US20020079106A1 - Procedures and equipment for profiling and jointing of pipes - Google Patents
Procedures and equipment for profiling and jointing of pipes Download PDFInfo
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- US20020079106A1 US20020079106A1 US09/469,690 US46969099A US2002079106A1 US 20020079106 A1 US20020079106 A1 US 20020079106A1 US 46969099 A US46969099 A US 46969099A US 2002079106 A1 US2002079106 A1 US 2002079106A1
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- pipe
- rollers
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- tool
- bore
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Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B7/00—Special methods or apparatus for drilling
- E21B7/20—Driving or forcing casings or pipes into boreholes, e.g. sinking; Simultaneously drilling and casing boreholes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D17/00—Forming single grooves in sheet metal or tubular or hollow articles
- B21D17/04—Forming single grooves in sheet metal or tubular or hollow articles by rolling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/04—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of tubes with tubes; of tubes with rods
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/08—Tube expanders
- B21D39/10—Tube expanders with rollers for expanding only
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B29/00—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B29/00—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
- E21B29/002—Cutting, e.g. milling, a pipe with a cutter rotating along the circumference of the pipe
- E21B29/005—Cutting, e.g. milling, a pipe with a cutter rotating along the circumference of the pipe with a radially-expansible cutter rotating inside the pipe, e.g. for cutting an annular window
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B29/00—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
- E21B29/10—Reconditioning of well casings, e.g. straightening
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/13—Methods or devices for cementing, for plugging holes, crevices, or the like
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/13—Methods or devices for cementing, for plugging holes, crevices, or the like
- E21B33/138—Plastering the borehole wall; Injecting into the formation
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/08—Screens or liners
- E21B43/084—Screens comprising woven materials, e.g. mesh or cloth
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/10—Setting of casings, screens, liners or the like in wells
- E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/10—Setting of casings, screens, liners or the like in wells
- E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
- E21B43/105—Expanding tools specially adapted therefor
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/10—Setting of casings, screens, liners or the like in wells
- E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
- E21B43/106—Couplings or joints therefor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
- Y10T29/49863—Assembling or joining with prestressing of part
- Y10T29/4987—Elastic joining of parts
- Y10T29/49872—Confining elastic part in socket
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
- Y10T29/49908—Joining by deforming
- Y10T29/49909—Securing cup or tube between axially extending concentric annuli
- Y10T29/49911—Securing cup or tube between axially extending concentric annuli by expanding inner annulus
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
- Y10T29/49908—Joining by deforming
- Y10T29/49938—Radially expanding part in cavity, aperture, or hollow body
- Y10T29/4994—Radially expanding internal tube
Landscapes
- Engineering & Computer Science (AREA)
- Geology (AREA)
- Mining & Mineral Resources (AREA)
- Life Sciences & Earth Sciences (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Fluid Mechanics (AREA)
- Environmental & Geological Engineering (AREA)
- Physics & Mathematics (AREA)
- Geochemistry & Mineralogy (AREA)
- Mechanical Engineering (AREA)
- Earth Drilling (AREA)
- Shaping Of Tube Ends By Bending Or Straightening (AREA)
- Rigid Pipes And Flexible Pipes (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
- Gasket Seals (AREA)
- Circuits Of Receivers In General (AREA)
- Enzymes And Modification Thereof (AREA)
- Pharmaceuticals Containing Other Organic And Inorganic Compounds (AREA)
- Medicines That Contain Protein Lipid Enzymes And Other Medicines (AREA)
- Acyclic And Carbocyclic Compounds In Medicinal Compositions (AREA)
- Crushing And Grinding (AREA)
- Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
- Dowels (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Turning (AREA)
- Lubricants (AREA)
- Confectionery (AREA)
- Sorption Type Refrigeration Machines (AREA)
- Shaping By String And By Release Of Stress In Plastics And The Like (AREA)
- Piles And Underground Anchors (AREA)
Abstract
Description
- This invention relates to procedures and equipment for profiling and jointing of pipes, and relates more particularly but not exclusively to methods and apparatus for the shaping and/or expansion and/or conjoining of tubular casings in wells.
- In the hydrocarbon exploration and production industry there is a requirement to deploy tubular casings in relatively narrow-bore wells, and to expand the deployed casing in situ. The casing may require to be expanded throughout its length in order to line a bore drilled through geological material; the casing may additionally or alternatively require to be expanded at one end where it overlaps and lies concentrically within another length of previously deployed casing in order to form a swaged joint between the two lengths of casing. Proposals have been made that a slotted metal tube be expanded by mechanically pulling a mandrel through the tube, and that a solid-walled steel tube be expanded by hydraulically pushing a part-conical ceramic plunger through the tube. In both of these proposals, very high longitudinal forces would be exerted throughout the length of the tubing, which accordingly would require to be anchored at one end. Where mechanical pulling is to be employed, the pulling force would require to be exerted through a drillstring (in relatively large diameter wells) or through coiled tubing (in relatively small diameter wells). The necessary force would become harder to apply as the well became more deviated (i.e. more non-vertical), and in any event, coiled tubing may not tolerate high longitudinal forces. Where hydraulic pushing is to be employed, the required pressure may be hazardously high, and in any event the downhole system would require to be pressure-tight and substantially leak-free. (This would preclude the use of a hydraulically pushed mandrel for the expansion of s1otted tubes). The use of a fixed-diameter mandrel or plug would make it impracticable or impossible to control or to vary post-deformation diameter after the start of the expansion procedure.
- It is therefore an object of the invention to provide new and improved procedures and equipment for the profiling or jointing of pipes or other hollow tubular articles, which obviate or mitigate at least some of the disadvantages of the prior art.
- In the following specification and claims, references to a “pipe” are to be taken as references to a hollow tubular pipe and to other forms of hollow tubular article, and references to “profiling” are to be taken as comprising alteration of shape and/or dimension(s) which alteration preferably takes place substantially without removal of material.
- According to a first aspect of the present invention there is provided a profiling method for profiling a pipe or other hollow tubular article, the profiling method comprising the steps of applying a roller means to a part of the pipe bore selected to be profiled, translating the roller means across the bore in a direction including a circumferential component while applying a force to the roller means in a radially outwards direction with respect to the longitudinal axis of the pipe, and continuing such translation and force application until the pipe is plastically deformed substantially into the intended profile.
- The deformation of the pipe may be accomplished by radial compression of the pipe wall or by circumferential stretching of the pipe wall, or by a combination of such radial compression and circumferential stretching.
- Said direction may be purely circumferential, or said direction may partly circumferential and partly longitudinal.
- Said roller means is preferably peripherally profiled to be complementary to the profile into which the selected part of the pipe bore is intended to be formed.
- The selected part of the pipe bore may be remote from an open end of the pipe, and the profiling method then comprises the further steps of inserting the roller means into the open end of the pipe (if the roller means it not already in the pipe), and transferring the roller means along the pipe to the selected location. Transfer of the roller means is preferably accomplished by the step of actuating traction means coupled to or forming part of the roller means and effective to apply along-pipe traction forces to the roller means by reaction against parts of the pipe bore adjacent the roller means.
- The profiling method according to the first aspect of the present invention can be applied to the profiling of casings and liners deployed in a well (e.g. a hydrocarbon exploration or production well), and the profile created by use of the method may be a liner hanger, or a landing nipple, or another such downhole profile of the type which previously had to be provided by inserting an annular article or mechanism into the well, lowering it the required depth, and there anchoring it (which required either a larger diameter of well for a given through diameter, or a restricted through diameter for a given well diameter, together with the costs and inconvenience of manufacturing and installing the article or mechanism). Additionally or alternatively, the profiling method according to the first aspect of the present invention can be applied to increasing the diameter of a complete length of pipe; for example, where a well has been cased to a certain depth (the casing having a substantially constant diameter), the casing can be extended downwardly by lowering a further length of pipe (of lesser diameter such that it freely passes down the previously installed casing) to a depth where the top of the further length lies a short way into the lower end of the previously installed casing and there expanding the upper end of the further length to form a joint with the lower end of the previously installed casing (e.g. by using the method according to the second aspect of the present invention), followed by circumferential expansion of the remainder of the further length to match the bore of the previously installed casing.
- According to a second aspect of the present invention there is provided a conjoining method for conjoining two pipes or other hollow tubular articles, said conjoining method comprising the steps of locating one of the two pipes within and longitudinally overlapping one of the other of the two pipes, applying roller means to a part of the bore of the inner of the two pipes at a location where it is intended that the two pipes be conjoined, translating the roller means across the bore in a direction including a circumferential component while applying a radially outwardly directed force to the roller means, and continuing such translation and force application until the inner pipe is plastically deformed into permanent contact with the outer pipe and is thereby conjoined thereto.
- Said deformation may be accomplished by radial compression of the pipe wall or by circumferential stretching of the pipe wall, or by a combination of such radial compression and circumferential stretching.
- Said direction may be purely circumferential, or said direction may be partly circumferential and partly longitudinal.
- The location where the pipes are intended to be conjoined may be remove from an accessible end of the bore, and the conjoining method then comprises the further steps of inserting the roller means into the accessible end of the bore (if the roller means is not already in the bore), and transferring the roller means to the intended location. Transfer of the roller means is preferably accomplished by the step of actuating traction means coupled to or forming part of the roller means and effective to apply along-bore traction forces to the roller means by reaction against parts of the pipe bore adjacent the roller means.
- The conjoining method according to the second aspect of the present invention can be applied to the mutual joining of successive lengths of casing or liner deployed in a well (e.g. a hydrocarbon exploration or production well), such that conventional screw-threaded connectors are not required.
- According to third aspect of the present invention, there is provided expansion apparatus for expanding a pipe or other hollow tubular article, said expansion apparatus comprising roller means constructed or adapted for rolling deployment against the bore of the pipe, said roller means comprising at least one set of individual rollers each mounted for rotation about a respective rotation axis which is generally parallel to the longitudinal axis of the apparatus, the rotation axes of said at least one set of rollers being circumferentially distributed around the expansion apparatus and each being radially offset from the longitudinal axis of the expansion apparatus, the expansion apparatus being selectively rotatable around its longitudinal axis.
- The rotation axes of said at least one set of rollers may conform to a first regime in which each said rotation axis is substantially parallel to the longitudinal axis of the expansion apparatus in a generally cylindrical configuration, or the rotation axes of said at least one set of rollers may conform to a second regime in which each said rotation axis lies substantially in a respective radial plane including the longitudinal axis of the expansion apparatus and the rotation axes each converge substantially towards a common point substantially on the longitudinal axis of the expansion apparatus in a generally conical configuration, or the rotation axes of said at least one set of rollers may conform to third regime in which each said rotation axis is similarly skewed with respect to the longitudinal axis of the expansion apparatus in a generally helical configuration which may be non-convergent (cylindrical) or convergent (conical). Rollers in said first regime are particularly suited to profiling and finish expansion of pipes and other hollow tubular articles, rollers in said second regime are particularly suited to commencing expansion in, and to flaring of pipes, and other hollow tubular articles, while rollers in said third regime are suited to providing longitudinal traction in addition to such functions of the first or second regimes as are provided by other facets of the roller axes besides skew. The expansion apparatus may have only a single such set of rollers, or the expansion apparatus may have a plurality of such sets of rollers which may conform to two or more of the aforesaid regimes of roller axis alignments; in a particular example where the expansion apparatus has a set of rollers conforming to the second regime located at leading end of the exemplary expansion apparatus and another set of rollers conforming to the first regime located elsewhere on the exemplary expansion apparatus, this exemplary expansion apparatus is particularly suited to expanding complete lengths of hollow tubular casing by reason of the conically disposed leading set of rollers opening up previously unexpended casing and the following set of cylindrically disposed rollers finish-expanding the casing to its intended final diameter; if this exemplary expansion apparatus were modified by the addition of a further set of rollers conforming to third regime with non-convergent axes, this further set of rollers could be utilised for the purpose of applying traction forces to the apparatus by means of the principles described in the present inventor's previously published PACT patent application W/24728-A, the concerns of which are incorporated herein by reference.
- The rollers of said expansion apparatus may each be mounted for rotation about its respective rotation axis substantially without freedom of movement along its respective rotation axis, or the rollers may each be mounted for rotation about its respective rotation axis with freedom of movement along its respective rotation axis, preferably within predetermined limits of movement. In the latter case (freedom of along-axis movement within predetermined limits), this is advantageous in the particular case of rollers conforming to the adore-mentioned second regime (i.e. a conical array of rollers) in that the effective maximum outside diameter of the rollers depends on the position of the rollers along the axis of the expansion apparatus and this diameter is thereby effectively variable; this allows relief of radially outwardly directed forces by longitudinally retracting the expansion apparatus to allow the rollers collectively to move longitudinally in the convergent direction and hence collectively to retract radially inwards away from the bore against which they were immediately previously pressing.
- According to a fourth aspect of the present invention, there is provided profiling/conjoining apparatus for profiling or conjoining pipes or other hollow tubular articles, said profiling/conjoining apparatus comprising roller means and radial urging means selectively operable to urge the roller means radially outwards of a longitudinal axis of the profiling/conjoining apparatus, the radial urging means causing or allowing the roller means to move radially inwards towards the longitudinal axis of the profiling/conjoining apparatus when the radial urging means is not operated, the roller means comprising a plurality of individual rollers each mounted for rotation about a respective rotation axis which is substantially parallel to the longitudinal axis of the profiling/conjoining apparatus, the rotation axes of the individual rollers being circumferentially distributed around the apparatus and each said rotation axis being radially offset from the longitudinal axis of the profiling/conjoining apparatus, the profiling/conjoining apparatus being selectively rotatable around its longitudinal axis to translate the roller means across the bore of a pipe against which the roller means is being radially urged.
- The radial urging means may comprise a respective piston on which each said roller is individually rotatably mounted, each said piston being slidably sealed in a respective radially extending bore formed in a body of the profiling/conjoining apparatus, a radially inner end of each said bore being in fluid communication with fluid pressure supply means selectively pressurisable to operate said radial urging means.
- Alternatively, the radial urging means may comprise bi-conical race means upon which each said individual roller rolls in use of the profiling/conjoining apparatus, and separation variation means selectively operable controllably to vary the longitudinal separation of the two conical races of the bi-conical race means whereby correspondingly to vary the radial displacement of each said roller rotation axis from the longitudinal axis of the profiling/conjoining apparatus. The separation variation means may comprise hydraulic linear motor means selectively pressurisable to drive one of said two cones longitudinally towards and/or away from the other said cone.
- Embodiments of the invention will now be described by way of example, with reference to the accompanying drawings wherein:
- FIG. 1 is a plan view of a first embodiment of profiling tool;
- FIG. 2 is an elevation of the profiling tool of FIG. 1;
- FIG. 3 is a sectional perspective view of the profiling tool of FIGS. 1 & 2, the section being taken on the line III-III in FIG. 2;
- FIG. 4 is an exploded perspective view of the profiling tool of FIGS.1-4;
- FIGS. 5A, 5B, &5C are simplified sectional views of three successive stages of operation of the profiling tool of FIGS. 1-4;
- FIG. 6 is a schematic diagram illustrating the metallurgical principle underlying the operational stage depicted in FIG. 5C;
- FIGS. 7A & 78 are illustrations corresponding to FIGS. 5A & 5B but in respect of a variant of the FIGS.1-4 profiling tool having two rollers instead of three;
- FIGS. 8A & 8B are illustrations corresponding to FIGS. 5A & 5B but in respect of a variant of the FIGS.1-4 profiling tool having five rollers instead of three;
- FIGS. 9A & 9B respectively illustrate starting and finishing stages of a first practical application of the profiling tool of FIGS.1-4;
- FIGS. 10A & 10B respectively illustrate starting and finishing stages of a second practical application of the profiling tool of FIGS.1-4;
- FIGS. 11A & 11B respectively illustrate starting and finishing stages of a third practical application of the profiling tool of FIGS.1-4;
- FIGS. 12A & 12B respectively illustrate starting and finishing stages of a fourth practical application of the profiling tool of FIGS.1-4;
- FIGS. 13A & 13B respectively illustrate starting and finishing stages of a fifth practical application of the profiling tool of FIGS.1-4;
- FIGS. 14A & 14B respectively illustrate starting and finishing stages of a sixth practical application of the profiling tool of FIGS.1-4;
- FIGS. 15A & 15B respectively illustrate starting and finishing stages of a seventh practical application of the profiling tool of FIGS.1-4;
- FIGS. 16A & 16B respectively depict starting and finishing stages of an eighth practical application of the profiling tool of FIGS.1-4;
- FIGS. 17A & 17B respectively depict starting and finishing stages of a ninth practical application of the profiling tool of FIGS.1-4;
- FIG. 18 schematically depicts a tenth practical application of the profiling tool of FIGS.1-4;
- FIG. 19 schematically depicts an eleventh practical application of the profiling tool of FIGS.1-4;
- FIG. 20 is a longitudinal elevation of a first embodiment of expansion tool in accordance with the present invention;
- FIG. 21 is a longitudinal elevation, to an enlarged scale, of part of the expansion tool of FIG. 20;
- FIG. 21A is an exploded view of the tool part illustrated in FIG. 20;
- FIG. 22 a longitudinal section of the tool part illustrated in FIG. 20;
- FIG. 23 is a longitudinal section of the expansion tool illustrated in FIG. 21;
- FIG. 24 is an exploded view of part of the expansion tool illustrated in FIG. 20;
- FIG. 25 is a longitudinal section of an alternative form of the tool part illustrated in FIG. 21;
- FIG. 26 is a longitudinal section of a technical variant of the tool part illustrated in FIG. 21;
- FIG. 27 is a longitudinal elevation of a second embodiment of expansion tool in accordance with the present invention;
- FIGS. 28A, 28B, &28C are respectively a longitudinal section, a longitudinal elevation, and a simplified end view of a third embodiment of expansion tool in accordance with the present invention;
- FIGS. 29A & 29B are longitudinal sections of a fourth embodiment of expansion tool in accordance with the present invention, respectively in expanded and contracted configurations; and
- FIG. 30 is a longitudinal section of a fifth embodiment of expansion tool in accordance with the present invention.
- Referring first to FIGS. 1 & 2, these depict a three-
roller profiling tool 100 in accordance with the present invention. Thetool 100 has abody 102 which is hollow and generally tubular, with conventional screw-threadedend connectors 104 & 106 for connection to other components (not shown) of a downhole assembly. Theend connectors 104 & 106 are of reduced diameter (compared to the outside diameter of the longitudinallycentral body part 108 of the tool 100), and together with threelongitudinal flutes 110 on thecentral body part 108, allow the passage of fluids along the outside of thetool 100. Thecentral body part 108 has threelands 112 defined between the threeflutes 110, eachland 112 being formed with arespective recess 114 to hold a respective roller 116 (see also FIGS. 3 & 4). Each of therecesses 114 has parallel sides and extends radially from the radially perforatedtubular core 115 of thetool 100 to the exterior of therespective land 112. Each of the mutuallyidentical rollers 116 is near-cylindrical and slightly barrelled (i.e. of slightly greater diameter in its longitudinally central region than at either longitudinal end, with a generally convex profile having a discontinuity-free transition between greatest and least diameters). Each of therollers 116 is mounted by means of abearing 118 at each end of the respective roller for rotation about a respective rotation axis which is parallel to the longitudinal axis of thetool 100 and radially offset therefrom at 120-degree mutual circumferential separations around thecentral part 108. Thebearings 118 are formed as integral end members of radiallyslidable pistons 120, onepiston 120 being slidably sealed within each radially extendingrecess 114. The inner end of eachpiston 120 is exposed to the pressure of fluid within the hollow core of thetool 100 by way of the radial perforations in thetubular core 115; in use of thetool 100, this fluid pressure will be the downhole pressure of mud or other liquid within a drillstring or coiled tubing at or near the lower end of which thetoll 100 will be mounted. Thus by suitably pressurising thecore 115 of thetool 100, thepistons 120 can be driven radially outwards with a controllable force which is proportional to the pressurisation, and thereby the piston-mountedrollers 116 can be forged against a pipe bore in a manner to be detailed below. Conversely, when the pressurisation of thecore 115 of thetool 100 is reduced to below whatever is the ambient pressure immediately outside thetool 100, the pistons 120 (together with the piston-mounted rollers 116) are allowed to retract radially back into theirrespective recesses 114. (Such retraction can optionally be encouraged by suitably disposed springs (not shown)). - The principles by which the
profiling tool 100 functions will now be detailed with reference to FIGS. 5 and 6. - FIG. 5A is a schematic end view of the three
rollers 116 within the bore of aninner pipe 180, the remainder of thetool 100 being omitted for the sake of clarity. Thepipe 180 is nested within an outer pipe 190 whose internal diameter is somewhat greater than the outside diameter of theinner pipe 180. As depicted in FIG. 5A, the core of thetool 100 has been pressurised just sufficiently to push thepistons 120 radially outwards and thereby to bring the piston-mountedrollers 116 into contact with the bore of theinner pipe 180, but without at first exerting any significant forces on thepipe 180. - FIG. 5B depicts the next stage of operation of the
profiling tool 100, in which the internal pressurisation of thetool 100 is increased sufficiently above its external pressure (i.e. the pressure in the region between the exterior of thetool 100 and the bore of the pipe 180) such that therollers 116 each exert a substantial outward force, as denoted by the arrow-headed vectors superimposed on eachroller 116 in FIG. 5B. The effect of such outward forces on therollers 116 is circumferentially to deform the wall of the inner pipe 180 (with concomitant distortion of thepipe 180 which is shown in FIG. 5B for the sake of clarity). When the roller-extended lobes touch the bore of the outer pipe 190, theinner pipe 180 is thereby anchored against rotation with respect to the outer pipe 190, or at least constrained against free relative rotation. By simultaneously rotating thetool 100 around its longitudinal axis (which will normally be substantially coincident with the longitudinal axis of the pipe 180), the circumferential deformation of the wall of thepipe 180 tends to become uniform around thepipe 180, and thepipe 180 circumferentially extends into substantially uniform contact with the bore of the outer pipe 190, as depicted in FIG. 5C. This occurs due to the rollers causing rolling compressive yield of the inner pipe wall to cause reduction in wall thickness, increase in circumference and consequent increase in diameter. (Rotation of thetool 100 can be undertaken by any suitable procedure, several of which will subsequently be described). Circumferential deformation of thepipe 180 is initially elastic and may subsequently be plastic. A secondary effect of the process is to generate compressive hoop stress in the internal portion of the inner tube and an interference fit between the inner tube and the outer tube. - From the stage depicted in FIG. 5C wherein the
inner pipe 180 has initially been circumferentially deformed just into full contact with the bore of the outer pipe 190 (thus removing the previous clearance between thepipes 180 and 190) but without stretching or distortion of the outer pipe 190, continued (and possibly increased) internal pressurisation of thetool 100 in conjunction with continued rotation of the tool 100 (at the same rotational speed or at a suitably different rotational speed) forces theinner pipe 180 outwards against the resistance to deformation of the outer pipe 190. Since theinner pipe 180 is now backed by the outer pipe 190 with respect to the radially outward forces being applied by therollers 116 such that the wall of theinner pipe 180 is now pinched between therollers 116 and the outer pipe 190, the mechanism of deformation of thepipe 180 changes to compressive extension by rolling (i.e. the same thinning/extension principle as prevails in conventional steel rolling mills, as schematically depicted in FIG. 6 wherein the circular rolling of FIGS. 5A-5C has been opened out and developed into an equivalent straight-line rolling procedure to enhance the analogy with steel rolling mills). - When operation of the
tool 100 is terminated and therollers 116 are caused or allowed to retract radially into the body of thetool 100 thereby to relieve thepipes 180 of all contact with therollers 116, the induced compressive hoop stress created in the wall of theinner pipe 180 due to the rolling process causes theinner pipe 180 to remain in contact with the inner wall of the outer pipe 190 with very high contact stresses at their interface. - FIGS. 7A & 7B correspond to FIGS. 5A & 5B, and schematically depict the equivalent stages of operation of a two-roller profiling tool (not otherwise shown per se) in order to illustrate the effects of using a profiling tool having fewer than the three rollers of the
profiling tool 100 detailed above. - FIGS. 8A & 8B also correspond to FIGS. 5A & 5B, and schematically depict the equivalent stages of operation of a five-roller profiling tool (not otherwise shown per se) in order to illustrate the effects or using a profiling tool having more than the three rollers of the
profiling tool 100 detailed above. - It should be noted that though the very high contact stresses existing at the interface of the
inner pipe 180 and outer pipe 190 may cause the outer pipe 190 to expand elastically or plastically, it is not a requirement of this process that the outer pipe 190 is capable of any expansion whatsoever. The process would still result in the high contact stresses between theinner pipe 180 and the outer pipe 190 even if the outer pipe 190 was incapable of expansion, eg by being thick walled, by being encased in cement, or being tightly embedded in a rock formation. - Various practical applications of profiling tools in accordance with the invention will now be described with reference to FIGS.9-19. the profiling tool used in these practical applications may be the
profiling tool 100 detailed above, or some variant of such a profiling tool which differs in one or more details without departing from the scope of the invention. - FIG. 5A schematically depicts the upper end of a first pipe or casing200 concentrically nested within the lower end of a second pipe or casing 202 whose bore (internal diameter) is marginally greater than the outside diameter of the first pipe or
casing 200. A profiling tool (not shown) is located within the upper end of the first pipe or casing 200 where it is overlapped by the second pipe orcasing 202. The rollers of the profiling tool are then radially extended into contact with the bore of the inner pipe or casing 200 by means of internal pressurisation of the profiling tool (or by any other suitable means which may alternatively be utilised for forcing the rollers radially outwards of the profiling tool). The outward forces exerted by the rollers on the bore of the first pipe orcasing 200 are schematically depicted by the force-vector-depictingarrows 204. - From the starting situation depicted in FIG. 9A, combined with suitable rotation of the profiling tool about its longitudinal axis (which is substantially coincident with the longitudinal axis of the first pipe or casing200), the finish situation schematically depicted in FIG. 9B is arrived at, namely the upper end of the inner pipe or
casing 200 is profiled by permanent plastic expansion into conjunction with the lower end of the second pipe orcasing 202. Thereby the two pipes or casings are permanently conjoined without the use of any form of separate connector and without the use of conventional joining techniques such as welding. - FIGS. 10A & 10B correspond to FIGS. 9A & 9B respectively, and schematically illustrate an optional modification of the profiling/conjoining technique described with respect to FIGS. 9A & 9B. The modification consists of applying an
adherent coating 206 of hard particulate material to the exterior of the upper end of the first (inner) pipe orcasing 200 prior to its location within the lower end of the second (outer) pipe orcasing 202. The hard particulate material may consist of carbide granules, e.g. tungsten carbide granules such as are commonly used to coat downhole reamers. In the application depicted in FIGS. 10A & 10B, the hard particulate material is selected for its crush resistance rather than for its abrasive qualities, and in particular the material is selected for its ability to interpenetrate the meeting surfaces of two sheets of steel which are pressed together with the hard particulate material sandwiched between the steel components. Such sandwiching is schematically depicted in FIG. 10B. Tests have shown a surprising increase in resistance to separation forces of pipes or other articles conjoined by a profiling tool in accordance with the invention to withstand, where a coating of hard particulate material was first interposed between the parts being conjoined. It is preferred that of the whole area to be coated, only a majority of the area is actually covered with the particulate material, e.g. 10% of the area. (It is believed that a higher covering factor actually reduces the interpenetration effect and hence diminishes the benefits below the optimum level). - Referring now to FIGS. 11A & 11B, these schematically depict an optional modification of the FIG. 9 conjoining procedure to achieve improved sealing between the two conjoined pipes or casings. As depicted in FIG. 11A, the modification comprises initially fitting the exterior of the first (inner) pipe or casing200 with a circumferentially extending and part-recessed
ductile metal ring 208, which may (for example) be formed of a suitable copper alloy or a suitable tin/lead alloy. The modification also comprises initially fitting the exterior of the first (inner) pipe or casing 200 with a circumferentially extending and fully recessedelastomeric ring 210. As depicted in FIG. 11B, therings casings 200 & 202 after these have been conjoined by the profiling tool, and thereby a mutual sealing is achieved which may be expected to be superior to the basic FIG. 9 arrangement in otherwise equal circumstances. In suitable situations, one or other of the sealing rings 208 and 210 may be omitted or multiplied to achieve a necessary or desirable level of sealing (e.g. as in FIG. 12). - Referring now to FIGS. 12A & 12B, these schematically depict an arrangement in which the lower end of the second (outer) casing202 is pre-formed to have a reduced diameter so as to function as a casing hanger. The upper end of the first (inner) casing 200 is correspondingly pre-formed to have an increased diameter which is complementary to the reduced diameter of the casing hanger formed at the lower end of the
outer casing 202, as depicted in FIG. 12A. Optionally, the upper end of the first (inner) casing 200 may be provided with an external seal in the form of anelastomeric ring 212 flush-mounted in a circumferential groove formed in the outer surface of thefirst casing 200. The arrangement of FIG. 12A differs from the arrangement of FIG. 9A in that the latter arrangement requires the pipe or casing 200 to be positively held up (to avoid dropping down the well our of its intended position) until joined to the upper pipe or casing as in FIG. 9B, whereas in the FIG. 12A arrangement the casing hanger allows the inner/lower casing 200 to be lowered into position and then released without the possibility of dropping out of position prior to the two casings being conjoined by the profiling tool, as depicted in FIG. 12B. - Referring now to FIGS. 13A & 13B, these schematically depict another optional modification of the FIG. 9 conjoining procedure in order to achieve a superior resistance to post-conjunction separation. As depicted in FIG. 13A, the modification consists of initially forming the bore (inner surface) of the second (outer) pipe or casing202 with two circumferentially extending
grooves 214 each having a width which reduces with increasing depth. As depicted in FIG. 13B, when the two pipes orcasings casing 200 will have been plastically deformed into thegrooves 214, thereby increasing the interlocking of the conjoined pipes or casings and extending their resistance to post-conjunction separation. While twogrooves 214 are shown in FIGS. 13A & 13B by way of example, this procedure can in suitable circumstances be carried with one such groove, or with three or more such grooves. While each of thegrooves 214 has been shown with a preferred trapezoidal cross-section, other suitable groove cross-sections can be substituted. - The superior joint strength of the FIG. 13 arrangement can be combined with the superior sealing function of the FIG. 11 arrangement, as shown in FIG. 14. FIG. 14A schematically depicts the pre-jointing configuration, in which the exterior of the first (inner) pipe or
casing 200 is fitted with a longitudinally spaced pair of circumferentially extending and part-recessed ductile metal rings 208, while the bore (inner surface) of the second (outer) pipe orcasing 202 is formed with two circumferentially extendinggrooves 214 each having a width which reduces with increasing depth. The longitudinal spacing of the twogrooves 214 is substantially the same as the longitudinal spacing of the seal rings 208. When the two pipes or casings are conjoined by use of the profiling tool (as schematically depicted in FIG. 14B), the first (inner) pipe orcasing 200 is not only plastically deformed into the corresponding grooves 214 (as in FIG. 13B), but the metal rings 208 are crushed into the bottoms of thesegrooves 214 thereby to form high grade metal-to-metal seals. - In the arrangements of FIGS.9-14, it is assumed that the second (outer) pipe or
casing 202 undergoes little or no permanent deformation, which may either be due to the outer pipe orcasing 202 being inherently rigid compared to the first (inner) pipe orcasing 200, or be due to the outer pipe or casing being rigidly backed (e.g. by cured concrete filling the annulus around the outer pipe or casing 202), or be due to a combination of these and/or other reasons. FIG. 15 schematically depicts an alternative situation in which the second (outer) pipe orcasing 202 does not have the previously assumed rigidity. As schematically depicted in FIG. 15A, the pre-jointing configuration is merely a variant of the previously described pipe-joining arrangements, in which the exterior of the upper end of the first (inner) pipe orcasing 200 is provided with two part-recessed metal seal rings 208 (each mounted in a respective circumferential groove), neither pipe being otherwise modified from its initial plain tubular shape. To conjoin thecasings - In each of the arrangements described with reference to FIGS.9-15, the bore of the first pipe or
casing 200 was generally smaller than the bore of the second pipe orcasing 202. However, there are situations where it would be necessary or desirable that these bores be about mutually equal following conjoining, and this requires variation of the previously described arrangements, as will now be detailed. - In the arrangement schematically depicted in FIG. 16A, the lower end of the second (outer) pipe or
casing 202 is pre-formed to have an enlarged diameter, the bore (inside diameter) of this enlarged end being marginally greater than the outside diameter of the first (inner) pipe or casing 200 intended to be conjoined thereto. The first (inner) pipe orcasing 200 has initial dimensions which are similar or identical to those of the second pipe or casing 202 (ocher than for the enlarged end of the pipe or casing 202). Following use of the profiling tool to expand the overlapping ends of the two pipes or casings, both bores have about the same diameter (as depicted in FIG. 16B) which has certain advantages (e.g. a certain minimum bore at depth in a well no longer requires a larger or much larger bore at lesser depth in the well). While surface-level pipes can be extended in this manner without difficulties in adding extra lengths of pipe, special techniques may be necessary for feeding successive lengths of casing to downhole locations when extending casing in a downhole direction. (One possible solution to this requirement may be provide successive lengths of casing with a reduced diameter, and to expand the entire length of each successive length of casing to the uniform bore of previously installed casing, this being achievable by further aspects of the invention to be subsequently described by way of example with reference to FIGS. 20 et seq). - A modification of the procedure and arrangement of FIG. 16 is schematically depicted in FIG. 17 wherein the end of the outer pipe or casing is not pre-formed to an enlarged diameter (FIG. 17A). It is assumed in this case that the profiling tool is capable of exerting sufficient outward force through its rollers as to be capable of sufficiently extending the diameter of the outer pipe or casing simultaneously with the diametral extension of the inner pipe or casing during forming of the joint (FIG. 17B).
- As well as conjoining pipes or casings, the profiling tool in accordance with the invention can be utilised for other useful purposes such as will now be detailed with reference to FIGS. 18 and 19.
- In the situation schematically depicted in FIG. 18, a riser220 has a
branch 222 which is to be blocked off while continuing to allow free flow of fluid along the riser 220. To meet this requirement, asleeve 224 is placed within the riser 220 in position to bridge thebranch 222. Thesleeve 224 initially has an external diameter which is just sufficiently less than the internal diameter of the riser 220 as to allow thesleeve 224 to be passed along the riser to its required location. Each end of thesleeve 224 is provided withexternal seals 226 of any suitable form, e.g. the seals described with reference to FIG. 11. When thesleeve 224 is correctly located across thebranch 222, a profiling tool (not shown in FIG. 18) is applied to each end of thesleeve 224 to expand the sleeve ends into mechanically anchoring and fluid-sealing contact with the bore of the riser 220, thus permanently sealing the branch (until such time as the sleeve may be milled away or a window may be cut through it). - FIG. 19 schematically depicts another alternative use of the profiling tool in accordance with the invention, in which a valve requires to be installed within plain pipe or casing240 (i.e. pipe or casing free of landing nipples or other means of locating and anchoring downhole equipment). A
valve 242 of a size to fit within the pipe orcasing 240 has a hollow tubular sleeve 244 welded or otherwise secured to one end of the valve. The sleeve 244 initially has an external diameter which is just sufficiently less than the internal diameter of the pipe or casing 240 as to allow the mutually attachedvalve 242 and sleeve 244 to passed down the pipe or casing 240 to the required location. The end of the sleeve 244 opposite to the end attached to thevalve 242 is provided withexternal seals 246 of any suitable form, e.g. the seals described with reference to FIG. 11. When thevalve 242 is correctly located where it is intended to be installed, a profiling tool (not shown in FIG. 19) is applied to the end of the sleeve opposite thevalve 242 to expand that end of the sleeve 244 into mechanically anchoring and fluid-sealing contact with the bore of the pipe orcasing 240. An optional modification of the FIG. 19 arrangement is to attach an expandable sleeve to both sides of the valve such that the valve can be anchored and sealed on either side instead of one side only as in FIG. 19. - Turning now to FIG. 20, this illustrates a side elevation of an embodiment of
expansion tool 300 in accordance with the present invention. Theexpansion tool 300 is an assembly of aprimary expansion tool 302 and asecondary expansion tool 304, together with aconnector sub 306 which is not essential to the invention but which facilitates mechanical and hydraulic coupling of theexpansion tool 300 to the downhole end of a drillstring (not shown) or to the downhole end of coiled tubing (not shown). Theprimary expansion tool 302 is shown separately and to an enlarged scale in FIG. 21 (and again, in exploded view, in FIG. 21A). Theexpansion tool 300 is shown in longitudinal section in FIG. 22, theprimary expansion tool 302 is shown separately in longitudinal section in FIG. 23, and thesecondary expansion tool 304 is shown separately in an exploded view in FIG. 24. - From FIGS.20-24 it will be seen that the general form of the
primary expansion tool 302 is that of a roller tool externally presenting a conical array of fourtapered rollers 310 tapering towards an imaginary point (not denoted) ahead of the leading end of theexpansion tool 300, i.e. the right end of thetool 300 as viewed in FIGS. 20 & 21. As may be more clearly seen in FIGS. 21A, 22, & 23, therollers 310 run on aconical race 312 integrally formed on the surface of the body of theprimary expansion cool 302, therollers 310 being constrained for true cracking by a longitudinally slottedcage 314. Anend retainer 316 for therollers 310 is secured on the screw-threadedleading end 318 of theprimary expansion tool 302 by means of aring nut 320. The trailingend 322 of theprimary expansion tool 302 is screw-threaded into theleading end 106 of thesecondary expansion tool 304 to form thecomposite expansion tool 300. Functioning of theprimary expansion tool 300 will be detailed subsequently. - The
secondary expansion tool 304 is substantially identical to the previously detailed profiling tool 100 (except for one important difference which is described below), and accordingly those parts of thesecondary expansion tool 304 which are the same as corresponding parts of the profiling tool 100 (or which are obvious modifications thereof) are given the same reference numerals. The important difference in thesecondary expansion tool 304 with respect to theprofiling tool 100 is that the rotation axes of therollers 116 are no longer exactly parallel to the longitudinal axis of the tool, but are skewed such that each individual roller rotation axis is tangential to a respective imaginary helix, though making only a small angle with respect to the longitudinal direction (compare FIG. 24 with FIG. 4). As particularly shown in FIGS. 20 and 24, the direction (or “hand”) of the skew of therollers 116 in thesecondary expansion tool 304 is such that the conventional clockwise rotation of the tool (as viewed from the uphole end of the tool, i.e. the left end as viewed in FIGS. 20 & 22) is such as to induce a reaction against the bore of the casing (not shown in FIGS. 20-24) which tends not only to rotate thetool 300 around its longitudinal axis but also to advance thetool 300 in a longitudinal direction, i.e. to drive thetool 300 rightwards as viewed in FIGS. 20 & 22. (The use of skewed bore-contacting rollers to cause a rotating downhole tool to drive itself along a casing is detailed in the above-mentioned WO93/24728-A1). - In use of the
expansion tool 300 to expand casing (not shown) previously deployed to a selected downhole location in a well, thetool 300 is lowered on a drillstring (not shown) or coiled cubing (now shown) until theprimary expansion cool 302 at the leading end of thetool 300 engages the uphole end of the unexpended casing. The core of thetool 300 is pressurised to force the roller-carryingpistons 120 radially outwards and hence to force therollers 116 into firm contact with the casing bore. Thetool 300 is simultaneously caused to rotate clockwise (as viewed from its uphole end) by any suitable means (e.g. by rotating the drillstring (if used), or by actuating a downhole mud motor (not shown) through which thetool 300 is coupled to the drillstring or coiled cubing), and this rotation combines with the skew of therollers 116 of thesecondary tool 304 to drive thetool 300 as a whole in the downhole direction. The conical array ofrollers 310 in theprimary expansion cool 302 forces its way into the uphole end of the unexpended casing where the combination of thrust (in a downhole direction) and rotation rolls the casing into a conical shape that expands until its inside diameter is just greater than the maximum diameter of the array of rollers 310 (i.e. the circumscribing diameter of the array ofrollers 310 at its upstream end). Thereby theprimary expansion tool 302 functions to bring about the primary or initial expansion of the casing. - The secondary expansion tool304 (which is immediately uphole of the primary expansion tool 302) is internally pressurised to a pressure which not only ensures that the
rollers 116 contact the casing bore with sufficient force as to enable the longitudinal traction force to be generated by rotation of the tool about its longitudinal axis but also forces thepistons 120 radially outwards to an extent that positions the piston-carriedrollers 116 sufficiently radially distant from the longitudinal axis of the tool 304 (substantially coincident with the centreline of the casing) as to complete the diametral expansion of the casing to the intended final diameter of the casing. Thereby thesecondary expansion tool 304 functions to bring about the secondary expansion of the casing. (This secondary expansion will normally be the final expansion of the casing, but if further expansion of the casing is necessary or desirable, theexpansion tool 300 can be driven through the casing again with therollers 116 of the secondary expansion tool set at a greater radial distance from the longitudinal axis of thetool 304, or a larger expansion tool can be driven through the casing). While theprimary expansion tool 302 with its conical array ofrollers 310 is preferred for initial expansion of casing, thesecondary expansion tool 304 with its radially adjustable rollers has the advantage that the final diameter to which the casing is expanded can be selected within a range of diameters. Moreover, this final diameter can not only be adjusted while thetool 304 is static but can also be adjusted during operation of the tool by suitable adjustment of the extent to which the interior of thetool 304 is pressurised above the pressure around the outside of thetool 104. This feature also gives the necessary compliance to deal with variances in wall thickness. - FIG. 25 is a longitudinal section of a
primary expansion tool 402 which is a modified version of the primary expansion tool 302 (detailed above with reference to FIGS. 20-24). Components of thetool 402 which correspond to components of thetool 302 are given the sane reference numeral except that the leading “3” is replaced by a leading “4”. Thetool 402 is essentially the same as thetool 302 except that therollers 410 are longer than therollers 310, and theconical race 412 has a cone angle which is less than the cone angle of the race 312 (i.e. therace 412 tapers less and is more nearly cylindrical than the race 312). As shown in FIG. 25, the trailing (uphole) end of thetool 402 is broken away. For details of other parts of thetool 402, reference should be made to the foregoing description of thetool 302. In contrast to FIGS. 20-24, FIG. 25 also shows a fragment ofcasing 480 which is undergoing expansion by thetool 402. - FIG. 26 is a longitudinal section of a
primary expansion tool 502 which is a further-modified version of theprimary expansion tool 302. Components of thetool 502 which correspond to components of thetool 302 are given the same reference numeral except that the a leading “3” is replaced by a leading “5”. Thetool 502 is identical to thetool 402 except that the rollers 510 have a length which is somewhat less than the length of therollers 410. This reduced length allows the rollers 510 some longitudinal freedom within their windows in the cage 514. Consequently, although expansion operation of theprimary expansion tool 502 is essentially identical to operation of the primary expansion tool 410 (and similar to operation of theprimary expansion tool 310 except for functional variations occasioned by the different conicities of the respective races), reversal of longitudinal thrust on the tool 502 (I.e. pulling thetool 502 uphole instead of pushing thetool 502 downhole) will cause or allow the rollers 510 to slide along theconical race 512 in the direction of its reducing diameter, thus allowing the rollers 510 radially to retract from the casing bore as illustrated in FIG. 26. Such roller retraction frees thetool 502 from thecasing 480 and permits free withdrawal of thetool 502 in an uphole direction whereas thenon-retracting rollers 410 of thetool 402 might possibly jam thetool 402 within thecasing 480 in the event of attempted withdrawal of thetool 402. - Turning now to FIG. 27, this is a simplified longitudinal elevation of a casing expander assembly600 for use in downhole expansion of a solid, slotted or
imperforate metal tube 602 within a casing 604 which lines a well. The casing expander assembly 600 is a three-stage expansion tool which is generally similar (apart from the number of expansion stages) to the two-stage expansion tool 300 described above with reference to FIGS. 20-24. - In order from its leading (downhole) end, the expander assembly600 comprises a running/
guide assembly 610, a first-stage conical expander 612, aninter-stage coupling 614, a second-stage conical expander 616, a furtherinter-stage coupling 618, and a third-stage cylindrical expander 620. - The first-
stage conical expander 612 comprises a conical array of tapered rollers which may be the same as either one of theprimary expansion tools - The second-
stage conical expander 616 is an enlarged-diameter version of the first-stage conical expander 612 dimensioned to provide the intermediate expansion stage of the three-stage expansion assembly 600. The diameter of the leading (narrow) end of the second-stage expander 616 (the lower end of theexpander 616 as viewed in FIG. 27) is marginally less than the diameter of the trailing (wide) end of the first-stage expander 612 (the upper end, of theexpander 612 as viewed in FIG. 27) such that the second-stage expander 616 is not precluded from entering initially expandedtube 602 resulting from operation of the first-stage expander 612. - The third-
stage expander 620 is a generally cylindrical expander which may be similar either to theprofiling tool 100 or to thesecondary expansion tool 304. (Although the rollers of the third-stage expander 620 may be termed “cylindrical” in order to facilitate distinction over the conical rollers of the first-stage and second-stage expanders 612 & 616, and although in certain circumstances such so-called “cylindrical” rollers may in fact be truly cylindrical, the rollers of the cylindrical expander will usually be barrelled to avoid excessive end stresses). The rollers of the third-stage expander 620 will normally be radially extended from the body of theexpander 620 by an extent that the third-stage expander 620 rolls thetube 602 into its final extension against the inside of casing 604, such that no further expansion of thetube 602 is required in the short term. - The
interstage couplings - The rollers of the third-
stage expander 620 may be skewed such that rotation of the assembly 600 drives the assembly in a downhole direction; alternatively, the rollers may be unskewed and forward thrust on the expanders be provided by suitable weights, e.g. bydrill collars 630 immediately above the assembly 600. Where the third-stage rollers are skewed, drill collars can be employed to augment the downhole thrust provided by rotation of the assembly 600. - As depicted in FIG. 27, the three-stage expander assembly600 is suspended from a
drillstring 640 which not only serves for transmitting rotation to the assembly 600 but also serves for transmitting hydraulic fluid under pressure to the assembly 600 for radial extension of the third-stage rollers, for cooling the assembly 600 and newlydeformed tube 602, and for flushing debris out of the work region. - In suitable circumstances, the
drillstring 640 may be substituted by coiled tubing (not shown) of a form known per se. - Turning now to FIG. 28 which is divided into three mutually related FIGS. 28A, 28B, &28C), these illustrate a
primary expansion tool 702 which may be summarised as being the primary expansion tool 402 (FIG. 25) with hardsteel bearing balls 710 substituted for therollers 410. Each of theballs 710 runs in a respectivecircumferential groove 712, and is located for proper tracking by a suitablyperforated cage 714. As with thetool 402, thecage 714 is retained by aretainer 716 secured on the screw-threaded leading end 718 of thetool 702 by means of aring nut 720. Operation of thetool 702 is functionally similar to operation of thetool 402, as is illustrated by the expansion effect of thetool 702 oncasing 480. - The
primary expansion tool 702 as shown in FIGS. 28A-28C could be modified by the substitution of the series ofcircumferential ball tricks 712 with a single spiral track (not shown) around which theballs 710 would circulate at ever-increasing radii to create the requisite expansion forces on the casing. At the point of maximum radius, theballs 710 would be recirculated back to the point of minimum radius (near the leading end of thetool 702, adjacent the retainer 716) by means of a channel (not shown) formed entirely within the central body of thetool 702 in a form analogous to a recirculating ball-screw (known per se). - FIGS. 29A & 29B illustrate a
modification 802 of the ball-type expansionprimary expansion tool 702 of FIG. 28 analogous to the FIG. 26modification 502 of the FIG. 25 roller-typeprimary expansion tool 402. In the modified ball-typeprimary expansion tool 802, the hard steel bearing balls 810 run in longitudinally-extendinggrooves 812 instead of thecircumferential grooves 712 of thetool 702. The ball-guiding perforations in thecage 814 are longitudinally extended into slots which allow individual balls 810 to take up different longitudinal positions (and hence different effective radii) according to whether thetool 802 is being pushed downhole (FIG. 28A) or being pulled uphole (FIG. 28B). In the latter case, the balls 810 are relieved from pressure on the surroundingcasing 480 and thereby obviate any risk of thetool 802 becoming jammed in partly-expanded casing. - In the profiling and expansion tools with controllably displaceable rollers as previously described, e.g. with reference to FIGS. 4 and 24, the ability to obtain and to utilise hydraulic pressure may place practical limits on the forces which can be exerted by the rollers. FIG. 30 illustrates a roller-type expansion/
profiling tool 900 which utilises a mechanical force-multiplying mechanism to magnify a force initially produced by controlled hydraulic pressure, and to apply the magnified force to profiling/expandingrollers 902. Each of the plurality of rollers 902 (only two being visible in FIG. 30) has a longitudinally central portion which is near-cylindrical and slightly barrelled (i.e. slightly convex), bounded on either side by end portions which are conical, both end portions tapering from conjunction with the central portion to a minimum diameter at each end. Rotation of eachroller 902 about a respective rotation axis which is parallel to the longitudinal axis of thetool 900 and at a controllably variable radial displacement therefrom is ensured by a roller-guidingcage 904 of suitable form. - The effective working diameter of the
tool 900 is dependent on the (normally equal) radial displacements of therollers 902 from the longitudinal axis of the tool 900 (such displacement being shown at a minimum in FIG. 30). The conical end portions of eachroller 902 each run on a respective one of twoconical races 906 and 908 whose longitudinal separation determines the radial displacement of therollers 902. Theconical races 906 and 909 are coupled for synchronous rotation but variable separation by means of asp1ined shaft 910 which is rigid with theupper race 906 and non-rotatably slidable in the lower race 908. Thetool 900 has a hollow core which hydraulically couples through anupper sub 912 to a drillstring (not shown) which both selectively rotates thetool 900 within surroundingcasing 990 which is to be profiled/expanded by thetool 900 and transmits controllable hydraulic pressure to the core of thetool 900 for controlling the roller displacement as will now be detailed. - The lower end of the tool900 (with which the lower race 908 is integral) is formed as
hollow cylinder 914 within which apiston 916 is slidably sealed. Thepiston 916 is mounted on the lower end of a downward extension of theshaft 910 which is hollow to link through the tool core and the drillstring to the controlled hydraulic pressure. Thepiston 916 divides thecylinder 914 into upper and lower parts. The upper part of thecylinder 914 is linked to the controlled hydraulic pressure by way of a side port 918 in thehollow shaft 910, just above thepiston 916. The lower part of thecylinder 914 is vented to the outside of thetool 900 through ahollow sub 920 which constitutes the lower end of the tool 900 (and which enables further components, tools, or drillstring (not shown)) to be connected below the tool 900). Thereby a controllable hydraulic pressure differential can be selectively created across thepiston 916, with consequent control of the longitudinal separation of the two roller-supportingconical races 906 and 908 which in turn controls the effective rolling diameter of thetool 900. - While certain modifications and variations of the invention have been described above, the invention is not restricted thereto, and other modifications and variations can be adopted without departing from the scope of the invention as defined in the appended claims.
Claims (34)
Priority Applications (15)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/828,508 US6578630B2 (en) | 1999-12-22 | 2001-04-06 | Apparatus and methods for expanding tubulars in a wellbore |
US09/969,089 US6752215B2 (en) | 1999-12-22 | 2001-10-02 | Method and apparatus for expanding and separating tubulars in a wellbore |
US09/990,092 US6698517B2 (en) | 1999-12-22 | 2001-11-21 | Apparatus, methods, and applications for expanding tubulars in a wellbore |
US10/123,035 US6695063B2 (en) | 1999-12-22 | 2002-04-15 | Expansion assembly for a tubular expander tool, and method of tubular expansion |
US10/212,304 US6712142B2 (en) | 1999-12-22 | 2002-08-05 | Apparatus and methods for expanding tubulars in a wellbore |
US10/217,833 US6702030B2 (en) | 1998-12-22 | 2002-08-13 | Procedures and equipment for profiling and jointing of pipes |
US10/750,208 US7124826B2 (en) | 1998-12-22 | 2003-12-31 | Procedures and equipment for profiling and jointing of pipes |
US10/796,250 US6902000B2 (en) | 1999-12-22 | 2004-03-09 | Apparatus and methods for expanding tubulars in a wellbore |
US10/863,825 US7373990B2 (en) | 1999-12-22 | 2004-06-08 | Method and apparatus for expanding and separating tubulars in a wellbore |
US10/954,866 US7275602B2 (en) | 1999-12-22 | 2004-09-30 | Methods for expanding tubular strings and isolating subterranean zones |
US10/990,331 US7367404B2 (en) | 1998-12-22 | 2004-11-16 | Tubing seal |
US11/082,738 US7086478B2 (en) | 1999-12-22 | 2005-03-17 | Apparatus and methods for expanding tubulars in a wellbore |
US11/865,850 US7543637B2 (en) | 1999-12-22 | 2007-10-02 | Methods for expanding tubular strings and isolating subterranean zones |
US12/119,216 US7921925B2 (en) | 1999-12-22 | 2008-05-12 | Method and apparatus for expanding and separating tubulars in a wellbore |
US12/467,103 US8006771B2 (en) | 1999-12-22 | 2009-05-15 | Methods for expanding tubular strings and isolating subterranean zones |
Applications Claiming Priority (12)
Application Number | Priority Date | Filing Date | Title |
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GBGB9828234.6A GB9828234D0 (en) | 1998-12-22 | 1998-12-22 | Pipe expansion apparatus |
GB9828234.6 | 1998-12-22 | ||
GB9828234 | 1998-12-22 | ||
GBGB9900835.1A GB9900835D0 (en) | 1999-01-15 | 1999-01-15 | Pipe expansion apparatus |
GB9900835.1 | 1999-01-15 | ||
GB9900835 | 1999-01-15 | ||
GBGB9923783.6A GB9923783D0 (en) | 1999-10-08 | 1999-10-08 | Pipe expansion apparatus |
GB9923783 | 1999-10-08 | ||
GB9923783.6 | 1999-10-08 | ||
GB9924189.5 | 1999-10-13 | ||
GB9924189 | 1999-10-13 | ||
GBGB9924189.5A GB9924189D0 (en) | 1999-10-13 | 1999-10-13 | Pipe expansion apparatus |
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US09/469,692 Continuation-In-Part US6325148B1 (en) | 1999-12-22 | 1999-12-22 | Tools and methods for use with expandable tubulars |
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US09/469,692 Continuation-In-Part US6325148B1 (en) | 1999-12-22 | 1999-12-22 | Tools and methods for use with expandable tubulars |
US09/828,508 Continuation-In-Part US6578630B2 (en) | 1999-12-22 | 2001-04-06 | Apparatus and methods for expanding tubulars in a wellbore |
US09/828,508 Continuation US6578630B2 (en) | 1999-12-22 | 2001-04-06 | Apparatus and methods for expanding tubulars in a wellbore |
US09/969,089 Continuation-In-Part US6752215B2 (en) | 1999-12-22 | 2001-10-02 | Method and apparatus for expanding and separating tubulars in a wellbore |
US6682402A Continuation-In-Part | 1999-12-22 | 2002-02-04 | |
US10/212,304 Division US6712142B2 (en) | 1999-12-22 | 2002-08-05 | Apparatus and methods for expanding tubulars in a wellbore |
US10/212,304 Continuation-In-Part US6712142B2 (en) | 1999-12-22 | 2002-08-05 | Apparatus and methods for expanding tubulars in a wellbore |
US10/217,833 Continuation US6702030B2 (en) | 1998-12-22 | 2002-08-13 | Procedures and equipment for profiling and jointing of pipes |
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US20020079106A1 true US20020079106A1 (en) | 2002-06-27 |
US6457532B1 US6457532B1 (en) | 2002-10-01 |
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US09/469,643 Expired - Lifetime US6543552B1 (en) | 1998-12-22 | 1999-12-22 | Method and apparatus for drilling and lining a wellbore |
US09/469,690 Expired - Lifetime US6457532B1 (en) | 1998-12-22 | 1999-12-22 | Procedures and equipment for profiling and jointing of pipes |
US09/470,176 Expired - Lifetime US6446323B1 (en) | 1998-12-22 | 1999-12-22 | Profile formation |
US09/469,526 Expired - Lifetime US6702029B2 (en) | 1998-12-22 | 1999-12-22 | Tubing anchor |
US09/469,681 Expired - Lifetime US6527049B2 (en) | 1998-12-22 | 1999-12-22 | Apparatus and method for isolating a section of tubing |
US10/145,599 Expired - Lifetime US6688400B2 (en) | 1998-12-22 | 2002-05-14 | Downhole sealing |
US10/217,833 Expired - Lifetime US6702030B2 (en) | 1998-12-22 | 2002-08-13 | Procedures and equipment for profiling and jointing of pipes |
US10/320,187 Expired - Fee Related US6923261B2 (en) | 1998-12-22 | 2002-12-16 | Apparatus and method for expanding a tubular |
US10/364,718 Expired - Lifetime US6742606B2 (en) | 1998-12-22 | 2003-02-11 | Method and apparatus for drilling and lining a wellbore |
US10/661,446 Expired - Lifetime US6976539B2 (en) | 1998-12-22 | 2003-09-11 | Tubing anchor |
US10/748,592 Expired - Lifetime US7168497B2 (en) | 1998-12-22 | 2003-12-30 | Downhole sealing |
US10/750,208 Expired - Fee Related US7124826B2 (en) | 1998-12-22 | 2003-12-31 | Procedures and equipment for profiling and jointing of pipes |
US10/853,494 Abandoned US20040216878A1 (en) | 1998-12-22 | 2004-05-25 | Method and apparatus for drilling and lining a wellbore |
US10/853,498 Expired - Fee Related US7117957B2 (en) | 1998-12-22 | 2004-05-25 | Methods for drilling and lining a wellbore |
US10/990,331 Expired - Fee Related US7367404B2 (en) | 1998-12-22 | 2004-11-16 | Tubing seal |
US11/183,574 Expired - Fee Related US7124821B2 (en) | 1998-12-22 | 2005-07-18 | Apparatus and method for expanding a tubular |
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US09/469,643 Expired - Lifetime US6543552B1 (en) | 1998-12-22 | 1999-12-22 | Method and apparatus for drilling and lining a wellbore |
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US09/470,176 Expired - Lifetime US6446323B1 (en) | 1998-12-22 | 1999-12-22 | Profile formation |
US09/469,526 Expired - Lifetime US6702029B2 (en) | 1998-12-22 | 1999-12-22 | Tubing anchor |
US09/469,681 Expired - Lifetime US6527049B2 (en) | 1998-12-22 | 1999-12-22 | Apparatus and method for isolating a section of tubing |
US10/145,599 Expired - Lifetime US6688400B2 (en) | 1998-12-22 | 2002-05-14 | Downhole sealing |
US10/217,833 Expired - Lifetime US6702030B2 (en) | 1998-12-22 | 2002-08-13 | Procedures and equipment for profiling and jointing of pipes |
US10/320,187 Expired - Fee Related US6923261B2 (en) | 1998-12-22 | 2002-12-16 | Apparatus and method for expanding a tubular |
US10/364,718 Expired - Lifetime US6742606B2 (en) | 1998-12-22 | 2003-02-11 | Method and apparatus for drilling and lining a wellbore |
US10/661,446 Expired - Lifetime US6976539B2 (en) | 1998-12-22 | 2003-09-11 | Tubing anchor |
US10/748,592 Expired - Lifetime US7168497B2 (en) | 1998-12-22 | 2003-12-30 | Downhole sealing |
US10/750,208 Expired - Fee Related US7124826B2 (en) | 1998-12-22 | 2003-12-31 | Procedures and equipment for profiling and jointing of pipes |
US10/853,494 Abandoned US20040216878A1 (en) | 1998-12-22 | 2004-05-25 | Method and apparatus for drilling and lining a wellbore |
US10/853,498 Expired - Fee Related US7117957B2 (en) | 1998-12-22 | 2004-05-25 | Methods for drilling and lining a wellbore |
US10/990,331 Expired - Fee Related US7367404B2 (en) | 1998-12-22 | 2004-11-16 | Tubing seal |
US11/183,574 Expired - Fee Related US7124821B2 (en) | 1998-12-22 | 2005-07-18 | Apparatus and method for expanding a tubular |
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EP (8) | EP2273064A1 (en) |
AU (5) | AU772327B2 (en) |
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2001
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- 2001-05-28 NO NO20012596A patent/NO330402B1/en not_active IP Right Cessation
- 2001-05-28 NO NO20012600A patent/NO325955B1/en not_active IP Right Cessation
- 2001-06-11 NO NO20012865A patent/NO326368B1/en not_active IP Right Cessation
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2002
- 2002-05-14 US US10/145,599 patent/US6688400B2/en not_active Expired - Lifetime
- 2002-08-13 US US10/217,833 patent/US6702030B2/en not_active Expired - Lifetime
- 2002-12-16 US US10/320,187 patent/US6923261B2/en not_active Expired - Fee Related
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2003
- 2003-02-11 US US10/364,718 patent/US6742606B2/en not_active Expired - Lifetime
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- 2003-12-31 US US10/750,208 patent/US7124826B2/en not_active Expired - Fee Related
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2004
- 2004-05-25 US US10/853,494 patent/US20040216878A1/en not_active Abandoned
- 2004-05-25 US US10/853,498 patent/US7117957B2/en not_active Expired - Fee Related
- 2004-11-16 US US10/990,331 patent/US7367404B2/en not_active Expired - Fee Related
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2005
- 2005-07-18 US US11/183,574 patent/US7124821B2/en not_active Expired - Fee Related
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2008
- 2008-07-31 NO NO20083355A patent/NO336147B1/en not_active IP Right Cessation
- 2008-10-01 NO NO20084143A patent/NO20084143L/en not_active Application Discontinuation
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US20040113428A1 (en) * | 2002-09-25 | 2004-06-17 | Macaulay Iain Cameron | Expandable connection |
US7895726B2 (en) | 2003-05-22 | 2011-03-01 | Weatherford/Lamb, Inc. | Tubing connector and method of sealing tubing sections |
US20050184521A1 (en) * | 2003-05-22 | 2005-08-25 | Maguire Patrick G. | Tubing connector |
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