spring 1610, and the
deactivation
tubular sleeve and the activation tubular sleeve 1630 are displaced in a
direction opposite to
the direction 1652 thereby moving the balls 1632 radially inwardly and out of
engagement
with the interior surface of the expandable wellbore casing 100.
[0157] In an exemplary embodiment, the ball gripper assembly 16 is operated to
engage
the interior surface of the expandable wellbore casing 100 in combination with
the operation
of the tension actuator assembly 18 to apply an upward tensile force to one or
more
elements of the system 10 coupled to and positioned below the tension actuator
assembly.
As a result, a reaction force comprising a downward tensile force is applied
to the lower
mandrel 1634 of the ball gripper assembly 16 in a direction opposite to the
direction 1652
during the operation of the tension actuator assembly 18. Consequently, due to
the
geometry of the tapered 1628a of the tubular ball race 1628, the balls 1632
are driven up the
tapered annuiar recesses 1628a of the tubular ball race 1628 with increased
force and the

CA 02522918 2007-08-27
WO 20041085790 PCT/US2004/009434
contact force between the balls 1632 and the interior surface of the
expandable welibore
casing 100 is significantly increased thereby correspondingly increasing the
gripping force
and effect of the ball gripper assembly.
[0155] In an exemplary embodiment, the ball gripper assembly 16 may be
operated to
radially e;cpand and plastically deform discrete portions of the expandable
wellbore casing
100 by controlling the amount of contact force applied to the interior surface
of the
expandable weellbQre casing by the balls 1632 of the ball gripper assembly. In
an
experimental test of an exemplary embodiment of the ball gripper assembly 16,
an
expandable wellbore casing was radially expanded and plastically defonned.
This was an
unexpected result.
[0159] In an exemplary embodiment, the tension actuator assembly 18 operates
and is provided substantially, at least in part, as disclosed in one or more
of the
following: WO 04/02720; WO 03/093623; WO 04/027200; and WO 03/042487.
[0160] ln an exemplary embodiment, as illustrated in Figs. 13A1 to 13A8 and
13B1 to
13B7, the tension actuator assembly 18 includes an upper tubular support
member 18002
that defines a Iongitudinal passage 18002a, and external internally threaded
radial openings,
18002b and 18002c, and an external annular recess 18002d and includes an
internally
threaded connection 18002e at one end and an external flange 18002f, an
external annular
recess 18002g having an extemally threaded connection, and an internal annular
recess
18002h having an internally threaded connection at another end. An end of a
tubular
actuator barrel 18004 that defines radial passages, 18004a and 18004b, at one
end and
radial passages, 18004c and 18004d, includes an internally threaded connection
18004e at
one end that mates with, receives, and is threadably coupled to the extemal
annular recess
18002g of the upper tubular support member 18002 and abuts and end face of the
extemal
flange 18002f of the upper tubular support member and an internally threaded
connection
18004f at another end.
[0161] Torsional locking pins, 18006a and 18006b, are coupled to and mounted
within
the extemal radial mounting holes, 18002b and 18002c, respectively, of the
upper tubular
support member and received within the radial passages, 18004a and 18004b, of
the end of
the tubular actuator barrel 18004. The other end of the tubular actuator
barrel 18004
36

CA 02522918 2007-08-27
WO 2004/085790 PCT/US2004/009434
receives and is threadably coupled to an end of a tubular barrel connector
18008 that
defines an internal annular recess 18008a, extemal radial mounting holes,
18008b and
18008c, radial passages, 18008d and 18008e, and extemal radial mounting holes,
18008f
and 18008g and includes circumferentially spaced apart teeth 18008h at one
end. A sealing
cartridge 18010 is received within and coupled to the internal annular recess
18008a of the
tubular barrel connector 18008 for fluidicly sealing the interface between the
tubular barrel
connector and the sealing cartridge. Torsional locking pins, 18012a and
18012b, are
coupled to and mounted within the external radial mounting holes, 18008b and
18008c,
respectively, of the tubular barrel connector 18008 and received within the
radial passages,
18004c and 18004d, of the tubular actuator barrel 18004.
[0162] A tubular member 18014 that defines a longitudinal passage 18014a
having one
or more internal splines 18014b at one end and circumferentially spaced apart
teeth 18014c
at another end for engaging the circumferentially spaced apart teeth 18008h of
the tubular
barrel connector 18008 mates with and is received within the actuator barrel
18004 and the
one end of the tubular member abuts an end face of the other end of the upper
tubular
support member 18002 and at another end abuts and end face of the tubular
barrel
connector 18008. A tubular guide member 18016 that defines a longitudinal
passage
18016a having a tapered opening 18016aa, and radial passages, 18016b and
18016c,
includes an external flange 18016d having an externally threaded connection at
one end that
is received within and coupled to the intemal annular recess 18002h of the
upper tubular
support member 18002.
[0163] The other end of the tubular barrel connector 18008 is threadably
coupled to and
is received within an end of a tubular actuator barrel 18018 that defines a
longitudinal
passage 18018a, radial passages, 18018b and 18018c, and radial passages,
18018d and
18018e. Torsional locking pins, 18020a and 18020b, are coupled to and mounted
within the
extemal radial mounting holes, 18008f and 18008g, respectively, of the tubular
barrel
connector 18008 and received within the radial passages, 18018b and 18018c, of
the tubular
actuator barrel 18018. The other end of the tubular actuator barrel 18018
receives and is
threadably coupled to an end of a tubular barrel connector 18022 that defines
an intemal
annular recess 18022a, external radial mounting holes, 18022b and 18022c,
radial
passages, 18022d and 18022e, and extemal radial mounting holes, 18022f and
18022g. A
sealing cartridge 18024= is received within and coupled to the internal
annular recess 18022a
of the tubular barrel connector 18022 for fluidicly sealing the interface
between the tubular
barrel connector and the sealing cartridge. Torsional locking pins, 18024a and
18024b, are
coupled to and mounted within the external radial mounting holes, 18022b and
18022c,
respectively, of the barrel connector 18022 and received within the radial
passages, 18018d
and 18018e, of the tubular actuator barrel 18018.
37

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WO 2004/085790 PCT/US2004/009434
[0164] The other end-of the tubular barrel connector 18022 is threadably
coupled to and
is received within an end of a tubular actuator barrel 18026 that defines a
longitudinal
passage 18026a, radial passages, 18026b and 18026c, and radial passages,
18026d and
18026e. Torsional locking pins, 18028a and 18028b, are coupled to and mounted
within the
external radial mounting holes, 18022f and 18022g, respectively, of the
tubular barrel
connector 18022 and received within the radial passages, 18026b and 18026c, of
the tubular
actuator barrel 18026. The other end of the tubular actuator barrel 18026
receives and is
threadably coupled to an end of a tubular barrel connector 18030 that defines
an internal
annular recess 18030a, extemal radial mounting holes, 18030b and 18030c,
radial
passages, 18030d and 18030e, and external radial mounting holes, 18030f and
18030g. A
sealing cartridge 18032 is received within and coupled to the internal annular
recess 18030a
of the tubular barrel connector 18030 for fluidicly sealing the interface
between the tubular
barrel connector and the sealing cartridge. Torsional locking pins, 18034a and
18034b, are
coupled to and mounted within the extemal radial mounting holes, 18030b and
18030c,
respectively, of the tubular barrel connector 18030 and received within the
radial passages,
18026d and 18026e, of the tubular actuator barrel 18026.
[0165] The other end of the tubular barrel connector 18030 is threadably
coupled to and
is received within an end of a tubular actuator barrel 18036 that defines a
longitudinal
passage 18036a, radial passages, 18036b and 18036c, and radial passages,
18036d and
18036e. Torsional locking pins, 18038a and 18038b, are coupled to and mounted
within the
external radial mounting holes, 18030f and 18030g, respectively, of the
tubular barrel
connector 18030 and received within the radial passages, 18036b and 18036c, of
the tubular
actuator barrel 18036. The other end of the tubular actuator barrel 18036
receives and is
threadably coupled to an end of a tubular barrel connector 18040 that defines
an internal
annular recess 18040a, external radial mounting holes, 18040b and 18040c,
radial
passages, 18040d and 18040e, and external radial mounting holes, 18040f and
18040g. A
sealing cartridge 18042 is received within and coupled to the intemal annular
recess 18040a
of the tubular barrel connector 18040 for fluidicly sealing the interface
between the tubular
barrel connector and the sealing cartridge. Torsional locking pins, 18044a and
18044b, are
coupled to and mounted within the extemal radial mounting holes, 18040b and
18040c,
.respectively, of the tubular barrel connector 18040 and received within the
radial passages,
18036d and 18036e, of the tubular actuator barrel 18036.
[0166] The other end of the tubular barrel connector 18040 is threadably
coupled to and
is received within an end of a tubular actuator barrel 18046 that defines a
longitudinal
passage 18046a, radial passages, 18046b and 18046c, and radial passages,
18046d and
18046e. Torsional locking pins, 18048a and 18048b, are coupled to and mounted
within the
extemal radial mounting holes, 18040f and 18040g, respectively, of the tubular
barrel
38

CA 02522918 2007-08-27
WO 2004/085790 PCT[US2004/009434
connector 18040 and received within the radial passages, 18046b and 18046c, of
the tubular
actuator barrel 18046. The other end of the tubular actuator barrel 18046
receives and is
threadably coupled to an end of a tubular barrel connector 18050 that defines
an intemal
annular recess 18050a, extemai radial mounting holes, 18050b and 18050c,
radiai
passages, 18050d and 18050e, and extemal radial mounting holes, 18050f and
18050g. A
sealing cartridge 18052 is received within and coupled to the intemal annular
recess 18050a
of the tubular barrel connector 18050 for fluidicly sealing the interface
between the tubular
barrel connector and the sealing cartridge. Torsional locking pins, 18054a and
18054b, are
coupled to and mounted within the external radial mounting holes, 18050b and
18050c,
respectively, of the tubular barrel connector 18050 and received within the
radial passages,
18046d and 18046e, of the tubular actuator barrel 18046.
[0167] The other end of the tubular barrel connector 18050 Is threadably
coupled to and
is received within an end of a tubular actuator barrel 18056 that defines a
longitudinal
passage 18056a, radial passages; 18056b and 18056c, and radial passages,
18056d and
18056e. Torsional locking pins, 18058a and 18058b, are coupled to and mounted
within the
external radial mounting holes, 18050f and 18050g, respectively, of the
tubular barrel
connector 18050 and received within the radial passages, 18056b and 18056c, of
the tubular
actuator barrel 18056. The other end of the tubular actuator barrel 18056
receives and is
threadably coupled to an end of a tubular lower stop 18060 that defines an
intemal annular
recess 18060a, external radial mounting holes, 18060b and 18060c, and an
intemal annular
recess 18060d that includes one or more circumferentially spaced apart locking
teeth
18060e at one end and one or more circumferentially spaced apart locking teeth
18060f at
the other end. A sealing cartridge 18062 is received within and coupled to the
intemal
annular recess 18060a of the tubular lower stop 18060 for fluidicly sealing
the interface
between the tubular lower stop and the sealing cartridge. Torsional locking
pins, 18064a
and 18064b, are coupled to and mounted within the external radial mounting
holes, 18060b
and 18060c, respectively, of the tubular lower stop 18060 and received within
the radial
passages, 18056d and 18056e, of the tubular actuator barrel 18056.
[0168] A connector tube 18066 that defines a longitudinal passage 18066a and
radial
mounting holes, 18066b and 18066c, and includes extemal splines 18066d at one
end for
engaging the internal splines 18014b of the tubular member 18014 and radial
mounting
holes, 18066e and 18066f, at another end is received within and sealingly and
movably
engages the interior surface of the sealing cartridge 18010 mounted within the
annular
recess 18008a of the tubular barrel connector 18008. In this manner, during
longitudinal
displacement of the connector tube 18066 relative to the tubular barrel
connector 18008, a
fluidic seal is maintained between the exterior surface of the connector tube
and the interior
surface of the tubular barrel connector. An end of the connector tube 18066
also receives
39

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and mates with the other end of the tubular guide member 18016. Mounting
screws, 18068a
and 18068b, are coupled to and received within the radial mounting holes,
18066b and
18066c, respectively of the connector tube 18066.
[0169] The other end of the connector tube 18066 is received within and
threadably
coupled to an end of a tubular piston 18070 that defines a longitudinal
passage 18070a,
radial mounting holes, 18070b and 18070c, radial passages, 18070d and 18070e,
and radial
mounting holes, 18070f and 18070g, that includes a flange 18070h at one end. A
sealing
cartridge 18072 is mounted onto and sealingly coupled to the exterior of the
tubular piston
18070 proximate the flange 18070h. The sealing cartridge 18072 also mates with
and
sealingly engages the interior surface of the tubular actuator barrel 18018.
In this manner,
during longitudinal displacement of the tubular piston 18070 relative to the
actuator barrel
18018, a fluidic seal is maintained between the exterior surface of the piston
and the interior
surface of the actuator barrel. Mounting screws, 18074a and 18074b, are
coupled to and
mounted within the extemal radial mounting holes, 18070b and 18070c,
respectively, of the
tubular piston 18070 and received within the radial passages, 18066e and
18066f, of the
connector tube 18066.
[0170] The other end of the tubular piston 18070 receives and is threadably
coupled to
an end of a connector tube 18076 that defines a longitudinal passage 18076a,
radial
mounting holes, 18076b and 18076c, at one end and radial mounting holes,
18076d and
18076e, at another end. The connector tube 18076 is received within and
sealingly and
movably engages the interior surface of the sealing cartridge 18024 mounted
within the
annular recess 18022a of the tubular barrel connector 18022. In this manner,
during
longitudinal displacement of the connector tube 18076 relative to the tubular
barrel
connector 18022, a fluidic seal is maintained between the exterior surface of
the connector
tube and the interior surface of the barrel connector. Mounting screws, 18078a
and 18078b,
are coupled to and mounted within the external radial mounting holes, 18070f
and 18070g,
respectively, of the tubular piston 18070 and received within the radial
passages, 18076b
and 18076c, of the connector tube 18076.
[0171] The other end of the connector tube 18076 is received within and
threadably
coupled to an end of a tubular piston 18080 that defines a longitudinal
passage 18080a,
. radial mounting holes, 18080b and 18080c, radial passages, 18080d and
18080e, and radial
mounting holes, 18080f and 18080g, that includes a flange 18080h at one end. A
sealing
cartridge 18082 is mounted onto and sealingly coupled to the exterior of the
tubular piston
18080 proximate the flange 18080h. The sealing cartridge 18082 also mates with
and
sealingly engages the interior surface of the tubular actuator barrel 18026.
In this manner,
during longitudinal displacement of the tubular piston 18080 relative to the
tubular actuator
barrel 18026, a fluidic seal is maintained between the exterior surface of the
piston and the

CA 02522918 2007-08-27
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interior surface of the actuator barrel. Mounting screws, 18084a and 18084b,
are coupled to
and mounted within the extemal radial mounting holes, 18080b and 18080c,
respectively, of
the tubular piston 18080 and received within the radial passages, 18076e and
18076f, of the
connector tube 18076.
[0172] The other end of the tubular piston 18080 receives and is threadably
coupled to
an end of a connector tube 18086 that defines a longitudinal passage 18086a,
radial
mounting holes, 18086b and 18086c, at one end and radial mounting holes,
18086d and
18086e, at another end. The connector tube 18086 is received within and
sealingly and
movably engages the interior surface of the sealing cartridge 18032 mounted
within the
annular recess 18030a of the tubular barrel connector 18030. In this manner,
during
longitudinal displacement of the connector tube 18086 relative to the tubular
barrel
connector 18030, a fluidic seal is maintained between the exterior surface of
the connector
tube and the interior surface of the barrel connector. Mounting screws, 18088a
and 18088b,
are coupled to and mounted within the external radial mounting holes, 18080f
and 18080g,
respectively, of the tubular piston 18080 and received within the radial
passages, 18086b
and 18086c, of the connector tube 18086.
[0173] The other end of the connector tube 18086 is received within and
threadably
coupled to an end of a tubular piston 18090 that defines a longitudinal
passage 18090a,
radial mounting holes, 18090b and 18090c, radial passages, 18090d and 18090e,
and radial
mounting holes, 18090f and 18090g, that includes a flange 18090h at one end. A
sealing
cartridge 18092 is mounted onto and sealingly coupied to the exterior of the
tubular piston
18090 proximate the flange 18090h. The sealing cartridge 18092 also mates with
and
sealingly engages the interior surface of the tubular actuator barrel 18036.
In this manner,
during longitudinal displacement of the tubular piston 18090 relative to the
tubular actuator
barrel 18036, a fluidic seal is maintained between the exterior surface of the
piston and the
interior surface of the actuator barrel. Mounting screws, 18094a and 18094b,
are coupled to
and mounted within the extemal radial mounting holes, 18090b and 18090c,
respectively, of
the tubular piston 18090 and received within the radial passages, 18086e and
18086f, of the
connector tube 18086.
[0174] The other end of the tubular piston 18090 receives and is threadably
coupled to
an end of a connector tube 18096 that defines a iongitudinal passage 18096a,
radial
mounting holes,18096b and 18096c, at one end and radial mounting holes, 18096d
and
18096e, at another end. The connector tube 18096 is received within and
sealingly and
movably engages the interior surface of the sealing cartridge 18042 mounted
within the
annular recess 18040a of the tubular barrel connector 18040. In this manner,
during
longitudinal displacement of the connector tube 18096 relative to the tubular
barrel
connector 18040, a fluidic seal is maintained between the exterior surface of
the connector
41

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tube and the interior surface of the barrel connector. Mounting screws, 18098a
and 18098b,
are coupled to and mounted within the extemal radial mounting holes, 18090f
and 18090g,
respectively, of the tubular piston 18090 and received within the radial
passages, 18096b
and 18096c, of the connector tube 18096.
[0176] The other end of the connector tube 18096 is received within and
threadably
coupled to an end of a tubular piston 18100 that defines a longitudinal
passage 18100a,
radial mounting holes, 18100b and 18100c, radial passages, 18100d and 18100e,
and radial
mounting holes, 18100f and 18100g, that includes a flange 18100h at one end. A
sealing
cartridge 18102 is mounted onto and sealingly coupled to the exterior of the
tubular piston
18100 proximate the flange 18100h. The sealing cartridge 18102 also mates with
and
sealingly engages the interior surface of the tubular actuator barrel 18046.
In this manner,
during longitudinal displacement of the tubular piston 18100 relative to the
tubular actuator
ban-el 18046, a fluidic seal is maintained between the exterior surface of the
piston and the
interior surface of the actuator barrel. Mounting screws, 18104a and 18104b,
are coupled to
and mounted within the external radial mounting holes, 18100b and 18100c,
respectively, of
the tubular piston 18100 and received within the radial passages, 18096e and
18096f, of the
connector tube 18096.
[0176] The other end of the tubular piston 18100 receives and is threadably
coupled to
an end of a connector tube 18106 that defines a longitudinal passage 18106a,
radial
mounting holes, 18106b and 18106c, at one end and radial mounting holes,
18106d and
18106e, at another end. The connector tube 18106 is received within and
sealingly and
movably engages the interior surface of the sealing cartridge 18052 mounted
within the
annular recess 18050a of the tubular barrel connector 18050. In this manner,
during
longitudinal displacement of the connector tube 18106 relative to the tubular
barrel
connector 18050, a fluidic seal is maintained between the exterior surface of
the connector
tube and the interior surface of the barrel connector. Mounting screws, 18108a
and 18108b,
are coupled to and mounted within the extemal radial mounting holes, 18100f
and 18100g,
respectively, of the tubular piston 18100 and received within the radial
passages, 18106b
and 18106c, of the connector tube 18106.
[0177] The other end of the connector tube 18106 is received within and
threadably
coupled to an end of a tubular piston 18110 that defines a longitudinal
passage 18110a,
radial mounting holes, 18110b and 18110c, radial passages, 18110d and 18110e,
radial
mounting holes, 18110f and 18110g, that includes a flange 18110h at one end
and
circumferentially spaced teeth 18110i at another end for engaging the one or
more
circumferentially spaced apart locking teeth 18060e of the tubular lower stop
18060. A
sealing cartridge 18112 is mounted onto and sealingly coupled to the exterior
of the tubular
piston 18110 proximate the flange 18110h. The sealing cartridge 18112 also
mates with and
42

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sealingly engages the interior surface of the actuator barrel 18056. In this
manner, during
longitudinal displacement of the tubular piston 18110 relative to the actuator
barrel 18056, a
fluidic seal is maintained between the exterior surface of the piston and the
interior surface
of the actuator barrel. Mounting screws, 18114a and 18114b, are coupled to and
mounted
within the extemal radial mounting holes, 18110b and 18110c, respectively, of
the tubular
piston 18110 and received within the radial passages, 18106d and 18106e, of
the connector
tube 18106.
[0178] The other end of the tubular piston 18110 receives and is threadably
coupled to
an end of a connector tube 18116 that defines a longitudinal passage 18116a,
radial
mounting holes, 18116b and 18116c, at one end and radial mounting holes,
18116d and
18116e, at another end that includes an external flange 18116f that includes
circumferentially spaced apart teeth 18116g that extend from an end face of
the external
flange for engaging the teeth 18060f of the tubular lower stop 18060, and an
externally
threaded connection 18116h at another end. The connector tube 18116 is
received within
and sealingly and movably engages the interior surface of the sealing
cartridge 18062
mounted within the annular recess 18060a of the lower tubular stop 18060. In
this manner,
during longitudinal displacement of the connector tube 18116 relative to the
lower tubular
stop 18060, a fluidic seal is maintained between the exterior surface of the
connector tube
and the interior surface of the lower tubular stop. Mounting screws, 18118a
and 18118b, are
coupled to and mounted within the external radial mounting holes, 18110f and
18110g,
respectively, of the tubular piston 18110 and received within the radial
passages, 18116b
and 181 16c, of the connector tube 18116.
[0179] In an exemplary embodiment, as illustrated in Figs. 13A1 to 13A8, the
internally
threaded connection 18002e of the upper tubular support member 18002 receives
and is
coupled to the extemally threaded connection 1234g of the lower mandrel 1234
of the ball
grabber assembly 16 and the extemally threaded connection 18116h of the
connector tube
18116 is received within and is coupled to an intemally threaded connection
20a of an end of
the safety sub assembly 20.
[0180] In an exemplary embodiment, as illustrated in Figs. 13A1 to 13A8,
during
operation of the tension actuator assembly 18, the tension actuator assembly
is positioned
.within the expandable welibore casing 100 and fluidic material 13200 is
injected into the
tension actuator assembly through the passages 18002a, 18016a, 18066a, 18070a,
18076a,
18080a, 18086a, 18090a, 18096a, 18100a, 18106a, 18110a, and 18116a. The
injected
fluidic material 13200 will also pass through the radial passages, 18070d and
18070e,
18080d and 18080e, 18090d and 18090e, 18100d and 18100e, 18110d and 18110e, of
the
tubular pistons, 18070, 18080, 18090, 18100, and 18110, respectively, into
annular piston
chambers, 13202, 13204, 13206, 13208, 13208, and 13210.
43

CA 02522918 2007-08-27
WO 2004/085790 PCT/US2004/009434
[0181] As illustrated in Figs. 13B1 to 13B7, the operating pressure of the
fluidic material
13200 may then be increased by, for example, controllably blocking or limiting
the flow of the
fluidic materiai through the passage 18116a and/or increasing the operating
pressure of the
outlet of a pumping device for injecting the fluidic materia113200 into the
tension actuator
assembly 18. As a result, of the increased operating pressure of the fluidic
material 13200
within the tension actuator assembly 18, the operating pressures of the
annular piston
chambers, 13202, 13204, 13206, 13208,13208, and 13210, will be increased
sufficiently to
displace the tubular pistons, 18070, 18080, 18090, 18100, and 18110, upwardly
in the
direction 13212 thereby also displacing the connector tube 18116. As a result,
a upward
tensile force is applied to all elements of the system 10 coupled to and
positioned below the
connector tube 18116. In an exemplary embodiment, during the upward
displacement of the
tubular pistons, 18070, 18080, 18090, 18100, and 18110, fluidic materials
displaced by the
tubular pistons within discharge annular chambers, 13214, 13216, 13218, 13220,
and 13222
are exhausted out of the tension actuator assembly 18 through the radial
passages, 18008d
and 18008e, 18022d and 18022e, 18030d and 18030e, 18040d and 18040e, 18050d
and
18050e, respectively. Furthermore, in an exemplary embodiment, the upward
displacement
of the tubular pistons, 18070, 18080, 18090, 18100, and 18110, further causes
the external
splines 18066d of the connector tube 18066 to engage the internal splines
18014b of the
tubular member 18014 and the circumferentially spaced apart teeth 18116g of
the connector
tube 18116 to engage the circumferentially spaced teeth 18060f of the tubular
lower stop
18060. As a resuft of the interaction of the extemal splines 18066d of the
connector tube
18066 to engage the internal splines 18014b of the tubular member 18014 and
the
circumferentially spaced apart teeth 18116g of the connector tube 18116 to
engage the
circumferentially spaced teeth 18060f of the tubular lower stop 18060,
torsional loads may
be transmitted through the tension actuator assembly 18.
[0182] In an exemplary embodiment, as illustrated in Fig. 14A, the safety sub
assembly
20 includes a tubular body 200a that defines a longitudinal passage 200b and
includes an
external flange 200c and an internal annular recess 200d at one end, and
external annular
recesses, 200e, 200f, 200g, and 200h at another end. A sealing member 202 is
positioned
within the external annular recess 200h at the other end of the tubular body
200a.
[0183] In an exemplary embodiment, as illustrated in Figs. 14A, 14B and 14C,
the
sealing cup assembly 22 includes an upper tubular mandrel 2202 that defines a
longitudinal
passage 2202a and internally threaded radial mounting holes, 2202b and 2202c,
and
includes an internal annular recess 2202d at one end, an intemal annular
recess 2202e, an
intemal annular recess 2202f, an internal annular recess 2202g, and an
internally threaded
internal annular recess 2202h and an extemal flange 2202i at another end. The
internal
annular recesses, 2202d, 2202e, and 2202f, of the upper tubular mandrel 2202
of the
44

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WO 2004/085790 PCT/US2004/009434
sealing cup assembly 22 receive, mate with, and are coupled to the other end
of the tubular
body 200a of the safety sub assembly 20.
[0184] An extemally threaded end of a lower tubular mandrel 2204 that defines
a
longitudinal passage 2204a and includes an extemal annular recess 2204b at one
end, an
extemal annular recess 2204c, an external flange 2204d, an extemal annular
recess 2204e,
an externally threaded external flange 2204f, and an external annular recess
2204g at
another end mates with, is received within, and is coupled to the intemal
annular recesses,
2202g and 2202h, of the other end of the upper tubular mandrel 2202.
[0185] Mounting screws, 2250a and 2205b, are received within and coupled to
the
mounting holes, 2202c and 2202b, respectively, of the tubular mandrel 2202
that extend into
and engage the extemal annular recess 2204c of the lower tubular mandrel 2204.
[0186] A tubular cup seal spacer 2206 receives and is mounted upon the lower
tubular
mandrel 2204 proximate the extemal flange 2202i of the upper tubular mandrel
2202. A
tubular cup seal retainer 2208 that includes an intemal flange 2208a at one
end receives
and is mounted upon the lower tubular mandrel 2204 proximate the tubular cup
seal spacer
2206. A tubular cup seal retainer 2210 that includes an internal flange 2210a
at one end
receives and is mounted upon the lower tubular mandrel 2204 proximate the
other end of the
tubular cup seal retainer 2208. In an exemplary embodiment, the tubular cup
seal retainer
2210 is nested within the other end of the tubular cup seal retainer 2208. A
tubular cup seal
2212 that includes an intemal flange 2212a at one end receives and is mounted
upon the
lower tubular mandrel 2204 proximate the other end of the tubular cup seal
retainer 2210. In
an exemplary embodiment, the tubular cup seal 2212 is nested within the other
end of the
tubular cup seal retainer 2210.
[0187] A sealing member 2211 is received within the extemal annular recess
2204b of
the lower tubular mandre12204 for sealing the interface between the lower
tubular mandrel
and the upper tubular mandrel 2202.
[0188] A tubular spacer 2214 receives and is mounted upon the lower tubular
mandrel
2204 proximate the other end of the tubular cup seal 2212.
[0189] A tubular cup seal spacer 2216 receives and is mounted upon the lower
tubular
mandrel 2204 proximate the other end of the tubular spacer 2214. A tubular cup
seal
retainer 2218 that includes an internal flange 2218a at one end receives and
is mounted
upon the lower tubular mandrel 2204 proximate the other end of the tubular cup
seal spacer
2216. A tubular cup seal retainer 2220 that includes an intemal flange 2220a
at one end
receives and is mounted upon the lower tubular mandrel 2204 proximate the
other end of the
tubular cup seal retainer 2218. In an exemplary embodiment, the tubular cup
seal retainer
2220 is nested within the other end of the tubular cup seal retainer 2218. A
tubular cup seal
2222 that includes an internal flange 2222a at one end receives and is mounted
upon the

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lower tubular mandrel 2204 proximate the other end of the tubular cup seal
retainer 2220. In
an exemplary embodiment, the tubular cup seal 2222 is nested within the other
end of the
tubular cup seal retainer 2220.
[0190] A tubular spacer 2224 receives and is mounted upon the lower tubular
mandrel
2204 proximate the other end of the tubular cup seal 2222 at one end and
proximate the
extemal flange 2204d of the lower tubular mandrel at another end. A retaining
ring 2226
receives and is mounted upon the other end of the tubular spacer 2224
proximate the
external flange 2204d of the lower tubular mandrel 2204.
[0191] In an exemplary embodiment, during operation of the system 10, the end
of the
tubular body 200a of the safety sub assembly 20 is coupled to and receives and
is coupled
to an end of the tension actuator assembly 18 and the other end of the lower
tubular mandrel
2204 of the sealing cup assembly 22 is received within and is coupled to an
end of the
casing lock assembly 24.
[0192] In an exemplary embodiment, during operation of the system 10, the
tubular cup
seals, 2212 and/or 2222, sealingly engage the interior surface of the
expandable tubular
member 100. In this manner, when an annulus defined between the system 10 and
the
expandable wellbore casing 10, below the tubular cup seals, 2212 and/or 2222,
is
pressurized, the resulting pressure differential across the tubular cup seals
applies an
upward tensile force to the system thereby pulling the adjustable bell section
expansion cone
assembly 28 and/or the adjustable casing expansion cone assembly 30 through
the
expandable wellbore casing. In this manner, the adjustable bell section
expansion cone
assembly 28 and/or the adjustable casing expansion cone assembly 30, ff either
or both are
adjusted to an outside diameter suitable for a radial expansion operation, may
radially
expand and plastically deform the expandable wel(bore casing 100.
[0193] In an exemplary embodiment, the sealing cup assembly 22 operates and
is provided substantially, at least in part, as disclosed in one or more of
the following:
WO 03/042487; WO 04/027200; WO 03/042486; WO 03/078785; WO 04/02720;
and WO 03/106130.
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[0194] In an exemplary embodiment, the casing lock assembly 24 operates and
is provided substantially, at least in part, as disclosed in one or more of
the following:
WO 03/042487; WO 04/02720; and WO 03/093623.
[0195] In an exemplary embodiment, the adjustable bell section expansion
cone assembly 28 operates and is provided substantially, at least in part,
as disclosed in one or more of the following: WO 03/042487; WO 03/093623;
WO 04/02720; WO 03/042486; WO 03/078785 and WO 031106130.
[00102] In an exemplary embodiment, as illustrated in Figs. 15-1 and 15-2,
15A1 to 15A2,
1581 to 1562, 15C, 15D, 15E, 15F, 15G, 15H, 151, 15j, 15K, 15L, 15M, 15N, 150,
15P, 15R,
15S, 15T, 15U, 15V, 15W, 15X, 15Y, 15Z1 to 15Z4, 15AA1 to 15AA4, 15AB1 to
15AB4,
15AC1 to 15AC4, 15AD, and 15AE, the adjustable bell section expansion cone
assembly 28
includes an upper tubular tool joint 28002 that defines a longitudinal passage
28002a and
mounting holes, 28002b and 28002c, and includes an internal threaded
connection 28002d,
an inner annular recess 28002e, an inner annular recess 28002f, and an intemal
threaded
connection 28002g. A tubular torque plate 28004 that defines a longitudinal
passage
28004a and includes circumferentially spaced apart teeth 28004b is received
within, mates
with, and is coupled to the internal annular recess 28002e of the upper
tubular tool joint
28002.
[00103] Circumferentially spaced apart teeth 28006a of an end of a tubular
lower mandrel
28006 that defines a longitudinal passage 28006b, a radial passage 28006ba,
and a radial
passage 28006bb and includes an extemal threaded connection 28006c, an extemal
flange
28006d, an external annular recess 28006e having a step 28006f at one end, an
external
47

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WO 2004/085790 PCT/US2004/009434
annular recess 28006g, extemal teeth 28006h, an extemal threaded connection
28006i, and
an extemal annular recess 28006j engage the circumferentially spaced apart
teeth 28004b
of the tubular torque plate 28004. An internal threaded connection 28008a of
an end of a
tubular toggle bushing 28008 that defines a longitudinal passage 28008b, an
upper
longitudinal slot 28008c, a lower longitudinal slot 28008d, mounting holes,
28008e, 28008f,
28008g, 28008h, 28008i, 28008j, 28008k, 280081, 28008m, 28008n, 28008o,
28008p,
28008q, 28008r, 28008s, 28008t, 28008u, 28008v, 28008w, 28008x, 28008xa, and
28008xb, and includes an external annular recess 28008y, intemal annular
recess 28008z,
external annular recess 28008aa, and an extemal annular recess 28008ab
receives and is
coupled to the external threaded connection 28006c of the tubul-dir lower
mandrel 28006.
[0196] A sealing element 28010 is received within the extemal annular recess
28008y of
the tubular toggle bushing 28008 for sealing the interface between the tubular
toggle
bushing and the upper tubular tool joint 28002. A sealing element 28012 is
received within
the internal annular recess 28008z of the tubular toggle bushing 28008 for
sealing the
interface between the tubular toggle bushing and the tubular lower mandrel
28006.
[0197] Mounting screws, 28014a and 28014b, mounted within and coupled to the
mounting holes, 28008w and 28008x, respectively, of the tubular toggle bushing
28008 are
also received within the mounting holes, 28002b and 28002c, of the upper
tubular tool joint
28002. Mounting pins, 28016a, 28016b, 28016c, 28016d, and 28016e, are mounted
within
the mounting holes, 28008e, 28008f, 28008g, 28008h, and 28008i, respectively.
Mounting
pins, 28018a, 28018b, 28018c, 28018d, and 28018e, are mounted within the
mounting
holes, 28008t, 28008s, 28008r, 28008q, and 28008p, respectively. Mounting
screws,
28020a and 28020b, are mounted within the mounting holes, 28008u and 28008v,
respectively.
[0198] A first upper toggle link 28022 defines mounting holes, 28022a and
28022b, for
receiving the mounting pins, 28016a and 28016b, and includes a mounting pin
28022c at
one end. A first lower toggle link 28024 defines mounting holes, 28024a,
28024b, and
28024c, for receiving the mounting pins, 28022c, 28016c, and 28016d,
respectively and
includes an engagement arm 28024d. A first trigger 28026 defines a mounting
hole 28026a
for receiving the mounting pin 28016e and includes an engagement arm 28026b at
one end,
.an engagement member 28026c, and an engagement arm 28026d at another end.
[0199] A second upper toggle link 28028 defines mounting holes, 28028a and
28028b,
for receiving the mounting pins, 28018a and 28018b, and includes a mounting
pin 28028c at
one end. A second lower toggle link 28030 defines mounting holes, 28030a,
28030b, and
28030c, for receiving the mounting pins, 28028c, 28018c, and 28018d,
respectively and
includes an engagement arm 28030d. A second trigger 28032 defines a mounting
hole
28032a for receiving the mounting pin 28018e and includes an engagement arm
28032b at
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WO 2004/085790 PCT/US2004/009434
one end, an engagement member 28032c, and an engagement arm 28032d at another
end.
[0200] An end of a tubular spring housing 28034 that defines a longitudinal
passage
28034a, mounting holes, 28034b and 28034c, and mounting holes, 28034ba and
28034ca,
and includes an internal flange 28034d and an intemal annular recess 28034e at
one end,
and an internal flange 28034f, an internal annular recess 28034g, an internal
annular recess
28034h, and an extemal threaded connection 28034i at another end receives and
mates
with the end of the tubular toggle bushing 28008. Mounting screws, 28035a and
28035b,
are mounted within and coupled to the mounting holes, 28008xb and 28008xa,
respectively,
of the tubular toggle bushing 28008 and are received within the mounting
holes, 28034ba
and 28034ca, respectively, of the tubular spring housing 28034.
[0201] A tubular retracting spring ring 28036 that defines mounting holes,
28036a and
28036b, receives and mates with a portion of the tubular lower mandrel 28006
and is
received within and mates with a portion of the tubular spring housing 28034.
Mounting
screws, 28038a and 28038b, are mounted within and coupled to the mounting
holes, 28036a
and 28036b, respectively, of the tubular retracting spring ring 28036 and
extend into the
mounting holes, 28034b and 28034c, respectively, of the tubular spring housing
28034.
[0202] Casing diameter sensor springs, 28040a and 28040b, are positioned
within the
longitudinal slots, 28008c and 2808d, respectively, of the tubular toggle
bushing 28008 that
engage the engagement members, 28026c and 28032c, and engagement arms,28026d
and
28032d, of the first and second triggers, 28026 and 28032, respectively. An
inner flange
28042a of an end of a tubular spring washer 28042 mates with and receives a
portion of the
tubular lower mandrel 28006 and an end face of the inner flange of the tubular
spring washer
is positioned proximate and end face of the external flange 28006d of the
tubular lower
mandrel. The tubular spring washer 28042 is further received within the
longitudinal
passage 28034a of the tubular spring housing 28034.
[0203] An end of a retracting spring 28044 that receives the tubular lower
mandrel
28006 is positioned within the tubular spring washer 28042 in contact with the
internal flange
28042a of the tubular spring washer and the other end of the retracting spring
is positioned
in contact with an end face of the tubular retracting spring ring 28036.
[0204] A sealing element 28046 is received within the external annular recess
28006j of
-the tubular lower mandrel 28006 for sealing the interface between the tubular
lower mandrel
and the tubular spring housing 28034. A sealing element 28048 is received
within the
internal annular recess 28034h of the tubular spring housing 28034 for sealing
the interface
between the tubular spring housing and the tubular lower mandrel 28006.
[0205] An internal threaded connection 28050a of an end of a tubular upper
hinge
sleeve 28050 that includes an internal flange 28050b and an internal pivot
28050c receives
and is coupled to the external threaded connection 28034i of the end of the
tubular spring
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housing 28034.
[0206] An extemal flange 28052a of a base member 28052b of an upper cam
assembly
28052, that is mounted upon and receives the lower tubular mandrel 28006, that
includes an
internal flange 28052c that is received within the extemal annular recess
28006e of the
lower tubular mandrel 28006 and a plurality of circumferentially spaced apart
tapered cam
arms 28052d extending from the base member mates with and is received within
the tubular
upper hinge sleeve 28050. The base member 28052b of the upper cam assembly
28052
further includes a plurality of circumferentially spaced apart teeth 28052f
that mate with and
are received within a plurality of circumferentially spaced apart teeth 28034j
provided on the
end face of the tubular spring housing 28034 and an end face of the extemal
flange 28052a
of the base member of the upper cam assembly is positioned in opposing
relation to an end
face of the internal flange 28050b of the tubular upper hinge sleeve 28050.
Each of the
cam arms 28052d of the upper cam assembly 28052 include external cam surfaces
28052e.
In an exemplary embodiment, the teeth 28052f of the base member 28052b of the
upper
cam assembly 28052 and the teeth 28034j provided on the end face of the
tubular spring
housing 28034 permit torsional loads to be transmitted between the tubular
spring housing
and the upper cam assembly.
[0207] A plurality of circumferentially spaced apart upper expansion segments
28054 are
mounted upon and receive the lower tubular mandrel 28006 and each include an
external
pivot recess 28054a at one end for mating with and receiving the internal
pivot 28050c of the
tubular upper hinge sleeve 28050 and an external tapered expansion surface
28054b at
another end and are pivotally mounted within the tubular upper hinge sleeve
and are
interleaved with the circumferentially spaced apart cam arms 28052d of the
upper cam
assembly 28052. The upper expansion segments 28054 are interleaved among the
cam
arms 28052d of the upper cam assembly 28052.
[0208] A plurality of circumferentially spaced apart lower expansion segments
28058 are
mounted upon and receive the lower tubular mandrel 28006, are interleaved
among the
upper expansion segments 28054, are oriented in the opposite direction to the
upper
expansion segments 28054, each include an external pivot recess 28058a at one
end and
an external tapered expansion surface 28054b at another end and are positioned
in
opposing relation to corresponding circumferentially spaced apart cam arms
28052d of the
upper cam assembly 28052.
[0209] A lower cam assembly 28060 is mounted upon and receives the lower
tubular
mandrel 28006 that includes a base member 28060a having an extemal flange
28060b, a
plurality of circumferentially spaced apart cam arms 28060d that extend from
the base
member that each include extemal cam surfaces 28060e and define mounting holes
28060f
and 28060g. The base member 28060a of the lower cam assembly 28060 further
includes a

CA 02522918 2007-08-27
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plurality of circumferentially spaced apart teeth 28060h. The
circumferentially spaced apart
cam arms 28060d of the lower cam assembly 28060 are interteaved among the
lower
expansion segments 28058 and the circumferentially spaced apart cam arms
28052d of the
upper cam assembly 28052 and positioned in opposing relation to corresponding
upper
expansion segments 28054.
[0270] Mounting screws, 28062a, 28062b, 28062c, and 28062e, are mounted within
the
corresponding mounting holes, 28060f and 28060g, of the lower cam assembly
28060 and
are received within the extemal annular recess 28006g of the lower cam
assembly 28060.
[0211] A tubular lower hinge sleeve 28064 that receives the lower expansion
segments
28058 and the lower cam assembly 28060 includes an intemal flange 28064a for
engaging
the external flange 28060b of the base member of the lower cam assembly 28060,
an
intemal pivot 28064b for engaging and receiving the extemal pivot recess
28058a of the
lower expansion segments 28058 thereby pivotally mounting the lower expansion
segments
within the tubular lower hinge sleeve, and an intemal threaded connection
28064c.
[0212] An external threaded connection 28066a of an end of a tubular sleeve
28066 that
defines mounting holes, 28066b and 28066c, and includes an intemal annular
recess
28066d having a shoulder 28066e, an internal flange 28066f, and an intemal
threaded
connection 28066g at another end is received within and coupled to the intemal
threaded
connection 28064c of the tubular lower hinge sleeve 28064. An external
threaded
connection 28068a of an end of a tubular member 28068 that defines a
longitudinal passage
28068b and mounting holes, 28068c and 28068d, and includes an external annular
recess
28068e, and an extemal threaded connection 28068f at another end is received
within and is
coupled to the internal threaded connection 28066g of the tubular sleeve
28066.
[0213] Mounting screws, 28070a and 28070b, are mounted in and coupled to the
mounting holes, 28068c and 28068d, respectively, of the tubular member 28068
that also
extend into the mounting holes, 28066b and 28066c, respectively, of the
tubular sleeve
28066. A sealing element 28072 is received within the external annular recess
28068e of
the tubular member 28068 for sealing the interface between the tubular member
and the
tubular sleeve 28066.
[0214] An internal threaded connection 28074a of a tubular retracting piston
28074 that
,defines a longitudinal passage 28074b and includes an internal annular recess
28074c and
an external annular recess 28074d receives and is coupled to the external
threaded
connection 28006i of the tubular lower mandrel 28006. A sealing element 28076
is received
within the external annular recess 28074d of the tubular retracting piston
28074 for sealing
the interface between the tubular retracting piston and the tubular sleeve
28066. A sealing
element 28078 is received within the internal annular recess 28074c of the
tubular retracting
piston 28074 for sealing the interface between the tubular retracting piston
and the tubular
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lower mandrel 28006.
[0215] Locking dogs 28080 mate with and receive the external teeth 28006h of
the
tubular lower mandrel 28006. A spacer ring 28082 is positioned between an end
face of the
locking dogs 28080 and an end face of the lower cam assembly 28060. A release
piston
28084 mounted upon the tubular lower mandrel 28006 defines a radial passage
28084a for
mounting a burst disk 28086 includes sealing elements, 28084b, 28084c, and
28084d. The
sealing elements, 28084b and 28084d, sealing the interface between the release
piston
28084 and the tubular lower mandrel 28006. An end face of the release piston
28084 is
positioned in opposing relation to an end face of the locking dogs 28080.
[0216] A release sleeve 28088 that receives and is mounted upon the locking
dogs
28080 and the release piston 28084 includes an internal flange 28088a at one
end that
sealingly engages the tubular lower mandrel 28006. A bypass sleeve 28090 that
receives
and is mounted upon the release sleeve 28088 includes an intemal flange 28090a
at one
end.
[0217] In an exemplary embodiment, during operation of the adjustabie bell
section
expansion cone assembly 28, the retracting spring 28044 is compressed and
thereby
applies a biasing spring force in a direction 28092 from the lower tubular
mandrel 28006 to
the tubular spring housing 28034 that, in the absence of other forces, moves
andlor
maintains the upper cam assembly 28052 and the upper expansion segments 28054
out of
engagement with the lower expansion segments 28058 and the lower cam assembly
28060.
In an exemplary embodiment, during operation of the adjustable bell section
expansion cone
assembly 28, an external threaded connection 20a of an end of the sealing cup
assembly 20
is coupled to the intemal threaded connection 28002d of the upper tubular tool
joint 28002
and an intemal threaded connection 30a of an end of the adjustable casing
expansion cone
assembly 30 is coupled to the external threaded connection 28068f of the
tubular member
28068.
[0218] The upper cam assembly 28052 and the upper expansion segments 28054 may
be brought into engagement with the lower expansion segments 28058 and the
lower cam
assembly 28060 by pressurizing an annulus 28094 defined between the lower
tubular
mandrel 28006 and the tubular spring housing 28034. In particular, injection
of fluidic
materials into the adjustable bell section expansion cone assembly 28 through
the
longitudinal passage 28006b of the lower tubuiar mandrel 28006 and into the
radial passage
28006ba may pressurize the annulus 28094 thereby creating sufficient operating
pressure to
generate a force in a direction 28096 sufficient to overcome the biasing force
of the
retracting spring 28044. As a result, the spring housing 28034 may be
displaced in the
direction 28096 relative to the lower tubular mandrel 28006 thereby displacing
the tubular
upper hinge sleeve 28050, upper cam assembly 28052, and upper expansion
segments
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28054 in the direction 28096.
[0219] In an exemplary embodiment, as illustrated in Figs. 15P and 15R, the
displacement of the upper cam assembly 28052 and upper expansion segments
28054 in
the direction 28096 will cause the lower expansion segments 28058 to ride up
the cam
surfaces 28052e of the cam arms 28052d of the upper cam assembly 28052 while
also
pivoting about the lower tubular hinge segment 28064, and will also cause the
upper
expansion segments 28054 to ride up the cam surfaces 28060e of the cam arms
28060d of
the lower cam assembly 28060 while also pivoting about the upper tubular hinge
segment
28050. In an exemplary embodiment, when the upper and lower expansion
segments,
28054 and 28058, are brought into axial alignment, they define an outer
expansion surface
that is approximately contiguous in a circumferential direction and which
provides an outer
expansion surface that at least approximates a conical surface.
[0220] In an exemplary embodiment, during the operation of the adjustable bell
section
expansion cone assembly 28, when the upper and lower expansion segments, 28054
and
28058, brought into axial alignment into a radially expanded position, the
upper and lower
expansion segments, 28054 and 28058, are displaced relative to the expandable
wellbore
casing 100 to thereby radially expand and plastically deform at least a
portion of the
expandable wellbore casing. In an exemplary embodiment, during the radial
expansion and
plastic deformation of the expandable wellbore casing 100, the adjustable bell
section
expansion cone assembly 28 may then be rotated relative to the expandable
wellbore casing
to enhance and/or modify the rate at which the expandable wellbore casing is
radially
expanded and plastically deformed.
[0221] In an exemplary embodiment, the upper cam assembly 28052 and the upper
expansion segments 28054 may be moved out of engagement with the lower
expansion
segments 28058 and the lower cam assembly 28060 by reducing the operating
pressure
within the annulus 28094.
[0222] In an alternative embodiment, as illustrated in Figs. 15S, 15T, 15U and
15V,
during operation of the adjustable bell section expansion cone assembly 28,
the upper cam
assembly 28052 and the upper expansion segments 28054 may also be moved out of
engagement with the lower expansion segments 28058 and the lower cam assembly
28060
by sensing the operating pressure within the longitudinal passage 28006b of
the lower
tubular mandrel 28006. In particular, as illustrated in Fig. 15T, if the
operating pressure
within the longitudinal passage 28006b and radial passage 28006bb of the lower
tubular
mandrel 28006 exceeds a predetermined value, the burst disc 28086 will open
the passage
28084a thereby pressurizing the interior of the tubular release sleeve 28088
thereby
displacing the tubular release sleeve 28088 downwardly in a direction 28092
away from
engagement with the locking dogs 28080.
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[0223] As a result, as illustrated in Fig. 15U, the locking dogs 28080 'are
displaced
outwardly in the radial directed and thereby released from engagement with the
lower
tubular mandrel 28006 thereby permitting the lower expansion segments 28058
and the
lower cam assembly 28060 to be displaced downwardly relative to the lower
tubular
mandrel.
[0224] As a result, as illustrated in Fig. 15V, the operating pressure within
the lower
tubular mandrel 28066 may then cause the lower tubular mandrel to be displaced
downwardly in the direction 28094 relative to the tubular lower mandrel 28006
and the
retracting piston 28074. As a result, the lower tubular mandrel 28066, the
lower expansion
segments 28058, the lower cam assembly 28060, and tubular lower hinge sleeve
28064 are
displaced downwardly in the direction 28094 relative to the tubular spring
housing 28034
thereby moving the lower expansion segments 28058 and the lower cam assembly
28060
out of engagement with the upper cam assembly 28052 and the upper expansion
segments
28054.
[0225] In an exemplary embodiment, as illustrated in Figs. 15W, 15X, and 15Y,
during
operation of the adjustable bell section expansion cone assembly 28, the
adjustable bell
section expansion cone assembly senses the diameter of the expandable wellbore
casing
100 using the upper toggle links, 28022 and 28028, lower toggle links, 28024
and 28030,
and triggers, 28026 and 28032, and then prevents the engagement of the upper
cam
assembly 28052 and the upper expansion segments 28054 with the lower expansion
segments 28058 and the lower cam assembly 28060.
[0226] In particular, as illustrated in Fig. 15W, anytime the upper toggle
links, 28022 and
28028, and lower toggle links, 28024 and 28030, are positioned within a
portion of the
expandable welibore casing 100 that has been radially expanded and plastically
deformed
by the system 10, the triggers, 28026 and 28032, will be pivoted by the
engagement arms,
28024d and 28030d, of the lower toggle links, 28024 and 28030, to a position
in which the
triggers wili no longer engage the intemal flange 28034d of the end of the
tubular spring
housing 28034 thereby permitting the displacement of the tubular spring
housing in the
direction 28096. As a result, the upper cam assembly 28052 and the upper
expansion
segments 28054 can be brought into engagement with the lower expansion
segments 28058
and the lower cam assembly 28060. In an exemplary embodiment, the upper toggle
links,
28022 and 28028, and the lower toggle links, 28024 and 28030, are spring
biased towards
the position illustrated in Fig. 15W.
[0227] Conversely, as illustrated in Fig. 15X, anytime the upper toggle links,
28022 and
28028, and lower toggle links, 28024 and 28030, are positioned within a
portion of the
expandable wellbore casing 100 that has not been radially expanded and
plastically
deformed by the system 10, the triggers, 28026 and 28032, will be maintained
in a position
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in which the triggers will engage the intemal flange 28034d of the end of the
tubular spring
housing 28034 thereby preventing the displacement of the tubular spring
housing in the
-direction 28096. As a result, the upper cam assembly 28052 and the upper
expansion
segments 28054 cannot be brought into engagement with the lower expansion
segments
28058 and the lower cam assembly 28060. In an exemplary embodiment, the
triggers,
28026 and 28032, are spring biased towards the position illustrated in Fig.
15~:.
[022E] In an exemplary embodiment, as illustrated in Fig. 15Y, the tubular
spring
housing 28034 may be displaced upwardly in the direction 28098 even if the
upper toggle
links, 28022 and 28028, and lower toggle links, 28024 and 28030, are
positioned within a
portion of the expandable wellbore casing 100 that has not been radially
expanded and
plastically deformed by the system 10.
[0229] In an exemplary embodiment, as illustrated in Figs. 15Z1 to 15Z4, 15AA1
to
15AA4, 15AB1 to 15AB4, 15AC1 to 15AC4, 15AD, and 15AE, the tubular spring
housing
28034 of the adjustable bell section expansion cone assembly 28 defines
internal annular
recesses 28034k and 280341, spaced apart by an intemal flange 28034m, the
tubular toggle
bushing 28008 defines an external annular recess 28008ac, and the adjustable
bell section
expansion cone assembly further includes pins, 28100a and 28100b and 28102a
and
28102b, mounted in holes 28008j and 28008o and 28008k and 28008n,
respectively, of the
tubular toggle bushing, and a one-shot deactivation device 28104 mounted on
the tubular
toggle bushing between the pins, 28100a and 28100b and 28102a and 28102b.
[0230] The one-shot deactivation device 28104 includes a tubular body 28104a
that
defines radial holes, 28104b and 28014c, and includes an external annular
recess 28104d at
one end, a centrally positioned external flange 28104e, a centrally positioned
internal
annular recess 28104f, and an external annular recess 28104g at another end.
An
engagement member 28106 that includes a base member 28106a having a tapered
end
28106b and a key member 28106c having a tapered end 28106d is received within
a portion
of the internal annular recess 28104f of the tubular body 28104a and an
engagement
member 28108 that includes a base member 28108a having a tapered end 28108b
and a
key member 28108c having a tapered end 28108d is received within an opposite
portion of
the intemal annular recess 28104f of the tubular body 28104a. Spring members,
28110 and
28112, are received within the annular recess 28104f of the tubular body
28104a for biasing
the base members, base member 28106a and 28108a, of the engagement members,
28106
and 28108, respectively, radially inwardly relative to the tubular body
28104a.
[0231] In an exemplary embodiment, during operation of the adjustable bell
section
expansion cone assembly 28, as illustrated in Figs.=15Z1 to 15Z4, the one-shot
deactivafion
device 28104 are positioned proximate and in intimate contact with the pins,
28102a and
28102b, with the tapered ends, 28106b and 28108b, of the base members, 28106a
and

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28108a, of the engagement members, 28106 and 28108, received within the
extemal
annular recess 28008ac of the tubular toggle bushing 28008. When the one-shot
deactivation device 28104 is positioned as illustrated in Figs. 15Z1 to 15Z4,
the extemal
annular recess 28104d of the tubular body 28104a of the one-shot deactivation
device is
moved out of engagement with the engagement arms, 28026d and 28032d, of the
triggers,
28026 and 28032, respectively. As a result, the triggers, 28026 and 28032, may
operate
normally as described above with reference to Figs. 15W, 15X, and 15Y.
[0232] Conversely, in an exemplary embodiment, during operation of the
adjustable bell
section expansion cone assembly 28, as illustrated in Figs. 15AA1 to 15AA4,
the one-shot
deactivation device 28104 are positioned proximate and in intimate contact
with the pins,
28100a and 28100b, with the tapered ends, 28106b and 28108b, of the base
members,
28106a and 28108a, of the engagement members, 28106 and 28108, not received
within
the extemal annular recess 28008ac of the tubular toggle bushing 28008. When
the one-
shot deactivation device 28104 is positioned as illustrated in Fig. 15AA, the
extemal annular
recess 28104d of the tubular body 28104a of the one-shot deactivation device
is moved into
engagement with the engagement arms, 28026d and 28032d, of the triggers, 28026
and
28032, respectively. As a result, the triggers, 28026 and 28032, are
deactivated and may
not operate normally as described above with reference to Figs. 15W, 15X, and
15Y.
[0233] In an alternative embodiment, the elements of the adjustable bell
section
expansion cone assembly 28 that sense the diameter of the expandable wellbore
casing 100
may be disabled or omitted or adjusted to sense any pre-selected internal
diameter of the
expandable wellbore casing.
[0234] In an exemplary embodiment, the adjustable casing expansion cone
assembly 30
operates and is provided substantially, at least in part, as disclosed in one
or more of the
following: WO 03/042486; WO 03/042487; WO 03/078785; WO 04/027205;
WO 03/093623 and WO 03/106130.
[0235] In an exemplary embodiment, as illustrated in Figs. 16-1 and 16-2,16A1
to
16A2, 16B1 to 16B2, 16C, 16D, 16E, 16F, 16G, 16H, 161, 16j, 16K, 16L, 16M,
16N, 160,
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16P, 16R, 16S, 16T, 16U, 16V, 16W, 16X, 16Y, 16Z1-16Z4, 16AA1 to 16AA4, 16AB1
to
16AB4, 16AC1 to 16AC4, 16AD, and 16AE, the adjustable casing expansion cone
assembly
30 includes an upper tubular tool joint 30002 that defines a longitudinal
passage 30002a and
mounting holes, 30002b and 30002c, and includes an internal threaded
connection 30002d,
an inner annular recess 30002e, an inner annular recess 30002f, and an
internal threaded
connection 30002g. A tubular torque plate 30004 that defines a longitudinal
passage
30004a and includes circumferentially spaced apart teeth 30004b is received
within, mates
with, and is coupled to the internal annular recess 30002e of the upper
tubular tool joint
30002.
[00104=] Circumferentially spaced apart teeth 30006a of an end of a tubular
lower mandrel
30006 that defines a longitudinal passage 30006b, a radial passage 30006ba,
and a radial
passage 30006bb and includes an external threaded connection 30006c, an
external flange
30006d, an external annular recess 30006e having a step 30006f at one end, an
external
annular recess 30006g, external teeth 30006h, an external threaded connection
30006i, and
an external annular recess 30006j engage the circumferentially spaced apart
teeth 30004b
of the tubular torque plate 30004. An internal threaded connection 30008a of
an end of a
tubular toggle bushing 30008 that defines a longitudinal passage 30008b, an
upper
longitudinal slot 30008c , a lower longitudinal slot 30008d, mounting holes,
30008e, 30008f,
30008g, 30008h, 30008i, 30008j, 30008k, 300081, 30008m, 30008n, 30008o,
30008p,
30008q, 30008r, 30008s, 30008t, 30008u, 30008v, 30008w, 30008x, 30008xa, and
30008xb, and includes an external annular recess 30008y, intemal annular
recess 30008z,
external annular recess 30008aa, and an external annular recess 30008ab
receives and is
coupled to the extemal threaded connection 30006c of the tubular lower mandrel
30006.
[0236] A sealing element 30010 is received within the extemal annular recess
30008y of
the tubular toggle bushing 30008 for sealing the interface between the tubular
toggle
bushing and the upper tubular tool joint 30002. A sealing element 30012 is
received within
the internal annular recess 30008z of the tubular toggle bushing 30008 for
sealing the
interface between the tubular toggle bushing and the tubular lower mandrel
30006.
[0237] Mounting screws, 30014a and 30014b, mounted within and coupled to the
mounting holes, 30008w and 30008x, respectively, of the tubular toggle bushing
30008 are
also received within the mounting holes, 30002b and 30002c, of the upper
tubular tool joint
30002. Mounting pins, 30016a, 30016b, 30016c, 30016d, and 30016e, are mounted
within
the mounting holes, 30008e, 30008f, 30008g, 30008h, and 30008i, respectively.
Mounting
pins, 30018a, 30018b, 30018c, 30018d, and 30018e, are mounted within the
mounting
holes, 30008t, 30008s, 30008r, 30008q, and 30008p, respectively. Mounting
screws,
30020a and 30020b, are mounted within the mounting holes, 30008u and 30008v,
respectively.
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[0238] A first upper toggle link 30022 defines mounting holes, 30022a and
30022b, for
receiving the mounting pins, 30016a and 30016b, and includes a mounting pin
30022c at
one end. A first lower toggle link 30024 defines mounting holes, 30024a,
30024b, and
30024c, for receiving the mounting pins, 30022c, 30016c, and 30016d,
respectively and
includes an engagement arm 30024d. A first trigger 30026 defines a mounting
hole 30026a
for receiving the mounting pin 30016e and includes an engagement arm 30026b at
one end,
an engagement member 30026c, and an engagement arm 30026d at another end.
[0239] A second upper toggle link 30028 defines mounting holes, 30028a and
30028b,
for receiving the mounting pins, 30018a and 30018b, and includes a mounting
pin 30028c at
one end. A second lower toggle link 30030 defines mounting holes, 30030a,
30030b, and
30030c, for receiving the mounting pins, 30028c, 30018c, and 30018d,
respectively and
includes an engagement arm 30030d. A second trigger 30032 defines a mounting
hole
30032a for receiving the mounting pin 30018e and includes an engagement arm
30032b at
one end, an engagement member 30032c, and an engagement arm 30032d at another
end.
[0240] An end of a tubular spring housing 30034 that defines a longitudinal
passage
30034a, mounting holes, 30034b and 30034c, and mounting holes, 30034ba and
30034ca,
and includes an intemal flange 30034d and an internal annular recess 30034e at
one end,
and an internal flange 30034f, an internal annular recess 30034g, an internal
annular recess
30034h, and an external threaded connection 30034i at another end receives and
mates
with the end of the tubular toggle bushing 30008. Mounting screws, 30035a and
30035b,
are mounted within and coupled to the mounting holes, 30008xb and 30008xa,
respectively,
of the tubular toggle bushing 30008 and are received within the mounting
holes, 30034ba
and 30034ca, respectively, of the tubular spring housing 30034.
[0241] A tubular retracting spring ring 30036 that defines mounting holes,
30036a and
30036b, receives and mates with a portion of the tubular lower mandrel 30006
and is
received within and mates with a portion of the tubular spring housing 30034.
Mounting
screws, 30038a and 30038b, are mounted within and coupled to the mounting
holes, 30036a
and 30036b, respectively, of the tubular retracting spring ring 30036 and
extend into the
mounting holes, 30034b and 30034c, respectively, of the tubular spring housing
30034.
[0242] Casing diameter sensor springs, 30040a and 30040b, are positioned
within the
longitudinal slots, 30008c and 3008d, respectively, of the tubular toggle
bushing 30008 that
engage the engagement members, 30026c and 30032c, and engagement arms,30026d
and
30032d, of the first and second triggers, 30026 and 30032, respectively. An
inner flange
30042a of an end of a tubular spring washer 30042 mates with and receives a
portion of the
tubular lower mandrel 30006 and an end face of the inner flange of the tubular
spring washer
is positioned proximate and end face of the external flange 30006d of the
tubular lower
mandrel. The tubular spring washer 30042 is further received within the
longitudinal
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passage 30034a of the tubular spring housing 30034.
[0243] An end of a retracting spring 30044 that receives the tubular lower
mandrel
30006 is positioned wifhin the tubu(ar spring washer 30042 in contact with the
intemal flange
30042a of the tubular spring washer and the other end of the retracting spring
is positioned
in contact with an end face of the tubular retracting spring ring 30036.
[0244] A sealing element 30046 is received within the external annular recess
30006j of
the tubular lower mandrel 30006 for sealing the interface between the tubular
lower mandrel
and the tubular spring housing 30034. A sealing element 30048 is received
within the
internal annular recess 30034h of the tubu(ar spring housing 30034 for sealing
the interface
between the tubular spring housing and the tubular lower mandrel 30006.
[0245] An intemal threaded connection 30050a of an end of a tubular upper
hinge
sleeve 30050 that includes an intemal flange 30050b and an internal pivot
30050c receives
and is coupled to the external threaded connection 30034i of the end of the
tubular spring
housing 30034.
[0246] An external flange 30052a of a base member 30052b of an upper cam
assembly
30052, that is mounted upon and receives the lower tubular mandrel 30006, that
includes an
internal flange 30052c that is received within the external annular recess
30006e of the
lower tubular mandrel 30006 and a plurality of circumferentiaily spaced apart
tapered cam
arms 30052d extending from the base member mates with and is received within
the tubular
upper hinge sleeve 30050. The base member 30052b of the upper cam assembly
30052
further includes a plurality of circumferentially spaced apart teeth 30052f
that mate with and
are received within a plurality of circumferentially spaced apart teeth 30034j
provided on the
end face of the tubular spring housing 30034 and an end face of the external
flange 30052a
of the base member of the upper cam assembly is positioned in opposing
relation to an end
face of the internal flange 30050b of the tubular upper hinge sleeve 30050.
Each of the
cam arms 30052d of the upper cam assembly 30052 include external cam surfaces
30052e.
In an exemplary embodiment, the teeth 30052f of the base member 30052b of the
upper
cam assembly 30052 and the teeth 30034j provided on the end face of the
tubular spring
housing 30034 permit torsional loads to be transmitted between the tubular
spring housing
and the upper cam assembly.
[0247] A plurality of circumferentially spaced apart upper expansion segments
30054 are
mounted upon and receive the lower tubular mandrel 30006 and each include an
external
pivot recess 30054a at one end for mating with and receiving the intemal pivot
30050c of the
tubular upper hinge sleeve 30050 and an external tapered expansion surface
30054b at
another end and are pivotally mounted within the tubular upper hinge sleeve
and are
interleaved with the circumferentially spaced apart cam arms 30052d of the
upper cam
assembly 30052. The upper expansion segments 30054 are interleaved among the
cam
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arms 30052d of the upper cam assembly 30052.
[0248] A plurality of circumferentially spaced apartlower expansion segments
30058 are
mounted upon and receive the lower tubular mandrel 30006, are interleaved
among the
upper expansion segments 30054, are oriented in the opposite direction to the
upper
expansion segments 30054, each include an external pivot recess 30058a at one
end and
an extemal tapered expansion surface 30054b at another end and are positioned
in
opposing relation to corresponding circumferentially spaced apart cam arms
30052d of the
upper cam assembly 30052.
[0249] A lower cam assembly 30060 is mounted upon and receives the lower
tubular
mandrel 30006 that includes a base member 30060a having an external flange
30060b, a
plurality of circumferentially spaced apart cam arms 30060d that extend from
the base
member that each include extemal cam surfaces 30060e and define mounting holes
30060f
and 30060g. The base member 30060a of the lower cam assembly 30060 further
includes a
plurality of circumferentially spaced apart teeth 30060h. The
circumferentially spaced apart
cam arms 30060d of the lower cam assembly 30060 are interleaved among the
lower
expansion segments 30058 and the circumferentially spaced apart cam arms
30052d of the
upper cam assembly 30052 and positioned in opposing relation to corresponding
upper
expansion segments 30054.
[0250] Mounting screws, 30062a, 30062b, 30062c, and 30062e, are mounted within
the
corresponding mounting holes, 30060f and 30060g, of the lower cam assembly
30060 and
are received within the extemal annular recess 30006g of the lower cam
assembly 30060.
[0251] A tubular lower hinge sleeve 30064 that receives the lower expansion
segments
30058 and the lower cam assembly 30060 includes an internal flange 30064a for
engaging
the extemal flange 30060b of the base member of the lower cam assembly 30060,
an
intemal pivot 30064b for engaging and receiving the extemal pivot recess
30058a of the
lower expansion segments 30058 thereby pivotally mounting the lower expansion
segments
within the tubular lower hinge sleeve, and an internal threaded connection
30064c.,
[0252] An external threaded connection 30066a of an end of a tubular sleeve
30066 that
defines mounting holes, 30066b and 30066c, and includes an intemal annular
recess
30066d having a shoulder 30066e, an intemal flange 30066f, and an intemal
threaded
connection 30066g at another end is received within and coupled to the
internal threaded
connection 30064c of the tubular lower hinge sleeve 30064. An external
threaded
connection 30068a of an end of a tubular member 30068 that defines a
longitudinal passage
30068b and mounting holes, 30068c and 30068d, and includes an extemal annular
recess
30068e, and an external threaded connection 30068f at another end is received
within and is
coupled to the intemal threaded connection 30066g of the tubular sleeve 30066.
[0253] Mounting screws, 30070a and 30070b, are mounted in and coupled to the

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mounting holes, 30068c and 30068d, respectively, of the tubular member 30068
that also
extend into the mounting holes, 30066b and 30066c, respectively, of the
tubular sleeve
30066. A sealing element 30072 is received within the external annular recess
30068e of
the tubular member 30068 for sealing the interface between the tubular member
and the
tubular sleeve 30066.
[0254] An internal threaded connection 30074a of a tubular retracting piston
30074 that
defines a longitudinal passage 30074b and includes an intemal annular recess
30074c and
an external annular recess 30074d receives and is coupled to the external
threaded
connection 30006i of the tubular lower mandrel 30006. A sealing element 30076
is received
within the extemal annular recess 30074d of the tubular retracting piston
30074 for sealing
the interface between the tubular retracting piston and the tubular sleeve
30066. A seaiing
element 30078 is received within the intemal annular recess 30074c of the
tubular retracting
piston 30074 for sealing the interface between the tubular retracting piston
and the tubular
lower mandre130006.
[0255] Locking dogs 30080 mate with and receive the external teeth 30006h of
the
tubular lower mandrel 30006. A spacer ring 30082 is positioned between an end
face of the
locking dogs 30080 and an end face of the lower cam assembly 30060. A release
piston
30084 mounted upon the tubular lower mandrel 30006 defines a radial passage
30084a for
mounting a burst disk 30086 includes sealing elements, 30084b, 30084c, and
30084d. The
sealing elements, 30084b and 30084d, sealing the interface between the release
piston
30084 and the tubular lower mandrel 30006. An end face of the release piston
30084 is
positioned in opposing relation to an end face of the locking dogs 30080.
[0256] A release sleeve 30088 that receives and is mounted upon the locking
dogs
30080 and the release piston 30084 includes an Internal flange 30088a at one
end that
seaiingly engages the tubular lower mandrel 30006. A bypass sleeve 30090 that
receives
and is mounted upon the release sleeve 30088 includes an internal flange
30090a at one
end.
[0257] In an exemplary embodiment, during operation of the adjustable casing
expansion cone assembly 30, the retracting spring 30044 is compressed and
thereby
applies a biasing spring force in a direction 30092 from the lower tubular
mandrel 30006 to
the tubular spring housing 30034 that, in the absence of other forces, moves
and/or
maintains the upper cam assembly 30052 and the upper expansion segments 30054
out of
engagement with the lower expansion segments 30058 and the lower cam assembly
30060.
In an exemplary embodiment, during operation of the adjustable bell section
expansion cone
assembly 28, an external threaded connection 20a of an end of the sealing cup
assembly 20
is coupled to the internal threaded connection 30002d of the upper tubular
tool joint 30002
and an intemal threaded connection 30a of an end of the adjustable casing
expansion cone
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assembly 30 is coupled to the external threaded connection 30068f of the
tubular member
30068.
[0258] The upper cam assembly 30052 and the upper expansion segments 30054 may
be brought into engagement with the lower expansion segments 30058 and the
lower cam
assembly 30060 by pressurizing an annulus 30094 defined between the lower
tubular
mandrel 30006 and the tubular spring housing 30034. In particular, injection
of fluidic
materials into the adjustable casing expansion cone assembly 30 through the
longitudinal
passage 30006b of the lower tubular mandrel 30006 and into the radial passage
30006ba
may pressurize the annulus 30094 thereby creating sufficient operating
pressure to generate
a force in a direction 30096 sufficient to overcome the biasing force of the
retracting spring
30044. As a result, the spring housing 30034 may be displaced in the direction
30096
relative to the lower tubular mandrel 30006 thereby displacing the tubular
upper hinge sleeve
30050, upper cam assembly 30052, and upper expansion segments 30054 in the
direction
30096.
[0259] In an exemplary embodiment, as illustrated in Figs. 16P, 16Q, and 16R,
the
displacement of the upper cam assembly 30052 and upper expansion segments
30054 in
the direction 30096 will cause the lower expansion segments 30058 to ride up
the cam
surfaces 30052e of the cam arms 30052d of the upper cam assembly 30052 while
also
pivoting about the lower tubular hinge segment 30064, and will also cause the
upper
expansion segments 30054 to ride up the cam surfaces 30060e of the cam arms
30060d of
the lower cam assembly 30060 while also pivoting about the upper tubular hinge
segment
30050. In an exemplary embodiment, when the upper and lower expansion
segments,
30054 and 30058, are brought into axial alignment, they define an outer
expansion surface
that is approximately contiguous in a circumferential direction and which
provides an outer
expansion surface that at least approximates a conical surface.
[0260] In an exemplary embodiment, during the operation of the adjustable
casing
expansion cone assembly 30, when the upper and lower expansion segments, 30054
and
30058, brought into axial alignment into a radially expanded position, the
upper and lower
expansion segments, 30054 and 30058, are displaced relative to the expandable
wellbore
casing 100 to thereby radially expand and plastically deform at least a
portion of the
expandable wellbore casing. In an exemplary embodiment, during the radial
expansion and
plastic deformation of the expandable wellbore casing 100, the adjustable
casing expansion
cone assembly 30 may then be rotated relative to the expandable wellbore
casing to
enhance and/or modify the rate at which the expandable wellbore casing is
radially
expanded and plastically deformed.
[0261] In an exemplary embodiment, the upper cam assembly 30052 and the upper
expansion segments 30054 may be moved out of engagement with the lower
expansion
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segments 30058 and the lower cam assembly 30060 by reducing the operating
pressure
within the annulus 30094.
.[0262] In an alternative embodiment, as illustrated in Figs. 16S, 16T, 16U
and 16V,
during operation of the adjustable casing expansion cone assembly 30, the
upper cam
assembly 30052 and the upper expansion segments 30054 may also be moved out of
engagement with the lower expansion segments 30058 and the lower cam assembly
30060
by sensing the operating pressure within the longitudinal passage 30006b of
the lower
tubular mandrel 30006. In particular, as illustrated in Fig. 16T, if the
operating pressure
within the longitudinal passage 30006b and radial passage 30006bb of the lower
tubular
mandrel 30006 exceeds a predetermined value, the burst disc 30086 will open
the passage
30084a thereby pressurizing the interior of the tubular release sleeve 30088
thereby
displacing the tubular release sleeve 30088 downwardly in a direction 30092
away from
engagement with the locking dogs 30080.
[0263] As a result, as illustrated in Fig. 16U, the locking dogs 30080 are
displaced
outwardly in the radial directed and thereby released from engagement with the
lower
tubular mandrel 30006 thereby permitting the lower expansion segments 30058
and the
lower cam assembly 30060 to be displaced downwardly relative to the lower
tubular
mandrel.
[0264] As a result, as illustrated in Fig. 16V, the operating pressure within
the lower
tubular mandrel 30066 may then cause the lower tubular mandrel to be displaced
downwardly in the direction 30094 relative to the tubular lower mandrel 30006
and the
retracting piston 30074. As a result, the lower tubular mandrel 30066, the
lower expansion
segments 30058, the lower cam assembly 30060, and tubular lower hinge sleeve
30064 are
displaced downwardly in the direction 30094 relative to the tubular spring
housing 30034
thereby moving the lower expansion segments 30058 and the lower cam assembly
30060
out of engagement with the upper cam assembly 30052 and the upper expansion
segments
30054.
[0265] In an exemplary embodiment, as illustrated in Figs. 16W, 16X, and 16Y,
during
operation of the adjustable casing expansion cone assembly 30, the adjustable
casing
expansion cone assembly senses the diameter of the expandable wellbore casing
100 using
the upper toggle links, 30022 and 30028, lower toggle links, 30024 and 30030,
and triggers,
30026 and 30032, and then prevents the engagement of the upper cam assembly
30052
and the upper expansion segments 30054 with the lower expansion segments 30058
and
the lower cam assembly 30060.
[0266] In particular, as illustrated in Fig. 16W, anytime the upper toggle
links, 30022 and
30028, and lower toggle links, 30024 and 30030, are positioned within a
portion of the
expandable wellbore casing 100 that has been radially expanded and plastically
deformed
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by the system 10, the triggers, 30026 and 30032, will be pivoted by the
engagement arms,
30024d and 30030d, of the lower toggle links, 30024 and 30030, to a position
in which the
triggers will no longer engage the internal flange 30034d of the end of the
tubular spring
housing 30034 thereby permitting the displacement of the tubular spring
housing in the
direction 30096. As a result, the upper cam assembly 30052 and the upper
expansion
segments 30054 can be brought into engagement with the lower expansion
segments 30058
and the lower cam assembly 30060. In an exemplary embodiment, the upper toggle
links,
30022 and 30028, and the lower toggle links, 30024 and 30030, are spring
biased towards
the position illustrated in Fig. 16W.
[0267] Conversely, as illustrated in Fig. 16X, anytime the upper toggle links,
30022 and
30028, and lower toggle links, 30024 and 30030, are positioned within a
portion of the
expandable wellbore casing 100 that has not been radially expanded and
plastically
deformed by the system 10, the triggers, 30026 and 30032, will be maintained
in a position
in which the triggers will engage the intemal flange 30034d of the end of the
tubular spring
housing 30034 thereby preventing the displacement of the tubular spring
housing in the
direction 30096. As a result, the upper cam assembly 30052 and the upper
expansion
segments 30054 cannot be brought into engagement with the lower expansion
segments
30058 and the lower cam assembly 30060. In an exemplary embodiment, the
triggers,
30026 and 30032, are spring biased towards the position illustrated in Fig.
16X.
[0268] In an exemplary embodiment, as illustrated in Fig, 16Y, the tubular
spring
housing 30034 may be displaced upwardly in the direction 30098 even if the
upper toggle
links, 30022 and 30028, and lower toggle links, 30024 and 30030, are
positioned within a
portion of the expandable wellbore casing 100 that has not been radially
expanded and
plastically deformed by the system 10.
[0269] In an exemplary embodiment, as illustrated in Figs. 16Z1 to 16Z4, 16AA1
to
16AA4, 16A81 to 16AB4, 16AC1 to 16AC4, 16AD, and 16AE, the tubular spring
housing
30034 of the adjustable casing expansion cone assembly 30 defines internal
annular
recesses 30034k and 300341, spaced apart by an intemal flange 30034m, the
tubular toggle
bushing 30008 defines an extemal annular recess 30008ac, and the adjustable
casing
expansion cone assembly further includes pins, 30100a and 30100b and 30102a
and
30102b, mounted in holes 30008j and 30008o and 30008k and 30008n,
respectively, of the
tubular toggle bushing, and a one-shot deactivation device 30104 mounted on
the tubular
toggle bushing between the pins, 30100a and 30100b and 30102a and 30102b.
[0270] The one-shot deactivation device 30104 includes a tubular body 30104a
that
defines radial holes, 30104b and 30014c, and includes an extemal annular
recess 30104d at
one end, a centrally positioned external flange 30104e, a centrally positioned
internal
annular recess 30104f, and an external annular recess 30104g at another end.
An
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engagement member 30106 that includes a base member 30106a having a tapered
end
30106b and a key member 30106c having a tapered end 30106d is received within
a portion
of the internal annular recess 30104f of the tubular body 30104a and an
engagement
member 30108 that includes a base member 301 08a having a tapered end 301 08b
and a
key member 30108c having a tapered end 30108d is received within an opposite
porBon of
the internal annular recess 30104f of the tubular body 30104a. Spring members,
30110 and
30112, are received within the annular recess 30104f of the tubular body
30104a for biasing
the base members, base member 30106a and 30108a, of the engagement members,
30106
and 30108, respectively, radially inwardly relative to the tubular body
30104a.
[0271] In an exemplary embodiment, during operation of the adjustable bell
section
expansion cone assembly 28, as illustrated in Fig. 16Z, the one-shot
deactivation device
30104 are positioned proximate and in intimate contact with the pins, 30102a
and 30102b,
with the tapered ends, 30106b and 30108b, of the base members, 30106a and
30108a, of
the engagement members, 30106 and 30108, received within the external annular
recess
30008ac of the tubular toggle bushing 30008. When the one-shot deactivation
device 30104
is positioned as illustrated in Fig. 16Z, the external annular recess 30104d
of the tubular
body 30104a of the one-shot deactivation device is moved out of engagement
with the
engagement arms, 30026d and 30032d, of the triggers, 30026 and 30032,
respectively. As
a result, the triggers, 30026 and 30032, may operate normally as described
above with
reference to Figs. 16W,16X, and 16Y.
[0272] Conversely, in an exemplary embodiment, during operation of the
adjustable
casing expansion cone assembly 30, as illustrated in Figs. 16AA1 to 16AA4, the
one-shot
deactivation device 30104 are positioned proximate and in intimate contact
with the pins,
30100a and 30100b, with the tapered ends, 30106b and 30108b, of the base
members,
30106a and 30108a, of the engagement members, 30106 and 30108, not received
within
the external annular recess 30008ac of the tubular toggle bushing 30008. When
the one-
shot deactivation device 30104 is positioned as illustrated in Figs. 16AA1 to
16AA4, the
extemal annular recess 30104d of the tubular body 30104a of the one-shot
deactivation
device is moved into erigagement with the engagement arms, 30026d and 30032d,
of the
triggers, 30026 and 30032, respectively. As a result, the triggers, 30026 and
30032, are
deactivated and may not operate normally as described above with reference to
Figs. 16W,
16X, and 16Y.
[0273] In an altemative embodiment, the elements of the adjustable casing
expansion
cone assembly 30 that sense the diameter of the expandable wellbore casing 100
may be
disabled or omitted or adjusted to sense any pre-selected intemal diameter of
the
expandable wellbore casing.
[0274] In an exemplary embodiment, as illustrated in 17A to 17C, the packer
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assembly 32 includes a tubular adaptor 3202 that defines a longitudinal
passage 3202a,
radial external mounting holes, 3202b and 3202c, radial passages, 3202d and
3202e, and
includes an external threaded connection 3202f at one end and an internal
annular recess
3202g having an intemal threaded connection at another end. An external
threaded
connection 3204a of an end of a tubular upper mandre13204 that defines a
longitudinal
passage 3204b, internally threaded external mounting holes, 3204c and 3204d,
and includes
an extemal annular recess 3204e, extemal annular recess 3204f, extemal annular
recess
3204g, external flange 3204h, external splines 3204i, and an internal threaded
connection
3204j at another end is received within and is coupled to the internally
threaded connection
of the internal annular recess 3202g of the other end of the tubular adaptor
3202. Mounting
screws, 3205a and 3205b, are received within and coupled to the mounting
holes, 3204c
and 3204d, of the tubular upper mandrel 3204 that also extend into the radial
passages,
3202d and 3202e, of the tubular adaptor 3202.
[0275] An external threaded connection 3206a of an end of a mandre13206 that
defines
a longitudinal passage 3206b and includes an external annular recess 3206c and
an
extemal annular recess 3206d having an external threaded connection is
received within
and is coupled to the internal threaded connection 3204j of the tubular upper
mandrel 3204.
An internal threaded connection 3208a of a tubular stinger 3208 that defines a
longitudinal
passage 3208b and includes an extemal annular recess 3208c, and an external
tapered
annular recess 3208d and an engagement shoulder 3208e at another end receives
and is
coupled to the external threaded connection of the external annular recess
3206d of the
mandrel 3206. A sealing member 3210 is mounted upon and coupled to the extemal
annular recess 3206d of the mandrel 3206.
[0276] An internal flange 3212a of a tubular key 3212 that includes an
external annular
recess 3212b at one end and an internal annular recess 3212c at another end is
movably
received within and engages the external annular recess 3204f of the tubular
upper mandrel
3204. A garter spring 3214 is received within and engages the extemal annular
recess
3212b of the tubular key 3212.
[0277] An end of a tubular bushing 3216 that defines a longitudinal passage
3216a for
receiving and mating with the upper mandrel 3204, and radial passages, 3216b
and 3216c,
and includes an external threaded connection 3216d at an intermediate portion,
and an
external flange 3216e, an internal annular recess 3216f, circumferentially
spaced apart teeth
3216g, and external flanges, 3216h and 3216i, at another end is received
within and mates
with the internal annular recess 3212c of the tubular key 3212. An internal
threaded
connection 3218a of a tubular drag block body 3218 that defines a longitudinal
passage
3218b for receiving the tubular bushing 3216, mounting holes, 3218c and 3218d,
mounting
holes, 3218e and 3218f, and includes an intemal threaded connection 3218g at
one end, a
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centrally positioned extemai annular recess 3218h, and an extemal threaded
connection
3218i at another end is received within and coupled to the extemal threaded
connection
3216d of the tubular bushing 3216.
[0278] A first tubular keeper 3220 that defines mounting holes, 3220a and
3220b, is
coupled to an end of the tubular drag block body 3218 by mounting screws,
3222a and
3222b, that are received within and are coupled to the mounting holes, 3218c
and 3218d, of
the tubular drag block body. A second tubular keeper 3224 that defines
mounting holes,
3224a and 3224b, is coupled to an end of the tubular drag block body 3218 by
mounting
screws, 3226a and 3226b, that are received within and are coupled to the
mounting holes,
3218e and 3218f, of the tubular drag block body.
[0279] Drag blocks, 3228 and 3230, that are received within the external
annular recess
3218h of the tubular drag block body 3218, include ends that mate with and are
received
within the end of the first tubular keeper 3220, and other ends that mate with
and are
received within the end of the second tubular keeper 3224. The drag blocks,
3228 and
3230, further include intemal annular recesses, 3228a and 3230a, respectively,
that receive
and mate with ends of springs, 3232 and 3234, respectively. The springs, 3232
and 3234,
also receive and mate with the extemal annular recess 3218h of the tubular
drag block body
3218.
[0280] An extemal threaded connection 3236a of an end of a tubular releasing
cap
extension 3236 that defines a longitudinal passage 3236b and includes an
internal annular
recess 3236c and an internal threaded connection 3236d at another end is
received within
and is coupled to the intemal threaded connection 3218g of the tubular drag
block body
3218. An external threaded connection 3238a of an end of a tubular releasing
cap 3238 that
defines a longitudinal passage 3238b and includes an intemal annular recess
3238c is
received within and coupled to the internal threaded connection 3236d of the
tubular
releasing cap extension 3236. A sealing element 3240 is received within the
internal annular
recess 3238c of the tubular releasing cap 3238 for fluidicly sealing the
interface between the
tubular releasing cap and the upper mandrel 3204.
[0281] An internal threaded connection 3242a of an end of a tubular setting
sleeve 3242
that defines a longitudinal passage 3242b, radial passage 3242c, radial
passages, 3242d
and 3242e, radial passage 3242f, and includes an internal flange 3242g at
another end
receives the extemal threaded connection 3218i of the tubular drag block body
3218. An
intemal flange 3244a of a tubular coupling ring 3244 that defines a
longitudinal passage
3244b and radial passages, 3244c and 3244d, receives and mates with the
external flange
3216h of the tubular bushing 3216 and an end face of the internal flange of
the tubular
coupling ring is positioned proximate and in opposing relation to an end face
of the extemal
flange 3216i of the tubular bushing.
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[0282] An intemal flange 3246a of a tubular retaining collet 3246 that
includes a plurality
of axially extending collet fingers 3246b, each having intemal flanges 3246c
at an end of
each collet finger, for engaging and receiving the tubular coupling ring 3244
receives and
mates with external flange 3216e of the tubular bushing 3216 and an end face
of the intemal
flange of the tubular retaining collet is positioned proximate and in opposing
relation to an
end face of the extemal flange 3216h of the tubular bushing.
[0283] In an exemplary embodiment, the packer assembly 36 operates and is
provided
substantially, at least in part, as disdosed in one or more of the following:
WO 03/093623 and WO 04/027200.
[0284] in an exemplary embodiment, as illustrated in Figs. 18-1 to 18-5, the
packer
assembly 36 includes a tubular upper adaptor 3602 that defines a longitudinal
passage
3602a having a tapered opening 3602b and mounting holes, 3602c and 3602d, that
includes
a plurality of circumferentially spaced apart teeth 3602e at one end, an
extemal flange
3602f, and an internal threaded connection 3602g at another end. In an
exemplary
embodiment, the tubular upper adaptor 3602 is fabricated from aluminum. An
external
threaded connection 3604a of an end of a tubular upper mandrel 3604 that
defines a
longitudinal passage 3604b, mounting holes, 3604c and 3604d, mounting holes,
3604e and
3604f, and mounting holes, 3604g and 3604h, and includes an extemal flange
3604i, an
intemal annular recess 3604j, and an intemal threaded connection 3604k at
another end is
received within and coupled to the internal threaded connection 3602g of the
tubular upper
adaptor 3602. In an exemplary embodiment, the tubular upper mandrel 3604 is
fabricated
from aluminum.
[0285] An upper tubular spacer ring 3606 that defines mounting holes, 3606a
and
3606b, receives and mates with the end of the tubular upper mandrel 3604 and
includes an
angled end face 3606c and another end face that is positioned proximate to an
end face of
the tubular upper adaptor 3602 is coupled to the tubular upper mandrel by
shear pins, 3608a
and 3608b, that are mounted within and coupled to the mounting holes, 3604c
and 3606a,
and, 3604d and 3606b, respectively, of the tubular upper mandrel and upper
tubular spacer
ring, respeciively. A lower tubular spacer ring 3610 that includes an angled
end face 3610a
receives, mates, and is coupled to the other end of the tubular upper mandrel
3604 and
includes another end face that is positioned proximate to an end face of the
external flange
3604i of the tubular upper mandrel 3604. In an exemplary embodiment, the upper
and
tubular spacer rings, 3606 and 3610, are fabricated from a composite matecial.
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[0286] An upper tubular slip 3612 that receives and is movably mounted upon
the
tubular upper mandrel 3604 defines a longitudinal passage 3612a having a
tapered opening
3612b and includes external annular recesses, 3612c, 3612d, 3612e, 3612f, and
3612g, and
an angled end face 3612h that mates with and is positioned proximate the
angled end face
3606c of the upper tubular spacer ring 3606. Slip retaining bands, 3614a,
3614b, 3614c,
3614d, and 3614e, are received within and coupled to the external annular
recesses, 3612c,
3612d, 3612e, 3612f, and 3612g, of the upper tubular slip 3612. A lower
tubular slip 3616
that receives and is movably mounted upon the tubular upper mandrel 3604
defines a
longitudinal passage 3616a having a tapered opening 3616b and includes
external annular
recesses, 3616c, 3616d, 3616e, 3616f, and 36i6g, and an angled end face 3616h
that
mates with and is positioned proximate the angled end face 3610a of the lower
tubular
spacer ring 3610. Slip retaining bands, 3618a, 3618b, 3618c, 3618d, and 3618e,
are
received within and coupled to the external annular recesses, 3616c, 3616d,
3616e, 3616f,
and 3616g, of the lower tubular slip 3616. In an exemplary embodiment, the
upper and
lower tubular slips, 3612 and 3616, are fabricated from composite materials,
and at least
some of the slip retaining bands, 3614a, 3614b, 3614c, 3614d, 3614e, 3618a,
3618b, 3618c,
3618d, and 3618e are fabricated from carbide insert materials.
[0287] An upper tubular wedge 3620 that defines an longitudinal passage 3620a
for
receiving the tubular upper mandrel 3604 and mounting holes, 3620b and 3620c,
and
includes an angled end face 3620d at one end that is received within and mates
with the
tapered opening 3612b of the upper tubular slip 3612, and an angled end face
3620e at
another end is coupled to the tubular upper mandrel by shear pins, 3622a and
3622b,
mounted within and coupled to the mounting holes, 3604e and 3620b, and, 3604f
and
3620c, respectively, of the tubular upper mandrel and upper tubular wedge,
respectively. A
lower tubular wedge 3624 that defines an longitudinal passage 3624a for
receiving the
tubular upper mandrel 3604 and mounting holes, 3624b and 3624c, and includes
an angled
end face 3624d at one end that is received within and mates with the tapered
opening 3616b
of the lower tubular slip 3616, and an angled end face 3624e at another end is
coupled to
the tubular upper mandrel by shear pins, 3626a and 3626b, mounted within and
coupled to
the mounting holes, 3604g and 3624b, and, 3604h and 3624c, respectively, of
the tubuiar
upper mandrel and lower tubular wedge, respectively. In an exemplary
embodiment, the
upper and lower tubular wedges, 3620 and 3624, are fabricated from composite
materials.
[0288] An upper tubular extrusion limiter 3628 that defines a longitudinal
passage 3628a
for receiving the tubular upper mandrel 3604 includes an angled end face 3628b
at one end
that mates with the angled end face 3620e of the upper tubular wedge 3620, an
angled end
face 3628c at another end having recesses 3628d, and external annular
recesses, 3628e,
3628f and 3628g. Retaining bands, 3630a, 3630b, and 3630c, are mounted within
and
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coupled to the extemal annular recesses, 3628e, 3628f and 3628g, respectively,
of the
upper tubular extrusion limiter 3628. Circular disc-shaped extrusion
preventers 3632 are
coupled and mounted within the recesses 3628d. A lower tubular extrusion
limiter 3634 that
defines a longitudinal passage 3634a for receiving the tubular upper mandrel
3604 includes
an angled end face 3634b at one end that mates with the angled end face 3624e
of the
lower tubular wedge 3624, an angled end face 3634c at another end having
recesses
3634d, and external annular recesses, 3634e, 3634f and 3634g. Retaining bands,
3636a,
3636b, and 3636c, are mounted within and coupled to the extemal annular
recesses, 3634e,
3634f and 3634g, respectively, of the lower tubular extrusion limiter 3634.
Circular disc-
shaped extrusion preventers 3638 are coupled and mounted within the recesses
3634d. In
an exemplary embodiment, the upper and lower extrusion limiters, 3628 and
3634, are
fabricated from composite materials.
[0289] An upper tubular elastomeric packer element 3640 that defines a
longitudinal
passage 3640a for receiving the tubular upper mandrel 3604 includes an angled
end face
3640b at one end that mates with and is positioned proximate the angled end
face 3628c of
the upper tubular extrusion limiter 3628 and an curved end face 3640c at
another end. A
lower tubular elastomeric packer element 3642 that defines a longitudinal
passage 3642a for
receiving the tubular upper mandrel 3604 includes an angled end face 3642b at
one end that
mates with and is positioned proximate the angled end face 3634c of the lower
tubular
extrusion limiter 3634 and an curved end face 3642c at another end.
[0290] A central tubular elastomeric packer element 3644 that defines a
longitudinal
passage 3644a for receiving the tubular upper mandrel 3604 includes a curved
outer surface
3644b for mating with and engaging the curved end faces, 3640c and 3642c, of
the upper
and lower tubular elastomeric packer elements, 3640 and 3642, respectively.
[0291] An external threaded connection 3646a of a tubular lower mandrel 3646
that
defines a longitudinal passage 3646b having throat passages, 3646c and 3646d,
and flow
ports, 3646e and 3646f, and a mounting hole 3646g, and includes an intemal
annular recess
3646h at one end, and an external flange 3646i, internal annular recess 3646j,
and internal
threaded connection 3646k at another end. In an exemplary embodiment, the
tubular lower
mandrel 3646 is fabricated from aluminum. A sealing element 3648 is received
within the
.inner annular recess 3604j of the other end of the tubular upper mandrel 3604
for sealing an
interface between the tubular upper mandrel and the tubular lower mandrel
3646.
[0292] A tubular sliding sleeve valve 3650 that defines a longitudinal passage
3650a and
radial flow ports, 3650b and 3650c, and includes collet fingers 3650d at one
end for
engaging the intemal annular recess 3646h of the lower tubular mandrel 3646,
an external
annular recess 3650e, an external annular recess 3650f, an external annular
recess 3650g,
and circumferentially spaced apart teeth 3650h at another end is received
within and is

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slidably coupled to the longitudinal passage 3646b of the tubular lower
mandrel 3646. In an
exemplary embodiment, the tubular sliding sleeve valve 3650 is fabricated from
aluminum.
A set screw 3652 is mounted within and coupled to the mounting hole 3646g of
the tubular
lower mandrel 3646 that is received within the extemal annular recess 3650e of
the tubular
sliding sleeve 3650. Sealing elements, 3654 and 3656, are mounted within the
external
annular recesses, 3650f and 3650g, respectively, of the tubular sliding sleeve
valve 3650 for
sealing an interface between the tubular sliding sleeve valve and the tubular
lower mandrel
3646.
[0293] An end of a tubular outer sleeve 3658 that defines a longitudinal
passage 3658a,
radial passages, 3658b and 3658c, upper flow ports, 3658d and 3658e, lower
flow ports,
3658f and 3658g, and radial passages, 3658h and 3658i, receives, mates with,
and is
coupled to the other end of the tubular upper mandrel 3604 and an end face of
the end of
the tubular outer sleeve is positioned proximate and end face of the lower
tubular spacer ring
3610. The other end of the tubular outer sleeve 3658 receives, mates with, and
is coupled
to the other end of the tubular lower mandrel 3646.
[0294] An external threaded connection 3660a of an end of a tubular bypass
mandrel
3660 that defines a longitudinal passage 3660b, upper flow ports, 3660c and
3660d, lower
flow ports, 3660e and 3660f, and a mounting hole 3660g and includes an
internal annular
recess 3660h and an external threaded connection 3660i at another end is
received within
and coupled to the internal threaded connection 3646k of the tubular lower
mandrel 3646. A
sealing element 3662 is received within the intemal annular recess 3646j of
the tubular lower
mandrel 3646 for sealing an interface between the tubular lower mandrel and
the tubular
bypass mandrel 3660.
[0295] A tubular plug seat 3664 that defines a longitudinal passage 3664a
having a
tapered opening 3664b at one end, and flow ports, 3664c and 3664d, and
includes an
external annular recess 3664e, an external annular recess 3664f, an extema!
annular recess
3664g, an external annular recess 3664h, and an external annular recess 3664i
having an
external threaded connection at another end is received within and is movably
coupled to the
longitudinal passage 3660b of the tubular bypass mandrel 3660. A tubular nose
3666 is
threadably coupled to and mounted upon the external annular recess 3664i of
the tubular
plug seat 3664. In an exemplary embodiment, the tubular plug seat 3664 is
fabricated from
aluminum. Sealing elements, 3668, 3670, and 3672, are received within the
extemal
annular recesses, 3664e, 3664g, and 3664h, respectively, of the tubular plug
seat 3664 for
sealing an interface between the tubular plug seat and the tubular bypass
mandrel 3660. A
set screw 3674 is mounted within and coupled to the mounting hole 3660g of the
tubular
bypass mandrel 3660 that is received within the external annular recess 3664f
of the tubular
plug seat 3664.
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[0296] An end of a tubular bypass sleeve 3676 that defines a longitudinal
passage
3676a and includes an internal annular recess 3676b at one end and an internal
threaded
connection 3676c at another end is coupled to the other end of the tubular
outer sleeve 3658
and mates with and receives the tubular bypass mandrel 3660. In an exemplary
embodiment, the tubular bypass sleeve 3676 is fabricated from aluminum.
[0297] An extemal threaded connection 3678a of a tubular valve seat 3678 that
defines
a longitudinal passage 3678b including a valve seat 3678c and up-jet flow
ports, 3678d and
3678e, and includes a spring retainer 3678f and an external annular recess
3678g is
received within and is coupled to the internal threaded connection 3676c of
the tubular
bypass sleeve 3676. In an exemplary embodiment, the tubular valve seat 3678 is
fabricated
from aiuminum. A sealing element 3680 is received within the external annular
recess
3678g of the tubular valve seat 3678 for fluidicly sealing an interface
between the tubular
valve seat and the tubular bypass sleeve 3676.
[0298] A poppet valve 3682 mates with and is positioned within the valve seat
3678c of
the tubular valve seat 3678. An end of the poppet valve 3682 is coupled to an
end of a stem
bolt 3684 that is slidingly supported for longitudinal displacement by the
spring retainer 3678f
A valve spring 3686 that surrounds a portion of the stem bolt 3684 is
positioned in opposing
relation to the head of the stem bolt and a support 3678fa of the spring
retainer 3678f.for
biasing the poppet valve 3682 into engagement with the valve seat 3678c of the
tubular
valve seat 3678.
[0299] An end of a composite nose 3688 that defines a longitudinal passage
3688a and
mounting holes, 3688b and 3688c, and includes an intemal threaded connection
3688d at
another end receives, mates with, and is coupled to the other end of the
tubular valve seat
3678. A tubular nose sleeve 3690 that defines mounting holes, 3690a and 3690b,
is
coupled to the composite nose 3688 by shear pins, 3692a and 3692b, that are
mounted in
and coupled to the mounting holes, 3688b and 3690a, and, 3688c and 3690b,
respectively,
of the composite nose and tubular nose sleeve, respectively.
[0300] An external threaded connection 3694a of a baffle nose 3694 that
defines
longitudinal passages, 3694b and 3694c, is received within and is coupled to
the internal
threaded connection internal threaded connection 3688d of the composite nose
3688.
[0301] In an exemplary embodiment, as illustrated in Figs. 19A1 to 19A5,
during the
operation of the packer setting tool assembly 32 and packer assembly 36, the
packer setting
tool and packer assembly are coupled to one another by inserting the end of
the tubular
upper adaptor 3602 into the other end of the tubular coupling ring 3244,
bringing the
circumferentially spaced teeth 3216g of the other end of the tubular bushing
3216 into
engagement with the circumferentially spaced teeth 3602e of the end of the
tubular upper
adaptor, and mounting.shear pins, 36100a and 36100b, within the mounting
holes, 3244c
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and 3602c, and, 3244d and 3602d, respectively, of the tubular coupling ring
and tubular
upper adaptor, respectively. As a result, the tubular mandrel 3206 and tubular
stinger 3208
of the packer setting tool assembly 32 are thereby positioned within the
longitudinal passage
3604a of the tubular upper mandrel 3604 with the 3208e of the tubular stinger
positioned
within the longitudinal passage 3646b of the tubular lower mandrel 3646
proximate the collet
fingers 3650d of the tubular sliding sleeve valve 3650.
[0302] Furthermore, in an exemplary embodiment, during the operation of the
packer
setting tool 32 and packer assembly 36, as illustrated in Figs. 19A1 to 19A5,
the packer
setting tool and packer assembly are positioned within the expandable wellbore
casing 100
and an internal threaded connection 30a of an end of the adjustable casing
expansion cone
assembly 30 receives and is coupled to the extemal threaded connection 3202f
of the end of
the tubular adaptor 3202 of the packer setting tool assembly. Furthermore,
shear pins,
36102a and 36102b, mounted within the mounting holes, 3658b and 3658c, of the
tubular
outer sleeve 3658 couple the tubular outer sleeve to the expandable wellbore
casing. As a
result, torsion loads may transferred between the tubular outer sleeve 3658
and the
expandable wellbore casing 100.
103031 In an exemplary embodiment, as illustrated in Figs. 19131 to 19B5, a
conventional
plug 36104 is then injected into the setting tool assembly 32 and packer
assembly 36 by
injecting a fluidic material 36106 into the setting tool assembly and packer
assembly through
the longitudinal passages, 3202a, 3204b, 3206b, 3208b, 3650a, 3646a, 3660b,
and 3664a of
the tubular adaptor 3202, tubular upper mandrel 3204, tubular mandrel 3206,
tubular stinger
3208, tubular sliding sleeve valve 3650, tubular lower mandrel 3646, tubular
bypass mandrel
3660, and tubular plug seat 3664, respectively. The plug 36104 is thereby
positioned within
the longitudinal passage 3664a of the tubular plug seat 3664. Continued
injection of the
fluidic material 36106 following the seating of the plug 1606 within the
longitudinal passage
3664a of the tubular plug seat 3664 causes the plug and the tubular plug seat
to be
displaced downwardly in a direction 36108 until further movement of the
tubular plug seat is
prevented by interaction of the set screw 3674 with the extemal annular recess
3664f of the
tubular plug seat. As a result, the flow ports, 3664c and 3664d, of the
tubular plug seat 3664
are moved out of alignment with the upper flow ports, 3660c and 3660d, of the
tubular
bypass mandrel 3660.
[0304] In an exemplary embodiment, as illustrated in Figs. 19C1 to 19C5, after
the
expandable wellbore casing 100 has been radially expanded and plastically
deformed to
form at least the bell section 112 of the expandable wellbore casing 100
thereby shearing
the shear pins, 36102a and 36102b, the setting tool assembly 32 and packer
assembly 36
are then moved upwardly to a position within the expandable wellbore casing
100 above the
bell section. The tubular adaptor 3202 is then rotated, by rotating the tool
string of the
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system 10 above the setting tool assembly 32, to displace and position the
drag blocks,
3228 and 3230, into engagement with the interior surface of the expandable
wellbore casing
100.
[0306] As a result of the engagement of the drag blocks, 3228 and 3230, with
the interior
surface of the expandable wellbore casing 100, further rotation of the drag
blocks relative to
the wellbore casing is prevented. Consequently, due to the operation and
interaction of the
threaded connections, 3216d and 3218a, of the tubular bushing 3216 and tubular
drag block
body 3218, respectively, further rotation of the tubular adaptor 3202 causes
the tubular drag
block body and setting sleeve 3242 to be displaced downwardly in a direction
36112 relative
to the remaining elements of the setting tool assembly 32 and packer assembly
36. As a
result, the setting sleeve 3242 engages and displaces the upper tubular spacer
ring 3606
thereby shearing the shear pins, 3622a and 3622b, and driving the upper
tubular slip 3612
onto and up the angled end face 3620d of the upper tubular wedge 3620 and into
engagement with the interior surface of the expandable wellbore casing 100. As
a resu(t,
longitudinal displacement of the upper tubular slip 3612 relative to the
expandable wellbore
casing 100 is prevented. Furthermore, as a result, the 3246b collet fingers of
the tubular
retaining collet 3246 are disengaged from the tubular upper adaptor 3602.
[0306] In an altemative embodiment, after the drag blocks, 3228 and 3230,
engage the
interior surface of the expandable wellbore casing 100, an upward tensile
force is applied to
the tubular support member 12, and the ball gripper assembly 16 is then
operate to engage
the interior surface of the expandable wellbore casing. The tension actuator
assembly 18 is
then operated to apply an upward tensile force to the tubular adaptor 3202
thereby pulling
the upper tubular spacer ring 3606, lower tubular spacer ring 3610, upper
tubular slip 3612,
lower tubular slip 3616, upper tubular wedge 3620, lower tubular wedge 3624,
upper tubular
extrusion limiter 3628, lower tubular extrusion limiter 3634, and central
tubular elastomeric
element 3644 upwardly into contact with the 3242 thereby compressing the upper
tubular
spacer ring, lower tubular spacer ring, upper tubular slip, lower tubular
slip, upper tubular
wedge, lower tubular wedge, upper tubular extrusion limiter, lower tubular
extrusion limiter,
and central tubular elastomeric element. As a result, the upper tubular slip
3612, lower
tubular slip 3616, and central tubular elastomeric element 3644 engage the
interior surface
of the expandable wellbore casing 100.
[0307] In an exemplary embodiment, as illustrated in Figs. 19D1 to 19D5, an
upward
tensile force is then applied to the tubular adaptor 3202 thereby compressing
the lower
tubular slip 3616, lower tubular wedge 3624, central elastomeric packer
element 3644, upper
tubular e~.~trusion limiter 3628, and upper tubular wedge 3620 between the
lower tubular
spacer ring 3610 and the stationary upper tubular slip 3612. As a result, the
lower tubular
slip 3616 is driven onto and up the angled end face 3624d of the lower tubular
wedge 3624
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and into engagement with the interior surface of the expandable wellbore
casing 100, and
the central elastomeric packer element 3644 is compressed radially outwardly
into
engagement with the interior surface of the expandable tubular member. As a
result, further
longitudinal displacement of the upper tubular slip 3612, lower tubular slip
3616, and central
elastomeric packer element 3644 relative to the expandable wellbore casing 100
is
prevented.
[030E] In an exemplary embodiment, as illustrated in Figs. 19E1 to 19E6,
continued
application of the upward tensile force to tubular adaptor 3202 will then
shear the shear pins,
1602a and 1602b, thereby disengaging the setting tool assembly 32 from the
packer
assembly 36.
[0309] In an exemplary embodiment, as illustrated in Figs. 19F1 to 19F6, with
the drag
blocks, 3228 and 3230, in engagement with the interior surface of the
expandable wellbore
casing 100, the tubular adaptor 102 is further rotated thereby causing the
tubular drag block
body 3218 and setting sleeve 3242 to be displaced further downwardly in the
direction 1612
until the tubular drag block body and setting sleeve are disengaged from the
tubular stinger
3208. As a result, the tubular stinger 3208 of the setting tool assembly 32
may then be
displaced downwardly into complete engagement with the tubular sliding sleeve
valve 3650.
[0310] In an exemplary embodiment, as illustrated in Figs. 19G1 to 19G6, a
fluidic
material 36114 is then injected into the setting tool assembly 32 and the
packer assembly 36
through the longitudinal passages 3202a, 3204b, 3206b, 3208b, 3604b, 3650a,
and 3646b
of the tubular adaptor 3202, tubular upper mandrel 3204, tubular mandrel 3206,
tubular
stinger 3208, tubular upper mandrel 3604, tubular sliding sleeve valve 3650,
and tubular
lower mandrel 3646, respectively. Because, the plug 36104 is seated within and
blocks the
longitudinal passage 3664a of the tubular plug seat 3664, the longitudinal
passages 3604b,
3650a, and 3646b of the tubular upper mandrel 3604, tubular sliding sleeve
valve 3650, and
tubular lower mandrel 3646 are pressurized thereby displacing the tubular
upper adaptor
3602 and tubular upper mandrel 3604 downwardly until the end face of the
tubular upper
mandrel impacts the end face of the upper tubular spacer ring 3606.
[0311] In an exemplary embodiment, as illustrated in Figs. 19H1 to 19H5, the
setting tool
assembly 32 is brought back into engagement with the packer assembly 36 until
the
engagement shoulder 3208e of the other end of the tubular stinger 3208 engages
the collet
fingers 3650d of the end of the tubular sliding sleeve valve 3650. As a
result, further
downward displacement of the tubular stinger 3208 displaces the tubular
sliding sleeve valve
3650 downwardly until the radial flow ports, 3650b and 3650c, of the tubular
sliding sleeve
valve are aligned with the flow ports, 3646e and 3646f, of the tubular lower
mandrel 3646. A
hardenable fluidic sealing material 36116 may then be injected into the
setting tool assembly
32 and the packer assembly 36 through the longitudinal passages 3202a, 3204b,
3206b,

CA 02522918 2007-08-27
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3208b, and 3650a of the tubular adaptor 3202, tubular upper mandrel 3204,
tubular mandrel
3206, tubular stinger 3208, and tubular sliding sleeve valve 3650,
respectively. The
hardenable fluidic sealing material may then flow out of the packer assembly
36 through the
upper flow ports, 3658d and 3658e, into the annulus between the expandable
welibore
casing 100 and the wellbore 102.
[0312] The tubular sliding sleeve valve 3650 may then be retumed to its
original
position, with the radial flow ports, 3650b and 3650c, of the tubular sliding
sleeve valve out
of alignment with the flow ports, 3646e and 3646f, of the tubular lower
mandrel 3646. The
hardenable fluidic sealing material 36116 may then be allowed to cure before,
during, or
after the continued operation of the system 10 to further radially expand and
plastically
deform the expandable wellbore casing.
[0313] In an exemplary embodiment, the system 10 is provided as illustrated in
Appendix A to the present application.
[0314] An apparatus for radially expanding and plastically deforming an
expandable
tubular member has been described that includes a support member, a cutting
device for
cutting the tubular member coupled to the support member, and an expansion
device for
radially expanding and plastically deforming the tubular member coupled to the
support
member. In an exemplary embodiment, the apparatus further includes a gripping
device for
gripping the tubular member coupled to the support member. In an exemplary
embodiment,
the gripping device comprises a plurality of movable gripping elements. In an
exemplary
embodiment, the gripping elements are moveable in a radial direction relative
to the support
member. In an exemplary embodiment, the gripping elements are moveable in an
axial
direction relative to the support member. In an exemplary embodiment, the
gripping
elements are moveable in a radial and an axial direction relative to the
support member. In
an exemplary embodiment, the gripping elements are moveable from a first
position to a
second position; wherein in the first position, the gripping elements do not
engage the
tubular member; wherein in the second position, the gripping elements do
engage the
tubular member; and wherein, during the movement from the first position to
the second
position, the gripping elements move in a radial and an axial direction
relative to the support
member. In an exemplary embodiment, the gripping elements are moveable from a
first
position to a second position; wherein in the first position, the gripping
elements do not
engage the tubular member, wherein in the second position, the gripping
elements do
engage the tubular member; and wherein, during the movement from the first
position to the
second position, the gripping elements move in a radial direction relative to
the support
member. In an exemplary embodiment, the gripping elements are moveable from a
first
position to a second position; wherein in the first position, the gripping
elements do not
engage the tubular member, wherein in the, second position, the gripping
elements do
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engage the tubular member; and wherein, during the movement from the first
position to the
second position, the gripping elements move in an axial direction relative to
the support
member. In an exemplary embodiment, if the tubular member is displaced in a
first axial
direction, the gripping device grips the tubular member, and, if the tubular
member is
displaced in a second axial direction, the gripping device does not grip the
tubular member.
In an exemplary embodiment, the gripping elements are moveable from a first
position to a
second position; wherein in the first position, the gripping elements do not
engage the
tubular member; wherein in the second position, the gripping elements do
engage the
tubular member; and wherein, the gripping elements are biased to remain in the
first
position. In an exemplary embodiment, the gripping device further includes an
actuator for
moving the gripping elements from a first position to a second position;
wherein in the first
position, the gripping elements do not engage the tubular member; wherein in
the second
position, the gripping elements do engage the tubular member; and
[0315] wherein the actuator is a fluid powered actuator. In an exemplary
embodiment,
the apparatus further includes a sealing device for sealing an interface with
the tubular
member coupled to the support member. In an exemplary embodiment, the sealing
device
seals an annulus defines between the support member and the tubular member. In
an
exemplary embodiment, the apparatus further includes a locking device for
locking the
position of the tubular member relative to the support member. In an exemplary
embodiment, the apparatus further includes a packer assembly coupled to the
support
member. In an exemplary embodiment, the packer assembly includes a packer; and
a
packer control device for controlling the operation of the packer coupled to
the support
member. In an exemplary embodiment, the packer includes: a support member
defining a
passage; a shoe comprising a float valve coupled to an end of the support
member; one or
more compressible packer elements movably coupled to the support member; and a
sliding
sleeve valve movably positioned within the passage of the support member. In
an
exemplary embodiment, the packer control device includes a support member, one
or more
drag blocks releasably coupled to the support member, and a stinger coupled to
the support
member for engaging the packer. In an exemplary embodiment, the packer
includes a
support member defining a passage; a shoe comprising a float valve coupled to
an end of
-the support member; one or more compressible packer elements movably coupled
to the
support member; and a sliding sleeve valve positioned within the passage of
the support
member; and wherein the packer control device includes: a support member; one
or more
drag blocks releasably coupled to the support member; and a stinger coupled to
the support
member for engaging the sliding sleeve valve. In an exemplary embodiment, the
apparatus
further includes an actuator for displacing the expansion device relative to
the support
member. In an exemplary embodiment, the actuator includes a first actuator for
pulling the
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expansion device; and a second actuator for pushing the expansion device. In
an exemplary
embodiment, the actuator includes means for transferring torsional loads
between the
support member and the expansion device. In an exemplary embodiment, the first
and
second actuators include means for transferring torsional loads between the
support
member and the expansion device. In an exemplary embodiment, the actuator
includes a
plurality of pistons positioned within corresponding piston chambers. In an
exemplary
embodiment, the cutting device includes a support member, and a plurality of
movable
cutting elements coupled to the support member. ln an exemplary embodiment,
the
apparatus further includes an actuator coupled to the support member for
moving the cutting
elements between a first position and a second position; wherein in the first
position, the
cutting elements do not engage the tubular member; and wherein in the second
position, the
cutting elements engage the tubular member. In an exemplary embodiment, the
apparatus
further includes a sensor coupled to the support member for sensing the
internal diameter of
the tubular member. In an exemplary embodiment, the sensor prevents the
cutting elements
from being moved to the second position if the internal diameter of the
tubular member is
less than a predetermined value. In an exemplary embodiment, the cutting
elements
includes a first set of cutting elements; and a second set of cutting
elements; wherein the
first set of cutting elements are interleaved with the second set of cutting
elements. In an
exemplary embodiment, in the first position, the first set of cutting elements
are not axially
aligned with the second set of cutting elements. In an exemplary embodiment,
in the second
position, the first set of cutting elements are axially aligned with the
second set of cutting
elements. In an exemplary embodiment, the expansion device includes a support
member,
and a plurality of movable expansion elements coupled to the support member.
In an
exemplary embodiment, apparatus further includes an actuator coupled to the
support
member for moving the expansion elements between a first position and a second
position;
wherein in the first position, the expansion elements do not engage the
tubular member; and
wherein in the second position, the expansion elements engage the tubular
member. In an
exemplary embodiment, the apparatus further includes a sensor coupled to the
support
member for sensing the internal diameter of the tubular member. In an
exemplary
embodiment, the sensor prevents the expansion elements from being moved to the
second
position if the internal diameter of the tubular member is less than a
predetermined value. In
an exemplary embodiment, the expansion elements include a first set of
expansion
elements; and a second set of expansion elements; wherein the first set of
expansion
elements are interleaved with the second set of expansion elements. In an
exemplary
embodiment, in the first position, the first set of expansion elements are not
axially aligned
with the second set of expansion elements. In an exemplary embodiment, in the
second
position, the first set of expansion elements are axially aligned with the
second set of
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expansion elements. In an exemplary embodiment, the expansion device includes
an
adjustable expansion device. In an exemplary embodiment, the expansion device
includes a
plurality of expansion devices. In an exemplary embodiment, at least one of
the expansion
devices includes an adjustable expansion device. In an exemplary embodiment,
the
adjustable expansion device includes a support member, and a plurality of
movable
expansion elements coupled to the support member. In an exemplary embodiment,
the
apparatus further includes an actuator coupled to the support member for
moving the
expansion elements between a first position and a second position; wherein in
the first
position, the expansion elements do not engage the tubular member; and wherein
in the
second position, the expansion elements engage the tubular member. In an
exemplary
embodiment, the apparatus further includes a sensor coupled to the support
member for
sensing the internal diameter of the tubular member. In an exemplary
embodiment, the
sensor prevents the expansion elements from being moved to the second position
if the
internal diameter of the tubular member is less than a predetennined value. In
an exemplary
embodiment, the expansion elements include a first set of expansion elements;
and a
second set of expansion elements; wherein the first set of expansion elements
are
interleaved with the second set of expansion elements. In an exemplary
embodiment, in the
first position, the first set of expansion elements are not axially aligned
with the second set of
expansion elements. In an exemplary embodiment, in the second position, the
first set of
expansion elements are axially aligned with the second set of expansion
elements.
[0316j An apparatus for radially expanding and plastically deforming an
expandable
tubular member has been described that includes a support member, an expansion
device
for radially expanding and plastically deforming the tubular member coupled to
the support
member, and an actuator coupled to the support member for displacing the
expansion
device relative to the support member. In an exemplary embodiment, the
apparatus further
includes a cutting device coupled to the support member for cutting the
tubular member. In
an exemplary embodiment, the cutting device includes a support member, and a
plurality of
movable cutting elements coupled to the support member. In an exemplary
embodiment,
the apparatus further includes an actuator coupled to the support member for
moving the
cutting elements between a first position and a second position; wherein in
the first position,
the cutting elements do not engage the tubular member, and wherein in the
second position,
the cutting elements engage the tubular member. In an exemplary embodiment,
the
apparatus further includes a sensor coupled to the support member for sensing
the intemal
diameter of the tubular member. In an exemplary embodiment, the sensor
prevents the
cutting elements from being moved to the second position if the intemal
diameter of the
tubular member is less than a predetermined value. In an exemplary embodiment,
the
cutting elements include a first set of cutting elements; and a second set of
cutting elements;
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wherein the first set of cutting elements are interleaved with the second set
of cutting
elements. In an exemplary embodiment, in the first position, the first set of
cutting elements
are not axially aligned with the second set of cutting elements. In an
exemplary
embodiment, in the second position, the first set of cutting elements are
axially aligned with
the second set of cutting elements. In an exemplary embodiment, the apparatus
further
includes a gripping device for gripping the tubular member coupled to the
support member.
In an exemplary embodiment, the gripping device includes a plurality of
movable gripping
elements. In an exemplary embodiment, the gripping elements are moveable in a
radial
direction relative to the support member. In an exemplary embodiment, the
gripping
elements are moveable in an axial direction relative to the support member. In
an exemplary
embodiment, the gripping elements are moveable in a radial and an axial
direction relative to
the support member. In an exemplary embodiment, the gripping elements are
moveable
from a first position to a second position; wherein in the first position, the
gripping elements
do not engage the tubular member; wherein in the second position, the gripping
elements do
engage the tubular member; and wherein, during the movement from the first
position to the
second position, the gripping elements move in a radial and an axial direction
relative to the
support member. In an exemplary embodiment, the gripping elements are moveable
from a
first position to a second position; wherein in the first position, the
gripping elements do not
engage the tubular member; wherein in the second position, the gripping
elements do
engage the tubular member; and wherein, during the movement from the first
position to the
second position, the gripping elements move in a radial direction relative to
the support
member. In an exemplary embodiment, the gripping elements are moveable from a
first
position to a second position; wherein in the first position, the gripping
elements do not
engage the tubular member; wherein in the second position, the gripping
elements do
engage the tubular member; and wherein, during the movement from the first
position to the
second position, the gripping elements move in an axial direction relative to
the support
member. In an exemplary embodiment, if the tubular member is displaced in a
first axial
direction, the gripping device grips the tubular member, and wherein, if the
tubular member
is displaced in a second axial direction, the gripping device does not grip
the tubular
member. In an exemplary embodiment, the gripping elements are moveable from a
first
position to a second position; wherein in the first position, the gripping
elements do not
engage the tubular member; wherein in the second position, the gripping
elements do
engage the tubular member; and wherein, the gripping elements are biased to
remain in the
first position. In an exemplary embodiment, the gripping device further
includes an actuator
for moving the gripping elements from a first position to a second position;
wherein in the
first position, the gripping elements do not engage the tubular member,
wherein in the
second position, the gripping elements do engage the tubular member; and
wherein the

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actuator is a fluid powered actuator. In an exemplary embodiment, the
apparatus further
includes a sealing device for sealing an interface with the tubular member
coupled to the
support member. In an exemplary embodiment, the sealing device seals an
annulus defines
between the support member and the tubular member. In an exemplary embodiment,
the
apparatus further includes a locking device for locking the position of the
tubular member
relative to the support member. In an exemplary embodiment, the apparatus
further
includes a packer assembly coupled to the support member. In an exemplary
embodiment,
the packer assembly includes a packer; and a packer control device for
controlling the
operation of the packer coupled to the support member. In an exemplary
embodiment, the
packer includes a support member defining a passage; a shoe comprising a float
valve
coupled to an end of the support member; one or more compressible packer
elements
movably coupled to the support member; and a sliding sleeve valve movably
positioned
within the passage of the support member. In an exemplary embodiment, the
packer control
device includes a support member; one or more drag blocks releasably coupled
to the
support member; and a stinger coupled to the support member for engaging the
packer. In
an exemplary embodiment, the packer includes a support member defining a
passage; a
shoe comprising a float valve coupled to an end of the support member; one or
more
compressible packer elements movably coupled to the support member; and a
sliding sleeve
valve positioned within the passage of the support member; and wherein the
packer control
device comprises: a support member, one or more drag blocks releasably coupled
to the
support member; and a stinger coupled to the support member for engaging the
sliding
sleeve valve. In an exemplary embodiment, the expansion device includes a
support
member; and a plurality of movable expansion elements coupled to the support
member. In
an exemplary embodiment, the apparatus further includes an actuator coupled to
the support
member for moving the expansion elements between a first position and a second
position;
wherein in the first position, the expansion elements do not engage the
tubular member; and
wherein in the second position, the expansion elements engage the tubular
member. In an
exemplary embodiment, the apparatus further includes a sensor coupled to the
support
member for sensing the intemal diameter of the tubular member. In an exempiary
embodiment, the sensor prevents the expansion elements from being moved to the
second
position if the internal diameter of the tubular member is less than a
predetermined value. In
an exemplary embodiment, the expansion elements include a first set of
expansion
elements; and a second set of expansion elements; wherein the first set of
expansion
elements are interleaved with the second set of expansion elements. In an
exemplary
embodiment, the in the first position, the first set of expansion elements are
not axially
aligned with the second set of expansion elements. In an exemplary embodiment,
in the
second position, the first set of expansion elements are axially aligned with
the second set of
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expansion elements. in an exemplary embodiment, the expansion device includes
an
adjustable expansion device. In an exemplary embodiment, the expansion device
includes a
plurality of expansion devices. In an exemplary embodiment, at least one of
the expansion
devices includes an adjustable expansion device. In an exemplary embodiment,
the
adjustable expansion device includes a support member, and a plurality of
movable
expansion elements coupled to the support member. In an exemplary embodiment,
the
apparatus further includes an actuator coupled to the support member for
moving the
expansion elements between a first position and a second position; wherein in
the first
position, the expansion elements do not engage the tubular member; and wherein
in the
second posifiion, the expansion elements engage the tubular member. In an
exemplary
embodiment, the apparatus further includes a sensor coupled to the support
member for
sensing the internal diameter of the tubular member. In an exemplary
embodiment, the
sensor prevents the expansion elements from being moved to the second position
if the
internal diameter of the tubular member is less than a predetermined value. In
an exemplary
embodiment, the expansion elements include a first set of expansion elements;
and a
second set of expansion elements; wherein the first set of expansion elements
are
interleaved with the second set of expansion elements. In an exemplary
embodiment, in the
first position, the first set of expansion elements are not axially aligned
with the second set of
expansion elements. In an exemplary embodiment, in the second position, the
first set of
expansion elements are axially aligned with the second set of expansion
elements.
[0317] An apparatus for radially expanding and plastically deforming an
expandable
tubular member has been described that includes a support member; an expansion
device
for radially expanding and plastically deforming the tubular member coupled to
the support
member; and a sealing assembly for sealing an annulus defined between the
support
member and the tubular member. In an exemplary embodiment, the apparatus
further
includes a gripping device for gripping the tubular member coupled to the
support member.
In an exemplary embodiment, the gripping device includes a plurality of
movable gripping
elements. In an exemplary embodiment, the gripping elements are moveable in a
radial
direction relative to the support member. In an exemplary embodiment, the
gripping
elements are moveable in an axial direction relative to the support member. In
an exemplary
embodiment, the gripping elements are moveable in a radial and an axial
direction relative to
the support member. In an exemplary embodiment, the gripping elements are
moveable
from a first position to a second position; wherein in the first position, the
gripping elements
do not engage the tubular member; wherein in the second position, the gripping
elements do
engage the tubular member; and wherein, during the movement from the first
position to the
second position, the gripping elements move in a radial and an axial direction
relative to the
support member. In an exemplary embodiment, the gripping elements are moveable
from a
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first position to a second position; wherein in the first position, the
gripping elements do not
engage the tubular member; wherein in the second position, the gripping
elements do
engage the tubular member, and wherein, during the movement from the first
position to the
second position, the gripping elements move in a radial direction relative to
the support
member. In an exemplary embodiment, the gripping elements are moveable from a
first
position to a second position; wherein in the first position, the gripping
elements do not
engage the tubular member; wherein in the second position, the gripping
elements do
engage the tubular member; and wherein, during the movement from the first
position to the
second position, the gripping elements move in an axial direction relative to
the support
member. In an exemplary embodiment, the if the tubular member is displaced in
a first axial
direction, the gripping device grips the tubular member; and wherein, if the
tubular member
is displaced in a second axial direction, the gripping device does not grip
the tubular
member. In an exemplary embodiment, the gripping elements are moveable from a
first
position to a second position; wherein in the first position, the gripping
elements do not
engage the tubular member; wherein in the second position, the gripping
elements do
engage the tubular member; and wherein, the gripping elements are biased to
remain in the
first position. In an exemplary embodiment, the gripping device further
includes an actuator
for moving the gripping elements from a first position to a second position;
wherein in the
first position, the gripping elements do not engage the tubular member;
wherein in the
second position., the gripping elements do engage the tubular member; and
wherein the
actuator is a fluid powered actuator. In an exemplary embodiment, the
apparatus further
includes a locking device for locking the position of the tubular member
relative to the
support member. In an exemplary embodiment, the apparatus further includes a
packer
assembly coupled to the support member. In an exemplary embodiment, the packer
assembly includes a packer, and a packer control device for controlling the
operation of the
packer coupled to the support member. In an exemplary embodiment, the packer
includes a
support member defining a passage; a shoe comprising a float valve coupled to
an end of
the support member; one or more compressible packer elements movably coupled
to the
support member; and a sliding sleeve valve movably positioned within the
passage of the
support member. In an exemplary embodiment, the packer control device includes
a
support member; one or more drag blocks releasably coupled to the support
member, and a
stinger coupled to the support member for engaging the packer. In an exemplary
embodiment, the packer includes a support member defining a passage; a shoe
comprising
a float valve coupled to an end of the support member; one or more
compressible packer
elements movably coupled to the support member; and a sliding sleeve valve
positioned
within the passage of the support member; and wherein the packer control
device includes a
support member; one or more drag blocks releasably coupled to the support
member; and a
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stinger coupled to the support tnember for engaging the sliding sleeve valve.
In an
exemplary embodiment, the apparatus further includes an actuator for
displacing the
expansion device relative to the support member. In an exemplary embodiment,
the
actuator includes a first actuator for pul[ing the expansion device; and a
second actuator for
pushing the expansion device. In an exemplary embodiment, the actuator
includes means
for transferring torsional loads between the support member and the expansion
device. In
an exemplary embodiment, the first and second actuators comprise means for
transferring
torsional loads between the support member and the expansion device. In an
exemplary
embodiment, the actuator includes a plurality of pistons positioned within
corresponding
piston chambers. In an exemplary embodiment, the cutting device includes a
support
member; and a plurality of movable cutting elements coupled to the support
member. In an
exemplary embodiment, the apparatus further includes an actuator coupled to
the support
member for moving the cutting elements between a first position and a second
position;
wherein in the first position, the cutting elements do not engage the tubular
member; and
wherein in the second position, the cutting elements engage the tubular
member. In an
exemplary embodiment, the apparatus further includes a sensor coupled to the
support
member for sensing the intemal diameter of the tubular member. In an exemplary
embodiment, the sensor prevents the cutting elements from being moved to the
second
position if the internal diameter of the tubular member is less than a
predetermined value. In
an exemplary embodiment, the cutting elements include a first set of cutting
elements; and a
second set of cutting elements; wherein the first set of cutting elements are
interleaved with
the second set of cutting elements. In an exemplary embodiment, in the first
position, the
first set of cutting elements are not axially aligned with the second set of
cutting elements. In
an exemplary embodiment, in the second position, the first set of cutting
elements are axially
aligned with the second set of cutting elements. In an exemplary embodiment,
the
expansion device includes a support member; and a plurality of movable
expansion
elements coupled to the support member. In an exemplary embodiment, the
apparatus
further includes an actuator coupled to the support member for moving the
expansion
elements between a first position and a second position; wherein in the first
position, the
expansion elements do not engage the tubular member; and wherein in the second
position,
the expansion elements engage the tubular member. In an exemplary embodiment,
the
apparatus further includes a sensor coupled to the support member for sensing
the internal
diameter of the tubular member. In an exemplary embodiment, the sensor
prevents the
expansion elements from being moved to the second position if the intemal
diameter of the
tubular member is less than a predetermined value. In an exemplary embodiment,
the
expansion elements includes a first set of expansion elements; and a second
set of
expansion elements; wherein the first set of expansion elements are
interleaved with the
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second set of expansion elements. In an exemplary embodiment, in the first
position, the
first set of expansion elements are not axially aligned with the second set of
expansion
elements. In an exemplary embodiment, in the second position, the first set of
expansion
elements are axially aligned with the second set of expansion elements. In an
exemplary
embodiment, the expansion device includes an adjustable expansion device. In
an
exemplary embodiment, the expansion device includes a plurality of expansion
devices. In
an exemplary embodiment, at least one of the expansion devices includes an
adjustable
expansion device. In an exemplary embodiment, the adjustable expansion device
includes a
support member; and a plurality of movable expansion elements coupled to the
support
member. In an exemplary embodiment, the apparatus further includes an actuator
coupled
to the support member for moving the expansion elements between a first
position and a
second position; wherein in the first position, the expansion elements do not
engage the
tubular member; and wherein in the second position, the expansion elements
engage the
tubular member. In an exemplary embodiment, the apparatus further includes a
sensor
coupled to the support member for sensing the internal diameter of the tubular
member. In
an exemplary embodiment, the sensor prevents the expansion elements from being
moved
to the second position if the internal diameter of the tubular member is less
than a
predetermined value. In an exemplary embodiment, the expansion elements
include a first
set of expansion elements; and a second set of expansion elements; wherein the
first set of
expansion elements are interleaved with the second set of expansion elements.
In an
exemplary embodiment, in the first position, the first set of expansion
elements are not
axially aligned with the second set of expansion elements. In an exemplary
embodiment, in
the second position, the first set of expansion elements are axially aligned
with the second
set of expansion elements.
[0318] An apparatus for radially expanding and plastically deforming an
expandable
tubular member has been described that includes a support member, a first
expansion
device for radially expanding and plastically deforming the tubular member
coupled to the
support member; and a second expansion device for radially expanding and
plastically
deforming the tubular member coupled to the support member. In an exemplary
embodiment, the apparatus further includes a gripping device for gripping the
tubular
member coupled to the support member. In an exemplary embodiment, the gripping
device
includes a plurality of movable gripping elements. In an exemplary embodiment,
the
gripping elements are moveable in a radial direction relative to the support
member. In an
exemplary embodiment, the gripping elements are moveable in an axial direction
relative to
the support member. In an exemplary embodiment, the gripping elements are
moveable in a
radial and an axial direction relative to the support member. In an exemplary
embodiment,
the gripping elements are moveable from a first position to a second position;
wherein in the

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first position, the gripping elements do not engage the tubular member;
wherein in the
second position, the gripping elements do engage the tubular member; and
wherein, during
the movement from the first position to the second position, the gripping
elements move in a
radial and an axial direction relative to the support member. In an exemplary
embodiment,
the gripping elements are moveable from a first position to a second position;
wherein in the
first position, the gripping elements do not engage the tubular member;
wherein in the
second position, the gripping elements do engage the tubular member; and
wherein, during
the movement from the first position to the second position, the gripping
elements move in a
radial direction relative to the support member. In an exemplary embodiment,
the gripping
elements are moveable from a first position to a second position; wherein in
the first position,
the gripping elements do not engage the tubular member; wherein in the second
position,
the gripping elements do engage the tubular member; and wherein, during the
movement
from the first position to the second position, the gripping elements move in
an axial direction
relative to the support member. In an exemplary embodiment, if the tubular
member is
displaced in a first axial direction, the gripping device grips the tubular
member; and wherein,
if the tubular member is displaced in a second axial direction, the gripping
device does not
grip the tubular member. In an exemplary embodiment, the gripping elements are
moveable
from a first position to a second position; wherein in the first position, the
gripping elements
do not engage the tubular member, wherein in the second position, the gripping
etements do
engage the tubular member; and wherein, the gripping elements are biased to
remain in the
first position. In an exemplary embodiment, the gripping device further
includes an actuator
for moving the gripping elements from a first position to a second position;
wherein in the
first position, the gripping elements do not engage the tubular member;
wherein in the
second position, the gripping elements do engage the tubular member; and
wherein the
actuator is a fluid powered actuator. In an exemplary embodiment, the
apparatus further
includes a sealing device for sealing an interface with the tubular member
coupled to the
support member. In an exemplary embodiment, the sealing device seals an
annulus defines
between the support member and the tubular member. In an exemplary embodiment,
the
apparatus further includes a locking device for locking the position of the
tubular member
relative to the support member. In an exemplary embodiment, the apparatus
further
includes a packer assembly coupled to the support member. In an exemplary
embodiment,
the packer assembly includes a packer; and a packer control device for
controlling the
operation of the packer coupled to the support member. In an exemplary
embodiment, the
packer includes a support member defining a passage; a shoe comprising a float
valve
coupled to an end of the support member; one or more compressible packer
elements
movably coupled to the support member, and a sliding sleeve valve movably
positioned
within the passage of the support member. In an exemplary embodiment, the
packer control
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device includes a support member; one or more drag blocks releasably coupled
to the
support member; and a stinger coupled to the support member for engaging the
packer. In
an exemplary embodiment, the packer includes a support member defining a
passage; a
shoe comprising a float valve coupled to an end of the support member; one or
more
compressible packer elements movably coupled to the support member, and a
sliding sleeve
valve positioned within the passage of the support member; and wherein the
packer control
device comprises: a support member; one or more drag blocks releasably coupled
to the
support member; and a stinger coupled to the support member for engaging the
sliding
sleeve valve. In an exemplary embodiment, the apparatus further includes an
actuator for
displacing the expansion device relative to the support member. In an
exemplary
embodiment, the actuator includes a first actuator for pulling the expansion
device; and a
second actuator for pushing the expansion device. In an exemplary embodiment,
the
actuator includes means for transferring torsional loads between the support
member and
the expansion device. In an exemplary embodiment, the first and second
actuators include
means for transferring torsional loads between the support member and the
expansion
device. In an exemplary embodiment, the actuator includes a plurality of
pistons positioned
within corresponding piston chambers. In an exemplary embodiment, the
apparatus further
includes a cutting device for cutting the tubular member coupled to the
support member. In
an exemplary embodiment, the cutting device includes a support member; and a
plurality of
movable cutting elements coupled to the support member. In an exemplary
embodiment,
the apparatus further includes an actuator coupled to the support member for
moving the
cutting elements between a first position and a second position; wherein in
the first posifion,
the cutting elements do not engage the tubular member; and wherein in the
second position,
the cutting elements engage the tubular member. In an exemplary embodiment,
the
apparatus further includes a sensor coupled to the support member for sensing
the internal
diameter of the tubular member. In an exemplary embodiment, the sensor
prevents the
cutting elements from being moved to the second position if the intemal
diameter of the
tubular member is less than a predetermined value. In an exemplary embodiment,
the
cutting elements include a first set of cutting elements; and a second set of
cutting elements;
wherein the first set of cutting elements are interleaved with the second set
of cutting
elements. In an exemplary embodiment, in the first position, the first set of
cutting elements
are not axially aligned with the second set of cutting elements. In an
exemplary
embodiment, in the second position, the first set of cutting elements are
axially aligned with
the second set of cutting elements. In an exemplary embodiment, at least one
of the first
second expansion devices include a support member; and a plurality of movable
expansion
elements coupled to the support member. In an exemplary embodiment, the
apparatus
further includes an actuator coupled to the support member for moving the
expansion
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elements between a first position and a second position; wherein in the first
position, the
expansion elements do not engage the tubular member, and wherein in the second
position,
.the expansion elements engage the tubular member. In an exemplary embodiment,
the
apparatus further includes a sensor coupled to the support member for sensing
the internal
diameter of the tubular member. In an exemplary embodiment, the sensor
prevents the
expansion elements from being moved to the second position if the internal
diameter of the
tubular member is less than a predetermined value. In an exemplary embodiment,
the
expansion elements include a first set of expansion elements; and a second set
of
expansion elements; wherein the first set of expansion elements are
interleaved with the
second set of expansion elements. In an exemplary embodiment, in the first
position, the
first set of expansion elements are not axially aligned with the second set of
expansion
elements. In an exemplary embodiment, in the second position, the first set of
expansion
elements are axially aligned with the second set of expansion elements. In an
exemplary
embodiment, at least one of the first and second expansion devices comprise a
plurality of
expansion devices. In an exemplary embodiment, at least one of the first and
second
expansion device comprise an adjustable expansion device. In an exemplary
embodiment,
the adjustable expansion device includes a support member, and a plurality of
movable
expansion elements coupled to the support member. In an exemplary embodiment,
the
apparatus further includes an actuator coupled to the support member for
moving the
expansion elements between a first position and a second position; wherein in
the first
position, the expansion elements do not engage the tubular member, and wherein
in the
second position, the expansion elements engage the tubular member. In an
exemplary
embodiment, the apparatus further includes a sensor coupled to the support
member for
sensing the intemal diameter of the tubular member. In an exemplary
embodiment, the
sensor prevents the expansion elements from being moved to the second position
if the
internal diameter of the tubular member is less than a predetermined value. In
an exemplary
embodiment, the expansion elements include a first set of expansion elements;
and a
second set of expansion elements; wherein the first set of expansion elements
are
interleaved with the second set of expansion elements. In an exemplary
embodiment, in the
first position, the first set of expansion elements are not axially aligned
with the second set of
expansion elements. In an exemplary embodiment, in the second position, the
first set of
expansion elements are axially aligned with the second set of expansion
elements.
(0319] An apparatus for radially expanding and plastically deforming an
expandable
tubular member has been described that includes a support member; an expansion
device
for radially expanding and plastically deforming the tubular member coupled to
the support
member; and a packer coupled to the support member. In an exemplary
embodiment, the
apparatus further includes a gripping device for gripping the tubular member
coupled to the
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support member. In an exemplary embodiment, the gripping device comprises a
plurality of
movable gripping elements. In an exemplary embodiment, the gripping elements
are
moveable in a radial direction relative to the support member. In an exemplary
embodiment,
the gripping elements are moveable in an axial direction relative to the
support member. In
an exemplary embodiment, the gripping elements are moveable in a radial and an
axial
direction relative to the support member. In an exemplary embodiment, the
gripping
elements are moveable from a first position to a second position; wherein in
the first position,
the gripping elements do not engage the tubular member; wherein in the second
position,
the gripping elements do engage the tubular member; and wherein, during the
movement
from the first position to the second position, the gripping elements move in
a radial and an
axial direction relative to the support member. In an exemplary embodiment,
the gripping
elements are moveable from a first position to a second position; wherein in
the first position,
the gripping elements do not engage the tubular member; wherein in the second
position,
the gripping elements do engage the tubular member; and wherein, during the
movement
from the first position to the second position, the gripping elements move in
a radial direction
relative to the support member. In an exemplary embodiment, the gripping
elements are
moveable from a first position to a second position; wherein in the first
position, the gripping
elements do not engage the tubular member, wherein in the second position, the
gripping
elements do engage the tubular member, and wherein, during the movement from
the first
position to the second position, the gripping elements move in an axial
direction relative to
the support member. In an exemplary embodiment, if the tubular member is
displaced in a
first axial direction, the gripping device grips the tubular member; and
wherein, if the tubular
member is displaced in a second axial direction, the gripping device does not
grip the tubular
member. In an exemplary embodiment, the gripping elements are moveable from a
first
position to a second position; wherein in the first position, the gripping
elements do not
engage the tubular member; wherein in the second position, the gripping
elements do
engage the tubular member; and wherein, the gripping elements are biased to
remain in the
first position. In an exemplary embodiment, the gripping device further
includes an actuator
for moving the gripping elements from a first position to a second position;
wherein in the
first position, the gripping elements do not engage the tubular member;
wherein in the
second position, the gripping elements do engage the tubular member; and
wherein the
actuator is a fluid powered actuator. In an exemplary embodiment, the
apparatus further
includes a sealing device for sealing an interface with the tubular member
coupled to the
support member. In an exemplary embodiment, the sealing device seals an
annulus defines
betv/een the support member and the tubular member. In an exemplary
embodiment, the
apparatus further includes a locking device for locking the position of the
tubular member
relative to the support member. In an exemplary embodiment, the packer
assembly includes
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a packer, and a packer control device for controlling the operation of the
packer coupled to
the support member. In an exemplary embodiment, the packer includes a support
member
defining a passage; a shoe comprising a float valve coupled to an end of the
support
member; one or more compressible packer elements movably coupled to the
support
member; and a sliding sleeve valve movably positioned within the passage of
the support
member. In an exemplary embodiment, the packer control device includes a
support
member; one or more drag blocks releasably coupled to the support member; and
a stinger
coupled to the support member for engaging the packer. In an exemplary
embodiment, the
packer includes a support member defining a passage; a shoe comprising a float
valve
coupled to an end of the support member; one or more compressible packer
elements
movably coupled to the support member; and a sliding sleeve valve positioned
within the
passage of the support member; and wherein the packer control device includes
a support
member; one or more drag blocks releasably coupled to the support member; and
a stinger
coupled to the support member for engaging the sliding sleeve valve. In an
exemplary
embodiment, the apparatus further includes an actuator for displacing the
expansion device
relative to the support member. In an exemplary embodiment, the actuator
includes a first
actuator for pulling the expansion device; and a second actuator for pushing
the expansion
device. In an exemplary embodiment, the actuator includes means for
transferring torsional
loads between the support member and the expansion device. In an exemplary
embodiment, the first and second actuators include means for transferring
torsional loads
between the support member and the expansion device. In an exemplary
embodiment, the
actuator includes a plurality of pistons positioned within corresponding
piston chambers. In
an exemplary embodiment, the apparatus further includes a cutting device
coupled to the
support member for cutting the tubular member. In an exemplary embodiment, the
cutting
device includes a support member; and a plurality of movable cutting elements
coupled to
the support member. In an exemplary embodiment, the apparatus further includes
an
actuator coupled to the support member for moving the cutting elements between
a first
position and a second position; wherein in the first position, the cutting
elements do not
engage the tubular member; and wherein in the second position, the cutting
elements
engage the tubular member. In an exemplary embodiment, the apparatus further
includes a
sensor coupled to the support member for sensing the internal diameter of the
tubular
member. In an exemplary embodiment, the sensor prevents the cutting elements
from being
moved to the second position if the internal diameter of the tubular member is
less than a
predetermined value. In an exemplary embodiment, the cutting elements include
a first set
of cutting elements; and a second set of cutting elements; wherein the first
set of cutting
elements are interleaved with the second set of cutting elements. In an
exemplary
embodiment, in the first position, the first set of cutting elements are not
axially aligned with

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the second set of cutting elements. In an exemplary embodiment, in the second
position,
the first set of cutting elements are axially aligned with the second set of
cutting elements. In
= an exemplary embodiment, the expansion device includes a support member, and
a plurality
of movable expansion elements coupled to the support member. In an exemplary
embodiment, the apparatus further includes an actuator coupled to the support
member for
moving the expansion elements between a first position and a second position;
wherein in
the first position, the expansion elements do not engage the tubular member;
and wherein in
the second position, the expansion elements engage the tubular member. In an
exemplary
embodiment, the apparatus further includes a sensor coupled to the support
member for
sensing the internal diameter of the tubular member. In an exemplary
embodiment, the
sensor prevents the expansion elements from being moved to the second position
if the
internal diameter of the tubular member is less than a predetermined value. In
an exemplary
embodiment, the expansion elements include a first set of expansion elements;
and a
second set of expansion elements; wherein the first set of expansion elements
are
interleaved with the second set of expansion elements. In an exemplary
embodiment, in the
first position, the first set of expansion elements are not axially aligned
with the second set of
expansion elements. In an exemplary embodiment, in the second position, the
first set of
expansion elements are axially aligned with the second set of expansion
elements. In an
exemplary embodiment, the expansion device includes an adjustable expansion
device. In
an exemplary embodiment, the expansion device includes a plurality of
expansion devices.
In an exemplary embodiment, at least one of the expansion devices comprises an
adjustable
expansion device. In an exemplary embodiment, the adjustable expansion device
includes a
support member; and a plurality of movable expansion elements coupled to the
support
member. In an exemplary embodiment, the apparatus further includes an actuator
coupled
to the support member for moving the expansion elements between a first
position and a
second position; wherein in the first position, the expansion elements do not
engage the
tubular member; and wherein in the second position, the expansion elements
engage the
tubular member. In an exemplary embodiment, the apparatus further includes a
sensor
coupled to the support member for sensing the internal diameter of the tubular
member. In
an exemplary embodiment, the sensor prevents the expansion elements from being
moved
to the second position if the internal diameter of the tubular member is less
than a
predetermined value. In an exemplary embodiment, the expansion elements
include a first
set of expansion elements; and a second set of expansion elements; wherein the
first set of
expansion elements are interleaved with the second set of expansion elements.
In an
exemplary embodiment, in the first position, the first set of expansion
elements are not
axially aligned with the second set of expansion elements. In an exemplary
embodiment, in
the second position, the first set of expansion elements are axially aligned
with the second
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set of expansion elements.
[0320] An apparatus for radially expanding and plastically deforming an
expandable
tubular member has been described that includes a support member; a cutting
device for
cutting the tubular member coupled to the support member, a gripping device
for gripping
the tubular member coupled to the support member; a sealing device for sealing
an interface
with the tubular member coupled to the support member; a locking device for
locking the
position of the tubular member relative to the support member; a first
adjustable expansion
device for radially expanding and plastically deforming the tubular member
coupled to the
support member; a second adjustable expansion device for radially expanding
and
plastically deforming the tubular member coupled to the support member; a
packer coupled
to the support member; and an actuator for displacing one or more of the
sealing assembly,
first and second adjustable expansion devices, and packer relative to the
support member.
In an exemplary embodiment, the gripping device includes a plurality of
movable gripping
elements. In an exemplary embodiment, the gripping elements are moveable in a
radial
direction relative to the support member. In an exemplary embodiment, the
gripping
elements are moveable in an axial direction relative to the support member. In
an exemplary
embodiment, the gripping elements are moveable in a radial and an axial
direction relative to
the support member. In an exemplary embodiment, the gripping elements are
moveable
from a first position to a second position; wherein in the first position, the
gripping elements
do not engage the tubular member, wherein in the second position, the gripping
elements do
engage the tubular member; and wherein, during the movement from the first
position to the
second position, the gripping elements move in a radial and an axial direction
relative to the
support member. ln an exemplary embodiment, the gripping elements are moveable
from a
first position to a second position; wherein in the first position, the
gripping elements do not
engage the tubular member; wherein in the second position, the gripping
elements do
engage the tubular member; and wherein, during the movement from the first
position to the
second position, the gripping elements move in a radial direction relative to
the support
member. In an exemplary embodiment, the gripping elements are moveable from a
first
position to a second position; wherein in the first position, the gripping
elements do not
engage the tubular member; wherein in the second position, the gripping
elements do
engage the tubular member; and wherein, during the movement from the first
position to the
second position, the gripping elements move in an axial direction relative to
the support
member. In an exemplary embodiment, if the tubular member is displaced in a
first axial
direction, the gripping device grips the tubular member; and wherein, if the
tubular member
is displaced in a second axial direction, the gripping device does not grip
the tubular
member. !n an exemplary embodiment, the gripping elements are moveable from a
first
position to a second position; wherein in the first position, the gripping
elements do not
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engage the tubular member; wherein in the second posltion, the gripping
elements do
engage the tubular member; and wherein, the gripping elements are biased to
remain in the
first position. In an exemplary embodiment, the gripping device further
includes an actuator
for moving the gripping elements from a first position to a second position;
wherein in the
first position, the gripping elements do not engage the tubular member;
wherein in the
second position, the gripping elements do engage the tubular member; and
wherein the
actuator is a fluid powered actuator. In an exemplary embodiment, the sealing
device seals
an annulus defines between the support member and the tubular member. In an
exemplary
embodiment, the packer assembly includes a packer, and a packer control device
for
controlling the operation of the packer coupled to the support member. In an
exemplary
embodiment, the packer includes a support member defining a passage; a shoe
comprising
a float valve coupled to an end of the support member; one or more
compressible packer
elements movably coupled to the support member; and a sliding sleeve valve
movably
positioned within the passage of the support member. In an exemplary
embodiment, the
packer control device includes a support member; one or more drag blocks
releasably
coupled to the support member; and a stinger coupled to the support member for
engaging
the packer. In an exemplary embodiment, the packer includes a support member
defining a
passage; a shoe comprising a float valve coupled to an end of the support
member; one or
more compressible packer elements movably coupled to the support member; and a
sliding
sleeve valve positioned within the passage of the support member, and wherein
the packer
control device includes a support member; one or more drag blocks releasably
coupled to
the support member, and a stinger coupled to the support member for engaging
the sliding
sleeve valve. In an exemplary embodiment, the actuator includes a first
actuator for pulling
the expansion device; and a second actuator for pushing. the expansion device.
In an
exemplary embodiment, the actuator includes means for transfening torsional
loads between
the support member and the expansion device. In an exemplary embodiment, the
first and
second actuators include means for transferring torsional loads between the
support
member and the expansion device. In an exemplary embodiment, the actuator
includes a
plurality of pistons positioned within corresponding piston chambers. In an
exemplary
embodiment, the cutting device includes a support member; and a plurality of
movable
cutting elements coupled to the support member. In an exemplary embodiment,
the
apparatus further includes an actuator coupled to the support member for
moving the cutting
elements between a first position and a second position; wherein in the first
position, the
cutting elements do not engage the tubular member, and wherein in the second
position, the
cutting elements engage the tubular member. In an exemplary embodiment, the
apparatus
further includes a sensor coupled to the support member for sensing the
intemal diameter of
the tubular member. In an exemplary embodiment, the sensor prevents the
cutting elements
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from being moved to the second position if the internal diameter of the
tubular member is
'less than a predetermined value. In an exemplary embodiment, the cutting
elements include
a first set of cutting elements; and a second set of cutting elements; wherein
the first set of
cutting elements are interleaved with the second set of cutting elements. In
an exemplary
embodiment, in the first position, the first set of cutting elements are not
axially aligned with
the second set of cutting elements. In an exemplary embodiment, in the second
position,
the first set of cutting elements are axially aiigned with the second set of
cutting elements. In
an exemplary embodiment, at least one of the adjustable expansion devices
include a
support member; and a plurality of movable expansion elements coupled to the
support
member. In an exemplary embodiment, the apparatus further includes an actuator
coupled
to the support member for moving the expansion elements between a first
position and a
second position; wherein in the first position, the expansion elements do not
engage the
tubular member, and wherein in the second position, the expansion elements
engage the
tubular member. In an exemplary embodiment, the apparatus further includes a
sensor
coupled to the support member for sensing the internal diameter of the tubular
member. In
an exemplary embodiment, the sensor prevents the expansion elements from being
moved
to the second position if the internal diameter of the tubular member is less
than a
predetermined value. In an exemplary embodiment, the expansion elements
include a first
set of expansion elements; and a second set of expansion elements; wherein the
first set of
expansion elements are interleaved with the second set of expansion elements.
In an
exemplary embodiment, in the first position, the first set of expansion
elements are not
axially aligned with the second set of expansion elements. In an exemplary
embodiment, in
the second position, the first set of expansion elements are axially aligned
with the second
set of expansion elements. In an exemplary embodiment, at least one of the
adjustable
expansion devices comprise a plurality of expansion devices. In an exemplary
embodiment,
at least one of the adjustable expansion devices include a support member; and
a plurality of
movable expansion elements coupled to the support member. In an exemplary
embodiment, the apparatus further includes an actuator coupled to the support
member for
moving the expansion elements between a first position and a second position;
wherein in
the first position, the expansion elements do not engage the tubular member;
and wherein in
the second position, the expansion elements engage the tubular member. In an
exemplary
embodiment, the apparatus further includes a sensor coupled to the support
member for
sensing the internal diameter of the tubular member. In an exemplary
embodiment, the
sensor prevents the expansion elements from being moved to the second position
if the
internal diameter of the tubular member is less than a predetermined value. In
an exemplary
embodiment, the expansion elements include a first set of expansion elements;
and a
second set of expansion elements; wherein the first set of expansion elements
are
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interleaved with the second set of expansion elements. In an exemplary
embodiment, in the
first position, the first set of expansion elements are not axially aligned
with the second set of
~expansion elements. In an exemplary embodiment, in the second position, the
first set of
expansion elements are axially aligned with the second set of expansion
elements.
[0321a An apparatus for cutting a tubular member has been described that
includes a
support member; and a plurality of movable cutting elements coupled to the
support
member. In an exemplary embodiment, the apparatus further includes an actuator
coupled
to the support member for moving the cutting elements between a first position
and a second
position; wherein in the first position, the cutting elements do not engage
the tubular
member; and wherein in the second position, the cutting elements engage the
tubular
member. In an exemplary embodiment, the apparatus further includes a sensor
coupled to
the support member for sensing the internal diameter of the tubular member. In
an
exemplary embodiment, the sensor prevents the cutting elements from being
moved to the
second position if the intemal diameter of the tubular member is less than a
predetermined
value. In an exemplary embodiment, the cutting elements include a first set of
cutting
elements; and a second set of cutting elements; wherein the first set of
cutting elements are
interleaved with the second set of cutting elements. In an exemplary
embodiment, in the first
position, the first set of cutting elements are not axially aligned with the
second set of cutting
elements. In an exemplary embodiment, in the second position, the first set of
cutting
elements are axially aligned with the second set of cutting elements.
[0322] An apparatus for engaging a tubular member has been described that
includes a
support member; and a plurality of movable elements coupled to the support
member. In an
exemplary embodiment, the apparatus further includes an actuator coupled to
the support
member for moving the elements between a first position and a second position;
wherein in
the first position, the elements do not engage the tubular member; and wherein
in the
second position, the elements engage the tubular member. In an exemplary
embodiment,
the apparatus further includes a sensor coupled to the support member for
sensing the
intemal diameter of the tubular member. In an exemplary embodiment, the sensor
prevents
the elements from being moved to the second position if the intemal diameter
of the tubular
member is less than a predetenrined value. In an exemplary embodiment, the
elements
include a first set of elements; and a second set of elements; wherein the
first set of
elements are interleaved with the second set of elements. In an exemplary
embodiment, in
the first position, the first set of elements are not axially aligned with the
second set of
elements. In an exemplary embodiment, in the second position, the first set of
elements are
axially aligned with the second set of elements.
[0323] An apparatus for gripping a tubular member has been described that
includes a
plurality of movable gripping elements. In an exemplary embodiment, the
gripping elements

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are moveable in a radial direction. In an exemplary embodiment, the gripping
elements are
.moveable in an axial direction. In an exemplary embodiment, the gripping
elements are
=moveable from a first position to a second position; wherein in the first
position, the gripping
elements do not engage the tubular member; wherein in the second position, the
gripping
elements do engage the tubular member; and wherein, during the movement from
the first
position to the second position, the gripping eiements move in a radial and an
axial direction.
In an exemplary embodiment, the gripping elements are moveable from a first
position to a
second position; wherein in the first position, the gripping elements do not
engage the
tubular member; wherein in the second position, the gripping elements do
engage the
tubular member; and wherein, during the movement from the first position to
the second
position, the gripping elements move in a radial direction. In an exemplary
embodiment, the
gripping elements are moveable from a first position to a second position;
wherein in the first
position, the gripping elements do not engage the tubular member, wherein in
the second
position, the gripping elements do engage the tubular member, and wherein,
during the
movement from the first position to the second position, the gripping elements
move in an
axial direction. In an exemplary embodiment, in a first axial direction, the
gripping device
grips the tubular member, and wherein, in a second axial direction, the
gripping device does
not grip the tubular member. In an exemplary embodiment, the apparatus further
includes
an actuator for moving the gripping elements. In an exemplary embodiment, the
gripping
elements include a plurality of separate and distinct gripping elements.
[0324] An actuator has been described that includes a tubular housing; a
tubular piston
rod movably coupled to and at least partially positioned within the housing; a
plurality of
annular piston chambers defined by the tubular housing and the tubular piston
rod; and a
plurality of tubular pistons coupled to the tubular piston rod, each tubular
piston movably
positioned within a corresponding annular piston chamber. In an exemplary
embodiment,
the actuator further includes means for transmitting torsional loads between
the tubular
housing and the tubular piston rod.
[0326] An apparatus for controlling a packer has been described that includes
a tubular
support member; one or more drag blocks releasably coupled to the tubular
support
member, and a tubular stinger coupled to the tubular support member for
engaging the
packer. In an exemplary embodiment, the apparatus further includes a tubular
sleeve
coupled to the drag blocks. In an exemplary embodiment, the tubular support
member
includes one or more axially aligned teeth for engaging the packer.
[03261 A packer has been described that includes a support member defining a
passage; a shoe comprising a float valve coupled to an end of the support
member; one or
more compressible packer elements movably coupled to the support member, and a
sliding
sleeve valve movably positioned within the passage of the support member.
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[0327] A method of radially expanding and plastically deforming an expandable
tubular
member within a borehole having a preexisting wellbore casing has been
described that
includes positioning the tubular member within the borehole in overlapping
relation to the
wellbore casing; radially expanding and plastically deforming a portion of the
tubular member
to form a bell section; and radially expanding and plastically deforming a
portion of the
tubular member above the bell section comprising a portion of the tubular
member that
overlaps with the welibore casing; wherein the inside diameter of the bell
section is greater
than the inside diameter of the radialiy expanded and plastically deformed
portion of the
tubular member above the bell section. In an exemplary embodiment, radially
expanding
and plastically deforming a portion of the tubular member to form a bell
section includes
positioning an adjustable expansion device within the expandable tubular
member;
supporting the expandable tubular member and the adjustable expansion device
within the
borehole; lowering the adjustable expansion device out of the expandable
tubular member;
increasing the outside dimension of the adjustable expansion device; and
displacing the
adjustable expansion device upwardly relative to the expandable tubular member
n times to
radially expand and plastically deform n portions of the expandable tubular
member, wherein
n is greater than or equal to 1.
[0328] A method for forming a mono diameter wellbore casing has been described
that
includes positioning an adjustable expansion device within a first expandable
tubular
member; supporting the first expandable tubular member and the adjustable
expansion
device within a borehole; lowering the adjustable expansion device out of the
first
expandable tubular member; increasing the outside dimension of the adjustable
expansion
device; displacing the adjustable expansion device upwardly relative to the
first expandable
tubular member m times to radially expand and plastically deform m portions of
the first
expandable tubular member within the borehole; positioning the adjustable
expansion device
within a second expandable tubular member; supporting the second expandable
tubular
member and the adjustable expansion device within the borehole in overlapping
relation to
the first expandable tubular member; lowering the adjustable expansion device
out of the
second expandable tubular member, increasing the outside dimension of the
adjustable
expansion device; and displacing the adjustable expansion device upwardly
relative to the
second expandable tubular member n times to radially expand and plastically
deform n
portions of the second expandable tubular member within the borehole.
[0329] A method for radially expanding and plastically deforming an expandable
tubular
member within a borehole has been described that includes positioning an
adjustable
expansion device trOthin the expandable tubular member; supporting the
expandable tubular
member and the adjustable expansion device within the borehole; lowering the
adjustable
expansion device out of the expandable tubular member; increasing the outside
dimension
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of the adjustable expansion device; displacing the adjustable expansion
mandrel upwardly
relative to the expandable tubular member n times to radially expand and
plastically deform
n portions of the expandable tubular member within the borehole; and
pressurizing an
interior region of the expandable tubular member above the adjustable
expansion device
during the radial expansion and plastic deformation of the expandable tubular
member within
the borehole.
[0330] A method for forming a mono diameter wellbore casing has been described
that
includes positioning an adjustable expansion device within a first expandable
tubular
member; supporting the first expandable tubular member and the adjustable
expansion
device within a borehole; lowering the adjustable expansion device out of the
first
expandable tubular member, iincreasing the outside dimension of the adjustable
expansion
device; displacing the adjustable expansion device upwardly relative to the
first expandable
tubular member m times to radially expand and plastically deform m portions of
the first
expandable tubular member within the borehole; pressurizing an interior region
of the first
expandable tubular member above the adjustable expansion device during the
radial
expansion and plastic deformation of the first expandable tubular member
within the
borehole; positioning the adjustable expansion mandrel within a second
expandable tubular
member; supporting the second expandable tubular member and the adjustable
expansion
mandrel within the borehole in overlapping relation to the first expandable
tubular member,
lowering the adjustable expansion mandrel out of the second expandable tubular
member,
increasing the outside dimension of the adjustable expansion mandrel;
displacing the
adjustable expansion mandrel upwardly relative to the second expandable
tubular member n
times to radially expand and plastically deform n portions of the second
expandable tubular
member within the borehole; and pressurizing an interior region of the second
expandable
tubular member above the adjustable expansion mandrel during the radial
expansion and
plastic deformation of the second expandable tubular member within the
borehole.
[0331] A method for radially expanding and plastically deforming an expandable
tubular
member within a borehole has been described that includes positioning first
and second
adjustable expansion devices within the expandable tubular member; supporting
the
expandable tubular member and the first and second adjustable expansion
devices within
the borehole; lowering the first adjustable expansion device out of the
expandable tubular
member; increasing the outside dimension of the first adjustable expansion
device;
displacing the first adjustable expansion device upwardly relative to the
expandable tubular
member to radially expand and plastically deform a lower portion of the
expandable tubular
member; displacing the first adjustable expansion device and the second
adjustable
expansion device downwardly relative to the expandable tubular member;
decreasing the
outside dimension of the first adjustable expansion device and increasing the
outside
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dimension of the second adjustable expansion device; displacing the second
adjustable
expansion device upwardly relative to the expandable tubular member to
radially expand
and plastically deform portions of the expandable tubular member above the
lower portion of
the expandable tubular member; wherein the outside dimension of the first
adjustable
expansion device is greater than the outside dimension of the second
adjustable expansion
device.
[0332] A method for forming a mono diameter wellbore casing has been described
that
includes positioning first and second adjustable expansion devices within a
first expandable
tubular member; supporting the first expandable tubular member and the first
and second
adjustable expansion devices within a borehole; lowering the first adjustable
expansion
device out of the first expandable tubular member; increasing the outside
dimension of the
first adjustable expansion device; displacing the first adjustable expansion
device upwardly
relative to the first expandable tubular member to radially expand and
plastically deform a
lower portion of the first expandable tubular member; displacing the first
adjustable
expansion device and the second adjustable expansion device downwardly
relative to the
first expandable tubular member; decreasing the outside dimension of the first
adjustable
expansion device and increasing the outside dimension of the second adjustable
expansion
device; displacing the second adjustable expansion device upwardly relative to
the first
expandable tubular member to radially expand and plastically deform portions
of the first
expandable tubular member above the lower portion of the expandable tubular
member;
positioning first and second adjustable expansion devices within a second
expandable
tubular member, supporting the first expandable tubular member and the first
and second
adjustable expansion devices within the borehole in overlapping relation to
the first
expandable tubular member; lowering the first adjustable expansion device out
of the
second expandable tubular member; increasing the outside dimension of the
first adjustable
expansion device; displacing the first adjustable expansion device upwardly
relative to the
second expandable tubular member to radially expand and plastically deform a
lower portion
of the second expandable tubular member; displacing the first adjustable
expansion device
and the second adjustable expansion device downwardly relative to the second
expandable
tubular member, decreasing the outside dimension of the first adjustable
expansion device
and Increasing the outside dimension of the second adjustable expansion
device; and
displacing the second adjustable expansion device upwardly relative to the
second
expandable tubular member to radially expand and plastically deform portions
of the second
expandable tubular member above the lower portion of the second expandable
tubular
member; wherein the outside dimension of the first adjustable expansion device
is greater
than the outside dimension of the second adjustable expansion device.
[0333] A method for radially expanding and plastically deforming an expandable
tubular
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member within a borehole has been described that includes positioning first
and second
adjustable expansion devices within the expandable tubular member, supporting
the
,expandable tubular member and the first and second adjustable expansion
devices within
the borehole; lowering the first adjustable expansion device out of the
expandable tubular
member; increasing the outside dimension of the first adjustable expansion
device;
displacing the first adjustable expansion device upwardly relative to the
expandable tubular
member to radially expand and plastically deform a lower portion of the
expandable tubular
member; pressurizing an interior region of the expandable tubular member above
the first
adjustable expansion device during the radial expansion of the lower portion
of the
expandable tubular member by the first adjustable expansion device; displacing
the first
adjustable expansion device and the second adjustable expansion device
downwardly
relative to the expandable tubular member, decreasing the outside dimension of
the first
adjustable expansion device and increasing the outside dimension of the second
adjustable
expansion device; displacing the second adjustable expansion device upwardly
relative to
the expandable tubular member to radially expand and plastically deform
portions of the
expandable tubular member above the lower portion of the expandable tubular
member; and
pressurizing an interior region of the expandable tubular member above the
second
adjustable expansion device during the radial expansion of the portions of the
expandable
tubular member above the lower portion of the expandable tubular member by the
second
adjustable expansion device; wherein the outside dimension of the first
adjustable expansion
device is greater than the outside dimension of the second adjustable
expansion device.
[0334] A method for forming a mono diameter wellbore casing has been described
that
indudes positioning first and second adjustable expansion devices within a
first expandable
tubular member; supporting the first expandable tubular member and the first
and second
adjustable expansion devices within a borehole; lowering the first adjustable
expansion
device out of the first expandable tubular member; increasing the outside
dimension of the
first adjustable expansion device; displacing the first adjustable expansion
device upwardly
relative to the first expandable tubular member to radially expand and
plastically deform a
lower portion of the first expandable tubular member; pressurizing an interior
region of the
first expandable tubular member above the first adjustable expansion device
during the
radial expansion of the lower portion of the first expandable tubular member
by the first
adjustable expansion device; displacing the first adjustable expansion device
and the
second adjustable expansion device downwardly relative to the first expandable
tubular
member; decreasing the outside dimension of the first adjustable expansion
device and
increasing the outside dimension of the second adjustable expansion device;
displacing the
second adjustable expansion device upwardly relative to the first expandable
tubular
member to radially expand and- plastically deform portions of the first
expandable tubular
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member above the lower portion of the expandable tubular member; pressurizing
an interior
region of the first expandable tubular member above the second adjustable
expansion
device during the radial expansion of the portions of the first expandable
tubular member
above the lower portion of the first expandable tubular member by the second
adjustable
expansion device; positioning first and second adjustable expansion devices
within a second
expandable tubular member; supporting the first expandable tubular member and
the first
and second adjustable expansion devices within the borehole in overlapping
relation to the
first expandable tubular member; lowering the first adjustable expansion
device out of the
second expandable tubular member; increasing the outside dimension of the
first adjustable
expansion device; displacing the first adjustable expansion device upwardly
relative to the
second expandable tubular member to radially expand and plastically deform a
lower portion
of the second expandable tubular member; pressurizing an interior region of
the second
expandable tubular member above the first adjustable expansion device during
the radial
expansion of the lower portion of the second expandable tubular member by the
first
adjustable expansion device; displacing the first adjustable expansion device
and the
second adjustable expansion device downwardly relative to the second
expandable tubular
member; decreasing the outside dimension of the first adjustable expansion
device and
increasing the outside dimension of the second adjustable expansion device;
displacing the
second adjustable expansion device upwardly relative to the second expandable
tubular
member to radially expand and plastically deform portions of the second
expandable tubular
member above the lower portion of the second expandable tubular member; and
pressurizing an interior region of the second expandable tubular member above
the second
adjustable expansion device during the radial expansion of the portions of the
second
expandable tubular member above the lower portion of the second expandable
tubular
member by the second adjustable expansion device; wherein the outside
dimension of the
first adjustable expansion device is greater than the outside dimension of the
second
adjustable expansion device.
[0335] A method for radially expanding and plastically deforming an expandable
tubular
member within a borehole has been described that includes supporting the
expandable
tubular member, an hydraulic actuator, and an adjustable expansion device
within the
borehole; increasing the size of the adjustable expansion device; and
displacing the
adjustable expansion device upwardly relative to the expandable tubular member
using the
hydraulic actuator to radially expand and plastically deform a portion of the
expandable
tubular member. In an exemplary embodiment, the method further includes
reducing the
size of the adjustable expansion device after the portion of the expandable
tubular member
has been radially expanded and plastically deformed. In an exemplary
embodiment, the
method further includes fluidicly seating the radially expanded and
plastically deformed end
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of the expandable tubular member after reducing the size of the adjustable
expansion
device. In an exemplary embodiment, the method further includes permitting the
position of
the expandable tubular member to float relative to the position of the
hydraulic actuator after
fluidicly sealing the radially expanded and plastically deformed end of the
expandable
tubular member. In an exemplary embodiment, the method further includes
injecting a
hardenable fluidic sealing material into an annulus between the expandable
tubular member
and a preexisting structure after permitting the position of the expandable
tubular member to
fioat relative to the position of the hydraulic actuator. In an exemplary
embodiment, the
method further includes increasing the size of the adjustable expansion device
after
permitting the position of the expandable tubular member to float relative to
the position of
the hydraulic actuator. In an exemplary embodiment, the method further
includes displacing
the adjustable expansion cone upwardly relative to the expandable tubular
member to
radially expand and plastically deform another portion of the expandable
tubular member. In
an exemplary embodiment, the method further includes if the end of the other
portion of the
expandable tubular member overlaps with a preexisting structure, then not
permitting the
position of the expandable tubular member to float relative to the position of
the hydraulic
actuator, and displacing the adjustable expansion cone upwardly relative to
the expandable
tubular member using the hydraulic actuator to radially expand and plastically
deform the
end of the other portion of the expandable tubular member that overlaps with
the preexisting
structure.
[0336] A method for forming a mono diameter wellbore casing within a borehole
that
includes a preexisting wellbore casing has been described that includes
supporting the
expandable tubular member, an hydraulic actuator, and an adjustable expansion
device
within the borehole; increasing the size of the adjustable expansion device;
displacing the
adjustable expansion device upwardly relative to the expandable tubular member
using the
hydraulic actuator to radially expand and plastically deform a portion of the
expandable
tubular member; and displacing-the adjustable expansion device upwardly
relative to the
expandable tubular member to radially expand and plastically deform the
remaining portion
of the expandable tubular member and a portion of the preexisting wellbore
casing that
overlaps with an end of the remaining portion of the expandable tubular
member. In an
exemplary embodiment, the method further includes reducing the size of the
adjustable
expansion device after the portion of the expandable tubular member has been
radially
expanded and plastically deformed. In an exemplary embodiment, the method
further
includes fluidicly sealing the radially expanded and plastically deformed end
of the
expandable tubular member after reducing the size of the adjustable expansion
device. In
an exemplary embodiment, the method further includes permitting the position
of the
expandable tubular member to float relative to the position of the hydraulic
actuator after
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fluidicly sealing the radially expanded and plastically deformed end of the
expandable
tubular member. In an exemplary embodiment, the method further includes
injecting a
hardenable fluidic sealing material into an annulus between the expandable
tubular member
and the borehole after permitting the position of the expandable tubular
member to float
relative to the position of the hydraulic actuator. In an exemplary
embodiment, the method
further includes increasing the size of the adjustable expansion device after
permitting the
position of the expandable tubular member to float relative to the position of
the hydraulic
actuator. in an exemplary embodiment, the method further includes displacing
the
adjustable expansion cone upwardly relative to the expandable tubular member
to radially
expand and plastically deform the remaining portion of the expandable tubular
member. In
an exemplary embodiment, the method further includes not permitting the
position of the
expandable tubular member to float relative to the position of the hydraulic
actuator, and
displacing the adjustable expansion cone upwardly relative to the expandable
tubular
member using the hydraulic actuator to radially expand and plastically deform
the end of the
remaining portion of the expandable tubular member that overlaps with the
preexisting
wellbore casing after not permitting the position of the expandable tubular
member to float
relative to the position of the hydraulic actuator.
[0337] A method of radially expanding and plastically deforming a tubular
member has
been described that includes positioning the tubular member within a
preexisting structure;
radially expanding and plastically deforming a lower portion of the tubular
member to form a
bell section; and radially expanding and plastically deforming a portion of
the tubular
member above the bell section. In an exemplary embodiment, positioning the
tubular
member with-n a preexisting structure includes locking the tubular member to
an expansion
device. In an exemplary embodiment, the outside diameter of the expansion
device is less
' than the inside diameter of the tubular member. In an exemplary embodiment,
the
expansion device is positioned within the tubular member. In an exemplary
embodiment, the
expansion device includes an adjustable expansion device. In an exemplary
embodiment,
the adjustable expansion device is adjustable to a plurality of sizes. In an
exemplary
embodiment, the expansion device includes a plurality of expansion devices. In
an
exemplary embodiment, at least one of the expansion devices includes an
adjustable
expansion device. In an exemplary embodiment, at least one of the adjustable
expansion
device is adjustable to a plurality of sizes. In an exemplary embodiment,
radially expanding
and plastically deforming a lower portion of the tubular member to form a bell
section
includes lowering an expansion device out of an end of the tubular member; and
pulling the
expansion device through the end of the tubular member. In an exemplary
embodiment,
lowering an expansion device out of an end of the tubular member includes
lowering the
expansion device out of the end of the tubular member, and adjusting the size
of the
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expansion device. In an exemplary embodiment, the adjustable expansion device
is
adjustable to a plurality of sizes. In an exemplary embodiment, the expansion
device
includes a plurality of adjustable expansion devices. In an exemplary
embodiment, at least
one of the adjustable expansion devices is adjustable to a plurality of sizes.
In an exemplary
embodiment, pulling the expansion device through the end of the tubular member
includes
gripping the tubular member; and pulling an expansion device through an end of
the tubular
member. In an exemplary embodiment, gripping the tubular member includes
permitting
axial displacement of the tubular member in a first direction; and not
permitting axial
displacement of the tubular member in a second direction. In an exemplary
embodiment,
pulling the expansion device through the end of the tubular member includes
pulling the
expansion device through the end of the tubular member using an actuator. In
an exemplary
embodiment, radially expanding and plastically deforming a portion of the
tubular member
above the bell section includes lowering an expansion device out of an end of
the tubular
member; and pulling the expansion device through the end of the tubular
member. In an
exemplary embodiment, lowering an expansion device out of an end of the
tubular member
includes lowering the expansion device out of the end of the tubular member;
and adjusting
the size of the expansion device. In an exemplary embodiment, the adjustable
expansion
device is adjustable to a plurality of sizes. In an exemplary embodiment, the
expansion
device includes a plurality of adjustable expansion devices. In an exemplary
embodiment, at
least one of the adjustable expansion devices is adjustable to a plurality of
sizes. In an
exemplary embodiment, pulling the expansion device through the end of the
tubular member
includes gripping the tubular member, and pulling an expansion device through
an end of the
tubular member. In an exemplary embodiment, gripping the tubular member
includes
permitting axial displacement of the tubular member in a first direction; and
not permitting
axial displacement of the tubular member in a second direction. In an
exemplary
embodiment, pulling the expansion device through the end of the tubular member
includes
pulling the expansion device through the end of the tubular member using an
actuator. In an
exemplary embodiment, pulling the expansion device through the end of the
tubular member
includes pulling the expansion device through the end of the tubular member
using fluid
pressure. In an exemplary embodiment, pulling the expansion device through the
end of the
tubular member using fluid pressure includes pressurizing an annulus within
the tubular
member above the expansion device. In an exemplary embodiment, radially
expanding and
plastically deforming a portion of the tubular member above the bell section
includes fluidicly
sealing an end of the tubular member; and pulling the expansion device through
the tubular
member. In an exemplary embodiment, the expansion device is adjustable. In an
exemplary embodiment, the expansion device is adjustable to a plurality of
sizes. In an
exemplary embodiment, .the expansion device comprises a plurality of
adjustable expansion
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devices. In an exemplary embodiment, at least one of the adjustable expansion
devices is
adjustable to a plurality of sizes. In an exemplary embodiment, pulling the
expansion device
-through the end of the tubular member includes gripping the tubular member;
and pulling an
expansion device through an end of the tubular member. In an exemplary
embodiment,
gripping the tubular member includes permitting axial displacement of the
tubular member in
a first direction; and not permitfiing axial displacement of the tubular
member in a second
direction. In an exemplary embodiment, pulling the expansion device through
the end of the
tubular member includes pulling the expansion device through the end of the
tubular
member using an actuator. In an exemplary embodiment, pulling the expansion
device
through the end of the tubular member includes pulling the expansion device
through the
end of the tubular member using fluid pressure. In an exemplary embodiment,
pulling the
expansion device through the end of the tubular member using fluid pressure
includes
pressurizing an annulus within the tubular member above the expansion device.
In an
exemplary embodiment, radially expanding and plastically deforming a portion
of the tubular
member above the bell section includes overlapping the portion of the tubular
member
above the bell section with an end of a preexisting tubuiar member; and
pulling an expansion
device through the overlapping portions of the tubular member and the
preexisting tubular
member. In an exemplary embodiment, the expansion device is adjustable. In an
exemplary embodiment, the expansion device is adjustable to a plurality of
sizes. In an
exemplary embodiment, the expansion device includes a plurality of adjustable
expansion
devices. In an exemplary embodiment, at least one of the adjustable expansion
devices is
adjustable to a plurality of sizes. In an exemplary embodiment, pulling the
expansion device
through the overlapping portions of the tubular member and the preexisting
tubular member
includes gripping the tubular member; and pulling the expansion device through
the
overlapping portions of the tubular member and the preexisting tubular member.
In an
exemplary embodiment, gripping the tubular member includes permitting axial
displacement
of the tubular member in a first direction; and not permitting axial
displacement of the tubular
member in a second direction. In an exemplary embodiment, pulling the
expansion device
through the overlapping portions of the tubular member and the preexisting
tubular member
includes pulling the expansion device through the overlapping portions of the
tubular
member and the preexisting tubular member using an actuator. In an exemplary
embodiment, pulling the expansion device through the overlapping portions of
the tubular
member and the preexisting tubular member includes pulling the expansion
device through
the overlapping portions of the tubular member and the preexisting tubular
member using
fluid pressure. In an exemplary embodiment, pulling the expansion device
through the
overlapping portions of the tubular member and the preexisting tubular member
using fluid
pressure includes pressurizing an annulus within the tubular member above the
expansion
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device. In an exemplary embodiment, the method further includes cutting an end
of the
portion of the tubular member that overlaps with the preexisfing tubular
member. In an
exemplary embodiment, the method further includes removing the cut off end of
the
expandable tubular member from the preexisting structure. In an exemplary
embodiment,
the method further includes injecting a hardenable fluidic sealing material
into an annulus
between the expandable tubular member and the preexisting structure. In an
exemplary
embodiment, the method further includes cutting off an end of the expandable
tubular
member. In an exemplary embodiment, the method further includes removing the
cut off
end of the expandable tubular member from the preexisting structure.
[0339] A method of radially expanding and plastically deforming a tubular
member has
been described that includes applying intemal pressure to the inside surface
of the tubular
member at a plurality of discrete location separated from one another.
[0339] A system for radially expanding and plastically deforming an expandable
tubular
member within a borehole having a preexisting wellbore casing has been
described that
includes means for positioning the tubular member within the borehole in
overlapping
relation to the wellbore casing; means for radially expanding and plastically
deforming a
portion of the tubular member to form a bell section; and means for radially
expanding and
plastically deforming a portion of the tubular member above the bell section
comprising a
portion of the tubular member that overlaps with the wellbore casing; wherein
the inside
diameter of the bell section is greater than the inside diameter of the
radially expanded and
plastically deformed porfion of the tubular member above the bell section. In
an exemplary
embodiment, means for radially expanding and plastically deforming a portion
of the tubular
member to form a bell section includes means for positioning an adjustable
expansion
device within the expandable tubular member, means for supporting the
expandable tubular
member and the adjustable expansion device within the borehole; means for
lowering the
adjustable expansion device out of the expandable tubular member; means for
increasing
the outside dimension of the adjustable expansion device; and means for
displacing the
adjustable expansion device upwardly relative to the expandable tubular member
n times to
radially expand and plastically deform n portions of the expandable tubular
member, wherein
n is greater than or equal to 1.
[0340] A system for forming a mono diameter wellbore casing has been described
that
includes means for positioning an adjustable expansion device within a first
expandable
tubular member; means for supporting the first expandable tubular member and
the
adjustable expansion device within a borehole; means for lowering the
adjustable -expansion
device out of the first expandable tubular member; means for increasing the
outside
dimension of the adjustable expansion device; means for displacing the
adjustable
expansion device upwardly relative to the first expandable tubular member m
times to
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radially expand and plastically deform m portions of the first expandable
tubuiar member
within the borehole; means for positioning the adjustable expansion device
within a second
expandable tubular member; means for supporting the second expandable tubular
member
and the adjustable expansion device within the borehole in overlapping
relation to the first
expandable tubular member, means for lowering the adjustable expansion device
out of the
second expandabie tubular member; means for increasing the outside dimension
of the
adjustable expansion device; and means for displacing the adjustable expansion
device
upwardly relative to the second expandable tubular member n times to radially
expand and
plastically deform n portions of the second expandable tubular member within
the borehole.
[0341] A system for radially expanding and plastically deforming an expandable
tubular
member within a borehole has been described that includes means for
positioning an
adjustable expansion device within the expandable tubular member; means for
supporting
the expandable tubular member and the adjustable expansion device within the
borehole;
means for lowering the adjustable expansion device out of the expandable
tubular member;
means for increasing the outside dimension of the adjustable expansion device;
means for
displacing the adjustable expansion mandrel upwardly relative to the
expandable tubular
member n times to radially expand and plastically deform n portions of the
expandable
tubular member within the borehole; and means for pressurizing an interior
region of the
expandable tubular member above the adjustable expansion device during the
radial
expansion and plastic deformation of the expandable tubular member within the
borehole.
[0342] A system for forming a mono diameter wellbore casing has been described
that
includes means for positioning an adjustable expansion device within a first
expandable
tubular member, means for supporting the first expandable tubular member and
the
adjustable expansion device within a borehole; means for lowering the
adjustable expansion
device out of the first expandable tubular member; means for increasing the
outside
dimension of the adjustable expansion device; means for displacing the
adjustable
expansion device upwardly relative to the first expandable tubular member m
times to
radially expand and plastically deform m portions of the first expandable
tubular member
within the borehole; means for pressurizing an interior region of the first
expandable tubular
member above the adjustable expansion device during the radial expansion and
plastic
deformation of the first expandable tubular member within the borehole; means
for
positioning the adjustable expansion mandrel within a second expandable
tubular mernber,
means for supporting the second expandable tubular member and the adjustable
expansion
mandrel within the borehole in overlapping relation to the first expandable
tubular member;
means for lowering the adjustable expansion mandrel out of the second
expandable tubular
member; means for increasing the outside dimension of the adjustable expansion
mandrel;
means for displacing the adjustable expansion mandrel upwardly relative to the
second
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expandable tubular member n times to radially expand and plastically deform n
portions of
the second expandable tubular member within the borehole; and means for
pressurizing an
interior region of the second expandable tubular member above the adjustabie
expansion
mandrel during the radial expansion and plastic deformation of the second
expandable
tubular member within the borehole.
[0343] A system for radially expanding and plastically deforming an expandable
tubular
member within a borehole has been described that includes means for
positioning first and
second adjustable expansion devices within the expandable tubular member;
means for
supporting the expandable tubular member and the first and second adjustable
expansion
devices within the borehole; means for lowering the first adjustable expansion
device out of
the expandabie tubular member; means for increasing the outside dimension of
the first
adjustable expansion device; means for displacing the first adjustable
expansion device
upwardly relative to the expandable tubular member to radially expand and
plastically
deform a lower portion of the expandable tubular member; means for displacing
the first
adjustable,expansion device and the second adjustable expansion device
downwardly
relative to the expandable tubular member; means for decreasing the outside
dimension of
the first adjustable expansion device and increasing the outside dimension of
the second
adjustable expansion device; means for displacing the second adjustable
expansion device
upwardly relative to the expandable tubular member to radially expand and
plastically
deform portions of the expandable tubular member above the lower portion of
the
expandable tubular member; wherein the outside dimension of the first
adjustable expansion
device is greater than the outside dimension of the second adjustable
expansion device.
[0344] A system for forming a mono diameter wellbore casing has been described
that
includes means for positioning first and second adjustable expansion devices
within a first
expandable tubular member, means for supporting the first expandable tubular
member and
the first and second adjustable expansion devices within a borehole; means for
lowering the
first adjustable expansion device out of the first expandable tubular member;
means for
increasing the outside dimension of the first adjustable expansion device;
displacing the first
adjustable expansion device upwardly relative to the first expandable tubular
member to
radially expand and plastically deform a lower portion of the first expandable
tubular
member; means for displacing the first adjustable expansion device and the
second
adjustable expansion device downwardly relative to the first expandable
tubular member;
means for decreasing the outside dimension of the first adjustable expansion
device and
increasing the outside dimension of the second adjustable expansion device;
means for
displacing the second adjustable expansion device upwardly relative to the
first eVandable
tubular member to radially expand and plastically deform portions of the first
expandable
tubular member above the lower.portion of the expandable tubular member; means
for
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positioning first and second adjustable expansion devices within a second
expandable
tubular member, means for supporting the first expandable tubular member and
the first and
second adjustable expansion devices within the borehole in overlapping
relation to the first
expandable tubular member; means for lowering the first adjustable expansion
device out of
the second expandable tubular member; means for increasing the outside
dimension of the
first adjustable expansion device; means for displacing the adjustable
expansion device
upwardly relative to the second expandable tubular member to radially expand
and
plastically deform a lower portion of the second expandable tubular member,
means for
displacing the first adjustable expansion device and the second adjustable
expansion device
downwardly relative to the second expandable tubular member, means for
decreasing the
outside dimension of the first adjustable expansion device and increasing the
outside
dimension of the second adjustable expansion device; and means for displacing
the second
adjustable expansion device upwardly relative to the second expandable tubular
member to
radially expand and plastically deform portions of the second expandable
tubular member
above the lower portion of the second expandable tubular member; wherein the
outside
dimension of the first adjustable expansion device is greater than the outside
dimension of
the second adjustable expansion device.
[0345] A system for radially expanding and plastically deforming an expandable
tubular
member within a borehole has been described that includes means for
positioning first and
second adjustable expansion devices within the expandable tubular member;
means for
supporting the expandable tubular member and the first and second adjustable
expansion
devices within the borehole; means for lowering the first adjustable expansion
device out of
the expandable tubular member; means for increasing the outside dimension of
the first
adjustable expansion device; means for displacing the first adjustable
expansion device
upwardly relative to the expandable tubular member to radially expand and
plastically
deform a lower portion of the expandable tubular member; means for
pressurizing an interior
region of the expandable tubular member above the first adjustable expansion
device during
the radial expansion of the lower portion of the expandable tubular member by
the first
adjustable expansion device; means for displacing the first adjustable
expansion device and
the second adjustable expansion device downwardly relative to the expandable
tubular
member, means for decreasing the outside dimension of the first adjustable
expansion
device and increasing the outside dimension of the second adjustable expansion
device;
means for displacing the second adjustable expansion device upwardly relative
to the
expandable tubular member to radially expand and plastically deform portions
of the
expandable tubular member above the lower portion of the expandable tubular
member; and
means for pressurizing an interior region of the expandable tubular member
above the
second adjustable expansion device during the radial expansion of the portions
of the
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expandable tubular member above the lower portion of the expandable tubular
member by
the second adjustable expansion device; wherein the outside dimension of the
first
adjustable expansion device is greater than the outside dimension of the
second adjustable
expansion device.
[0346] A system for forming a mono diameter wellbore casing has been described
that
includes means for positioning first and second adjustable expansion devices
within a first
expandable tubular member, means for supporting the first expandable tubular
member and
the first and second adjustable expansion devices within a borehole; means for
lowering the
first adjustable expansion device out of the first expandable tubular member;
means for
increasing the outside dimension of the first adjustable expansion device;
means for
displacing the first adjustable expansion device upwardly relative to the
first expandable
tubular member to radially expand and plastically deform a lower portion of
the first
expandable tubular member; means for pressurizing an interior region of the
first expandable
tubular member above the first adjustable expansion device during the radial
expansion of
the lower portion of the first expandable tubular member by the first
adjustable expansion
device; means for displacing the first adjustable expansion device and the
second adjustable
expansion device downwardly relative to the first expandable tubular member,
means for
decreasing the outside dimension of the first adjustable expansion device and
increasing the
outside dimension of the second adjustable expansion device; means for
displacing the
second adjustable expansion device upwardly relative to the first expandable
tubular
member to radially expand and plastically deform portions of the first
expandable tubular
member above the lower portion of the expandable tubular member; means for
pressurizing
an interior region of the first expandable tubular member above the second
adjustable
expansion device during the radial expansion of the portions of the first
expandable tubular
member above the lower portion of the first expandabie tubular member by the
second
adjustable expansion device; means for positioning first and second adjustable
expansion
devices within a second expandable tubular member; means for supporting the
first
expandable tubular member and the first and second adjustable expansion
devices within
the borehole in overlapping relation to the first expandable tubular member;
means for
lowering the first adjustable expansion device out of the second expandable
tubular
member; means for increasing the outside dimension of the first adjustable
expansion
device; means for displacing the first adjustable expansion device upwardly
relative to the
second expandable tubular member to radially expand and plastically deform a
lower portion
of the second expandable tubular member; means for pressurizing an interior
region of the
second expandable tubular member above the first adjustable expansion device
during the
radial expansion of the lower portion of the second expandable tubular member
by the first
adjustable expansion device; means for displacing the first adjustable
expansion device and
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the second adjustable expansion device downwardly relative to the second
expandable
tubular member; means for decreasing the outside dimension of the first
adjustable
expansion device and increasing the outside dimension of the second adjustable
expansion
device; means for displacing the second adjustable expansion device upwardly
relative to
the second expandable tubular member to radially expand and plastically deform
portions of
the second expandable tubular member above the lower portion of the second
expandable
tubular member; and means for pressurizing an interior region of the second
expandable
tubular member above the second adjustable expansion device during the radial
expansion
of the portions of the second expandable tubular member above the lower
portion of the
second expandable tubular member by the second adjustable expansion device;
wherein the
outside dimension of the first adjustable expansion device is greater than the
outside
dimension of the second adjustable expansion device.
[03471 A system for radially expanding and plastically deforming an expandable
tubular
member within a borehole has been described that includes means for supporting
the
expandable tubular member, an hydraulic actuator, and an adjustable expansion
device
within the borehole; means for increasing the size of the adjustable expansion
device; and
means for displacing the adjustable expansion device upwardly relative to the
expandable
tubular member using the hydraulic actuator to radially expand and plastically
deform a
portion of the expandable tubular member. In an exemplary embodiment, the
system further
includes means for reducing the size of the adjustable expansion device after
the portion of
the expandable tubular member has been radially expanded and plastically
deformed. In an
exemplary embodiment, the system further includes means for fluidicly sealing
the radially
expanded and plastically deformed end of the expandable tubular member after
reducing the
size of the adjustable expansion device. In an exemplary embodiment, the
system further
includes means for permitting the position of the expandable tubular member to
float relative
to the position of the hydraulic actuator after fluidicly sealing the radially
expanded and
plastically deformed end of the expandable tubular member. In an exemplary
embodiment,
the system further includes means for injecting a hardenable fluidic sealing
material into an
annulus between the expandable tubular member and a preexisting structure
after permitting
the position of the expandable tubular member to float relative to the
position of the hydraulic
actuator. In an exemplary embodiment, the system further indudes means for
increasing
the size of the adjustable expansion device after permitting the position of
the expandable
tubular member to float relative to the position of the hydraulic actuator. In
an exemplary
embodiment, system further includes means for displacing the adjustable
expansion cone
upwardly relative to the expandable tubular member to radially expand and
plastically
deform another portion of the expandable tubular member. In an exemplary
embodiment,
the system further includes if the end of the other portion of the expandable
tubular member
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overlaps with a preexisting structure, then means for not permitting the
position of the
expandable tubular member to float relative to the position of the hydraulic
actuator, and
means for displacing the adjustable expansion cone upwardiy relative to the
expandable
tubular member using the hydraulic actuator to radially expand and plastically
deform the
end of the other portion of the expandable tubular member that overlaps with
the preexisting
structure.
[034E1 A system for forming a mono diameter weilbore casing within a borehole
that
includes a preexisting wellbore casing has been described that includes means
for
supporting the expandable tubular member, an hydraulic actuator, and an
adjustable
expansion device within the borehole; means for increasing the size of the
adjustable
expansion device; means for displacing the adjustable expansion device
upwardly relative to
the expandable tubular member using the hydraulic actuator to radially expand
and
plastically deform a portion of the expandable tubular member; and means for
displacing the
adjustable expansion device upwardly relative to the expandable tubular member
to radially
expand and plastically deform the remaining portion of the expandable tubular
member and
a portion of the preexisting wellbore casing that overlaps with an end of the
remaining
portion of the expandable tubular member. In an exemplary embodiment, the
system further
includes means for reducing the size of the adjustable expansion device after
the portion of
the expandable tubular member has been radially expanded and plastically
deformed. In an
exemplary embodiment, the system further includes means for fluidicly sealing
the radially
expanded and plastically deformed end of the expandable tubular member after
reducing the
size of the adjustable expansion device. In an exemplary embodiment, the
system further
includes means for permitting the position of the expandable tubular member to
float relative
to the position of the hydraulic actuator after fluididy sealing the radially
expanded and
plastically deformed end of the expandable tubular member. In an exemplary
embodiment,
the system further includes means for injecting a hardenable fluidic sealing
material into an
annulus between the expandable tubular member and the borehole after
permitting the
position of the expandable tubular member to float relative to the position of
the hydraulic
actuator. In an exemplary embodiment, the system further includes means for
increasing
the size of the adjustable expansion device after permitting the position of
the expandable
tubular member to float relative to the position of the hydraulic actuator. In
an exemplary
embodiment, the system further includes means for displacing the adjustable
expansion
cone upwardly relative to the expandable tubular member to radially expand and
plastically
deform the remaining portion of the expandable tubular member. In an exemplary
embodiment, the system further includes means for not permitting the position
of the
expandable tubular member to float relative to the position of the hydraulic
actuator; and
means for displacing the adjustable expansion cone upwardly relative to the
expandable
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tubular member using the hydraulic actuator to radially expand and plastically
deform the
end of the remaining portion of the expandable tubular member that overlaps
with the
preexisting wellbore casing after not permitting the position of the
expandable tubular
member to float relative to the position of the hydraulic actuator.
[034.0] A system for radially expanding and plastically deforming a tubular
member has
been described that includes means for positioning the tubular member within a
preexisting
structure; means for radially expanding and plastically deforming a lower
portion of the
tubular member to form a bell section; and means for radially expanding and
plastically
deforming a portion of the tubular member above the bell section. In an
exemplary
embodiment, positioning the tubular member within a preexisting structure
includes means
for locking the tubular member to an expansion device. In an exemplary
embodiment, the
outside diameter of the expansion device is less than the inside diameter of
the tubular
member. In an exemplary embodiment, the expansion device is positioned within
the tubular
member. In an exemplary embodiment, the expansion device includes an
adjustable
expansion device. In an exemplary embodiment, the adjustable expansion device
is
adjustable to a plurality of sizes. In an exemplary embodiment, the expansion
device
includes a plurality of expansion devices. In an exemplary embodiment, at
least one of the
expansion devices includes an adjustable expansion device. In an exemplary
embodiment,
at least one of the adjustable expansion device is adjustable to a plurality
of sizes. In an
exempla .ry embodiment, means for radially expanding and plastically deforming
a lower
portion of the tubular member to form a bell section includes means for
iowering an
expansion device out of an end of the tubular member; and means for pulling
the expansion
device through the end of the tubular member. In an exemplary embodiment,
means for
lowering an expansion device out of an end of the tubular member includes
means for
lowering the expansion device out of the end of the tubular member; and means
for
adjusting the size of the expansion device. In an exemplary embodiment, the
adjustable
expansion device is adjustable to a plurality of sizes. In an exemplary
embodiment, the
expansion device includes a plurality of adjustable expansion devices. In an
exemplary
embodiment, at least one of the adjustable expansion devices is adjustable to
a plurality of
sizes. In an exemplary embodiment, means for pulling the expansion device
through the
end of the tubular member includes means for gripping the tubular member; and
means for
pulling an expansion device through an end of the tubular member. In an
exemplary
embodiment, means for gripping the tubular member includes means for
permitting axial
displacement of the tubular member in a first direction; and means for not
permitting axial
displacement of the tubular member in a second direction. In an exemplary
embodiment,
means for pulling the expansion device through the end of the tubular member
includes
means for pulling the expansion device through the end of the tubular member
using an
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actuator. In an exemplary embodiment, means for radially expanding and
plastically
deforming a portion of the tubular member above the bell section includes
means for
lowering an expansion device out of an end of the tubular member; and means
for pulling
the expansion device through the end of the tubular member. In an exemplary
embodiment,
means for lowering an expansion device out of an end of the tubular member
includes
means for lowering the expansion device out of the end of the tubular member;
and means
for adjusting the size of the expansion device. In an exemplary embodiment,
the adjustable
expansion device is adjustable to a plurality of sizes. In an exemplary
embodiment, the
expansion device comprises a plurality of adjustable expansion devices. In an
exemplary
embodiment, at least one of the adjustable expansion devices is adjustable to
a plurality of
sizes. In an exemplary embodiment, means for pulling the expansion device
through the
end of the tubular member includes means for gripping the tubular member; and
means for
pulling an expansion device through an end of the tubular member. In an
exemplary
embodiment, means for gripping the tubular member includes means for
permitting axial
displacement of the tubular member in a first direction; and means for not
permitting axial
displacement of the tubular member in a second direction. In an exemplary
embodiment,
means for pulling the expansion device through the end of the tubular member
includes
means for pulling the expansion device through the end of the tubular member
using an
actuator. In an exemplary embodiment, means for pulling the expansion device
through the
end of the tubular member includes means for pulling the expansion device
through the end
of the tubular member using fluid pressure. In an exemplary embodiment, means
for pulling
the expansion device through the end of the tubular member using fluid
pressure includes
means for pressurizing an annulus within the tubular member above the
expansion device.
In an exemplary embodiment, means for radially expanding and plastically
deforming a
portion of the tubular member above the bell section includes means for
fluidicly sealing an
end of the tubular member; and means for pulling the expansion device through
the tubular
member. In an exemplary embodiment, the expansion device is adjustable. In an
exemplary embodiment, the expansion device is adjustable to a plurality of
sizes. In an
exemplary embodiment, the expansion device includes a plurality of adjustable
expansion
devices. In an exemplary embodiment, at least one of the adjustable expansion
devices is
adjustable to a plurality of sizes. In an exemplary embodiment, means for
pulling the
expansion device through the end of the tubular member includes means for
gripping the
tubular member; and means for pulling an expansion device through an end of
the tubular
member. In an exemplary embodiment, means for gripping the tubular member
includes
means for permitEing axial displacement of the tubular member in a first
direction; and means
for not permitting axial displacement of the tubular member in a second
direction. In an
exemplary embodiment, means for pulling the expansion device through the end
of the
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tubular member includes means for pulling the expansion device through the end
of the
tubular member using an actuator. In an exemplary embodiment, means for
pulling the
expansion device through the end of the tubular member includes means for
pulling the
expansion device through the end of the tubular member using fluid pressure.
In an
exemplary embodiment, means for pulling the expansion device through the end
of the
tubular member using fluid pressure includes means for pressurizing an annulus
within the
tubular member above the expansion device. In an exemplary embodiment, means
for
radially expanding and plastically deforming a portion of the tubular member
above the bell
secfion includes means for overlapping the portion of the tubular member above
the bell
section with an end of a preexisting tubular member; and means for pulling an
expansion
device through the overlapping portions of the tubular member and the
preexisting tubular
member. In an exemplary embodiment, the expansion device is adjustable. ln an
exemplary embodiment, the expansion device is adjustable to a plurality of
sizes. In an
exemplary embodiment, the expansion device includes a plurality of adjustable
expansion
devices. In an exemplary embodiment, at least one of the adjustable expansion
devices is
adjustable to a plurality of sizes. In an exemplary embodiment, means for
pulling the
expansion device through the overlapping portions of the tubular member and
the
preexisting tubular member includes means for gripping the tubular member; and
means for
pulling the expansion device through the overlapping portions of the tubular
member and the
preexisting tubular member. In an exemplary embodiment, means for gripping the
tubular
member includes means for permitting axial displacement of the tubular member
in a first
direction; and means for not permitting axial displacement of the tubular
member in a second
direction. In an exemplary embodiment, means for pulling the expansion device
through the
overlapping portions of the tubular member and the preexisting tubular member
includes
means for pulling the expansion device through the overtapping portions of the
tubular
member and the preexisting tubular member using an actuator. In an exemplary
embodiment, means for pulling the expansion device through the overlapping
portions of the
tubular member and the preexisting tubular member includes means for pulling
the
expansion device through the overlapping portions of the tubuiar member and
the
preexisting tubular member using fluid pressure. In an exemplary embodiment,
means for
pulling the expansion device through the overlapping portions of the tubular
member and the
preexisting tubular member using fluid pressure includes means for
pressurizing an annulus
within the tubular member above the expansion device. In an exemplary
embodiment, the
system further includes means for cutting an end of the portion of the tubular
member that
overlaps with the preexisting tubular member. In an exemplary embodiment, the
system
further includes means for removing the cut off end of the expandable tubular
member from
the preexisting structure. In an exemplary embodiment, the system further
includes means
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for injecting a hardenable fluidic sealing material into an annulus between
the expandable
tubular member and the preexisting structure. In an exemplary embodiment, the
system
further includes means for cutting off an end of the expandable tubular
member. In an
exemplary embodiment, the system further includes means for removing the cut
off end of
the expandable tubular member from the preexisting structure.
[0350] A system of radially expanding and plastically deforming a tubular
member has
been described that includes a support member; and means for applying internal
pressure to
the inside surface of the tubular member at a plurality of discrete location
separated from
one another coupled to the support member.
[035q] A method of cutting a tubular member has been described that includes
positioning a plurality of cutting elements within the tubular member; and
bringing the cutting
elements into engagement with the tubular member. In an exemplary embodiment,
the
cutting elements include a first group of cutting elements; and a second group
of cutting
elements; wherein the first group of cutting elements are interleaved with the
second group
of cutting elements. In an exemplary embodiment, bringing the cutting elements
into
engagement with the tubular member includes bringing the cutting elements into
axial
alignment. In an exemplary embodiment, bringing the cutting elements into
engagement
with the tubular member further includes pivoting the cutting elements. In an
exemplary
embodiment, bringing the cutting elements into engagement with the tubular
member further
includes translating the cutting elements. In an exemplary embodiment,
bringing the cutting
elements into engagement with the tubular member further includes pivoting the
cutting
elements; and translating the cutting elements. In an exemplary embodiment,
bringing the
cutting elements into engagement with the tubular member includes rotating the
cutting
elements about a common axis. In an exemplary embodiment, bringing the cutting
elements =
into engagement with the tubular member includes pivoting the cutting elements
about
corresponding axes; translating the cutting elements; and rotating the cutting
elements
about a common axis. In an exemplary embodiment, the method further includes
preventing
the cutting elements from coming into engagement with the tubular member if
the inside
diameter of the tubular member is less than a predetermined value. In an
exemplary
embodiment, preventing the cutting elements from coming into engagement with
the tubular
member if the inside diameter of the tubular member is less than a
predetermined value
includes sensing the inside diameter of the tubular member.
[0352] A method of gripping a tubular member has been described that includes
positioning a plurality of gripping elements within the tubular member;
bringing the gripping
elements into engagement with the tubular member. In an exemplary embodiment,
bringing
the gripping elements into engagement with the tubular member includes
displacing the
gripping elements in an axial direction; and displacing the gripping elements
in a radial
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direction. In an exemplary embodiment, the method further includes biasing the
gripping
elements against engagement with the tubular member.
[0353] A method of operating an actuator has been described that includes
pressurizing
a plurality of pressure chamber. !n an exemplary embodiment, the method
further includes
transmitting torsional loads.
[0354] A method of injecting a hardenable fluidic sealing material into an
annulus
between a tubular member and a preexisting structure has been described that
includes
positioning the tubular member into the preexisting structure; sealing off an
end of the
tubular member; operating a valve within the end of the tubular member; and
injecting a
hardenable fluidic sealing material through the valve into the annulus between
the tubular
member and the preexisting structure.
[0355] A system for cutting a tubular member has been described that includes
means
for positioning a plurality of cutting elements within the tubuiar member; and
means for
bringing the cutting elements into engagement with the tubular member. In an
exemplary
embodiment, the cutting elements include a first group of cutting elements;
and a second
group of cutting elements; wherein the first group of cutting elements are
interleaved with the
second group of cutting elements. In an exemplary embodiment, means for
bringing the
cutting elements into engagement with the tubular member includes means for
bringing the
cutting elements into axial alignment. In an exemplary embodiment, means for
bringing the
cutting elements into engagement with the tubular member further includes
means for
pivoting the cutting elements. In an exemplary embodiment, means for bringing
the cutting
elements into engagement with the tubular member further includes means for
translating
the cutting elements. In an exemplary embodiment, means for bringing the
cutting elements
into engagement with the tubular member further includes means for pivoting
the cutting
elements; and means for translating the cutting elements. In an exemplary
embodiment,
means for bringing the cutting elements into engagement with the tubular
member includes
means for rotating the cutting elements about a common axis. In an exemplary
embodiment, means for bringing the cutting elements into engagement with the
tubular
member includes means for pivoting the cutting elements about corresponding
axes; means
for translating the cutting elements; and means for rotating the cutting
elements about a
common axis. In an exemplary embodiment, the system further includes means for
preventing the cutting elements from coming into engagement with the tubular
member if the
inside diameter of the tubular member is less than a predetermined value. In
an exemplary
embodiment, means for preventing the cutting elements from coming into
engagement with
the tubular member if the inside diameter of the tubular member is less than a
predetermined value includes means for sensing the inside diameter of the
tubular member.
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-[0356] A system for gripping a tubular member has been described that
includes means
for positioning a plurality of gripping elements within the tubular member;
and means for
bringing the gripping elements into engagement with the tubular member. In an
exemplary
embodiment, means for bringing the gripping elements into engagement with the
tubular
member includes means for displacing the gripping elements in an axial
direction; and
means for displacing the gripping elements in a radial direction. In an
etemplary
embodiment, the system further indudes means for biasing the gripping elements
against
engagement with the tubular member.
[0357] An actuator system has been described that includes a support member;
and
means for pressurizing a plurality of pressure chambers coupled to the support
member. In
an exemplary embodiment, the system further includes means for transmitting
torsional
loads.
[0358] A system for injecting a hardenable fluidic sealing material into an
annulus
between a tubular member and a preexisting structure has been described that
includes
means for positioning the tubular member into the preexisting structure; means
for sealing
off an end of the tubular member, means for operating a valve within the end
of the tubular
member; and means for injecting a hardenable fluidic sealing material through
the valve into
the annulus between the tubular member and the preexisting structure.
[0359] A method of engaging a tubular member has been described that includes
positioning a plurality of elements within the tubular member; and bringing
the elements into
engagement with the tubular member. In an exemplary embodiment, the elements
include a
first group of elements; and a second group of elements; wherein the first
group of elements
are interleaved with the second group of elements. In an exemplary embodiment,
bringing
the elements into engagement with the tubular member includes bringing the
elements into
axial alignment. In an exemplary embodiment, bringing the elements into
engagement with
the tubular member further includes pivoting the eiements. In an exemplary
embodiment,
bringing the elements into engagement with the tubular member further includes
translating
the elements. In an exemplary embodiment, bringing the elements into
engagement with the
tubular member further includes pivoting the elements; and translating the
elements. In an
exemplary embodiment, bringing the elements into engagement with the tubular
member
includes rotating the elements about a common axis. In an exemplary
embodiment, bringing
the elements into engagement with the tubular member includes pivoting the
elements about
corresponding axes; translating the elements; and rotating the elements about
a common
axis. In an exemplary embodiment, the method further includes preventing the
elements
from coming into engagement with the tubular member if the inside diameter of
the tubular
member is less than a predetermined value. In an exemplary embodiment,
preventing the
elements from coming into engagement with the tubular member if the inside
diameter of the
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tubular member is less than a predetermined value includes sensing the inside
diameter of
the tubular member.
[0360] A system for engaging a tubular member has been described that includes
means for positioning a plurality of elements within the tubular member; and
means for
bringing the elements into engagement with the tubular member. In an exemplary
embodiment, the elements include a first group of elements; and a second group
of
elements; wherein the first group of elements are interleaved with the second
group of
elements. In an exemplary embodiment, means for bringing the elements into
engagement
with the tubular member includes means for bringing the elements into axial
alignment. In
an exemplary embodiment, means for bringing the elements into engagement with
the
tubular member further includes means for pivoting the elements. In an
exemplary
embodiment, means for bringing the elements into engagement with the tubular
member
further includes means for translating the elements. In an exemplary
embodiment, means
for bringing the elements into engagement with the tubular member further
includes means
for pivoting the elements; and means for translating the elements. In an
exemplary
embodiment, means for bringing the elements into engagement with the tubular
member
includes means for rotating the elements about a common axis. In an exemplary
embodiment, means for bringing the elements into engagement with the tubular
member
includes means for pivoting the elements about corresponding axes; means for
translating
the elements; and means for rotating the elements about a common axis. In an
exemplary
embodiment, the system further includes means for preventing the elements from
coming
into engagement with the tubular member if the inside diameter of the tubular
member is
less than a predetermined value. In an exemplary embodiment, means for
preventing the
elements from coming into engagement with the tubular member if the inside
diameter of the
tubular member is less than a predetermined value includes means for sensing
the inside
diameter of the tubular member.
[0361] It is understood that variations may be made in the foregoing without
departing
from the scope of the invention. For example, the teachings of the present
illustrative
embodiments may be used to provide a wellbore casing, a pipeline, or a
structural support.
Furthermore, the elements and teachings of the various illustrative
embodiments may be
combined in whole or in part in some or all of the illustrative embodiments.
[0362] Although illustrative embodiments of the invention have been shown and
described, a wide range of modification, changes and substitution is
contemplated in the
foregoing disclosure. In some instances, some features of the present
invention may be
employed without a corresponding use of the other features. Accordingly, it is
appropriate
that the appended claims be construed broadly and in a manner consistent with
the scope of
the invention.
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