Abstract:
A casing apparatus is provided to install a hard, pressure-resistant seal along a wall of a well in situ. The casing apparatus includes a moving device and a deformable tubular sleeve having a first end and a second end and. The moveable element is radially inflatable and movable inside the deformable tubular sleeve along a longitudinal axis of the deformable tubular sleeve. When the moving device is radially inflatable to an inflated condition and is moved from the first end to the second end, the moving device deforms the deformable tubular sleeve radially against the wall and progressively from the first end to the second end. A force of deforming the tubular sleeve applied by the inflated moving device is adjustable by changing the inflated condition of the moving device during the deformation process.

Description:
FIELD 
   The present disclosure relates generally to casing apparatuses and methods for casing or repairing a well, borehole, or conduit, and more particularly to setting tools used therein. 
   BACKGROUND 
   The statements in this section merely provide background information related to the present disclosure and may not constitute prior art. 
   Conventional methods of casing or repairing wells, boreholes, conduits and the like include applying cementation, straddle packers, metallic patches, or through-tubing casing patch using in situ polymerization such as Patch Flex™ (a trademark of Schlumberger) on the wall of the wells, boreholes, or conduits. A Patch Flex system involves an in-situ polymerization technology to install a hard, pressure-resistant seal on the wall along its length. U.S. Pat. No. 6,044,906 (“the &#39;906 patent”) issued to Saltel discloses a conventional Patch Flex system, which comprises an inflatable setting element (“ISE”, called “inflatable tubular sleeve” in the &#39;906 patent) and a preform made of a thermosetting resin and disposed around the ISE. A nozzle which engages the ISE inflates the ISE, which in turn expands the thermosetting preform radially against the wall of the well. When the ISE is completely inflated, the entire thermosetting resin preform is inflated accordingly and is then heated to cause polymerization of the preform. The preform is thus secured to the wall of the well. The ISE is then deflated and removed, leaving in place a permanent hard preform against the wall of well. 
   The conventional Patch Flex system has a disadvantage in that the casing length or the repair zone of the well is restricted by the length of the ISE because the expansion of the preform depends on fully inflation of the ISE along the length of the ISE. Currently, the ISE can be made to have a length of no more than about 10 meters and thus can repair or case a zone of no more than 10 meters. Moreover, the thermosetting resin preform has a limited lifetime before polymerization and requires more time to heat and cure, thereby prolonging the casing or repair process. 
   SUMMARY 
   Embodiments of the present invention provide for a casing apparatus and method for casing or repairing a wall of a well wherein the casing length is not limited by a setting tool that is used to deform the resin preform. In one preferred form, the casing apparatus comprises a deformable tubular sleeve having a first end and a second end, and a moving device. The moving device is movable inside the deformable tubular sleeve along a longitudinal axis of the deformable tubular sleeve for deforming the tubular sleeve radially against the wall of the well. 
   In another preferred form, a setting tool for deforming a deformable tubular sleeve is provided. The setting tool comprises a radially inflatable moving device movable inside the deformable tubular sleeve along a longitudinal axis. When the moving device is inflated to an inflated condition and moved from a first end to a second end of the tubular sleeve, the moving device deforms the tubular sleeve radially and progressively from the first end to the second end. 
   In still another form, a method of casing a wall of a well is provided. The method comprises disposing a casing apparatus in the well, the casing apparatus comprising a deformable tubular sleeve and a moving device, the moving device being radially inflatable and being movable inside the tubular sleeve from a first end to a second end of the deformable tubular sleeve; inflating the moving device to an inflated condition; and causing the moving device to move in the inflated condition from the first end to the second end, a force being exerted on the tubular sleeve by the moving device in the inflated condition, when the moving device is moved from the first end to the second end, the tubular sleeve being deformed radially against the wall and progressively from the first end to the second end. 
   Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 

   
     DRAWINGS 
     The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
       FIG. 1  is a cross-sectional view of a casing apparatus in accordance with the teachings of the present disclosure, wherein the casing apparatus is in its initial, deflated condition; 
       FIG. 2  is a cross-sectional view of the casing apparatus of  FIG. 1 , showing an anchoring device in its inflated condition; 
       FIG. 3  is a cross-sectional view of the casing apparatus of  FIG. 1 , showing a moving device in its inflated condition; 
       FIG. 4  is a cross-sectional view of the casing apparatus of  FIG. 1 , showing the start of a deformation process by the moving device; 
       FIG. 5  is a cross-sectional view of the casing apparatus of  FIG. 1 , showing the conclusion of the deformation process by the moving device; 
       FIG. 6  is a cross-sectional view of the casing apparatus of  FIG. 1 , showing the moving device and the anchoring device in their deflated condition ready for withdrawal; and 
       FIG. 7  is a schematic flow diagram of a method of casing or repairing the well. 
   

   Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
   DETAILED DESCRIPTION 
   The description and drawings are presented solely for the purpose of illustrating the preferred embodiments of the invention and should not be construed as a limitation to the scope and applicability of the invention. While any compositions of the present invention are described herein as comprising certain materials, it should be understood that the composition could optionally comprise two or more chemically different materials. In addition, the composition can also comprise some components others than the ones already cited. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. 
   At the outset, it should be noted that “deformable,” “deform” or “deformation” used throughout the present disclosure, refers to an element that is (1) unfoldable or unfolded from a folded state to an unfolded state by simply unfolding without expanding, (2) expandable or expanded (without unfolding) by increasing the diameter of the element due to the effect of pressure applied to the inner surface of the element, or (3) successively unfolded from a folded state to an unfolded state and then expanded. 
   Referring to  FIGS. 1 and 2 , a casing apparatus for casing a wall of a well constructed in accordance with the teachings of the present disclosure is illustrated and generally indicated by reference numeral  10 . The casing apparatus  10  comprises a setting tool  12  and a tubular sleeve  14  disposed around the setting tool  12 . 
   The setting tool  12  comprises a tensioning device  16 , an anchoring device  18 , an inflatable moving device  20 , and a heating device  22 . The tensioning device  16  engages an upper end  24  of the tubular sleeve  14  for suspending the tubular sleeve  14  within the wellbore  26  which penetrates a subterranean formation. The anchoring device  18  is attached to a lower end  28  of the sleeve  14  through linking cables  30 . The linking cables  30  are made of chemically resistant and/or material resistant to mechanical forces, such as steel, polyaryletherether ketone polymer (PEEK), fibers, and the like. The linking cables  30  may be breakable by connection to a mechanical weak point, such as shear pin by nonlimiting example. 
   The anchoring device  18  engages a connecting member  32  passing through the moving device  20  and the heating device  22 , and connecting to a pump (not shown) for inflating the anchoring device  18 . The anchoring device  18  is made of an expandable material and can be inflated to an inflated condition to engage the well  26 . When inflated, the anchoring device  18  holds the lower end  28  of the sleeve  14  in place. The tensioning device  16  and the anchoring device  18  cooperatively maintain a proper tension along a longitudinal direction of the sleeve  14 . 
   Referring to  FIGS. 3 and 4 , the moving device  20  and the heating device  22  are suspended from a running tool  34  and movable inside the tubular sleeve  14 . The running tool  34  can be an electronic device, a pump or a cable head, which guides the movement of the moving device  20  and the heating device  22  and provides fluids to inflate the anchoring device  18  and the moving device  20 . The running tool  34  is connected to a cable or a coil tubing  36 . When the cable or coiled tubing  36  is pulled up, the moving device  20 , the heating device  22  and the running tool  34  are pulled up to move inside the tubular sleeve  14  along the longitudinal axis of the tubular sleeve  14 . 
   When a cable is used to connect to the running tool  34 , the cable  36  may be any suitable cable. Some non-limiting examples of cables are heptacable and quadcables. Preferably, the cable  36  is a heptacable, which refers to a cable consisting of seven conductors; a central conductor surrounded by six conductors and an outer steel armor. The heptacable provides for several different signal propagation modes, each of which transmits signals on a specific combination of the seven conductors and armor. By using the heptacable, control signals are transmitted through the cable  36  for controlling the switching on/off and temperature of the heating device  22 , the inflating/deflating of the moving device  20  and the anchoring device  18 . 
   The moving device  20  is made of an expandable material and can be radially inflatable and deflatable. The moving device  20  has a nut configuration with a central hole (not shown) to allow for passage of the connecting member  32  connected to the anchoring device  18 . The moving device  20  engages an inflating member (not shown) passing though the heating device  22  for inflating the moving device  20 . The connecting member  32  connected to the anchoring device  18  and the inflating member connected to the moving device  20  may be connected to the same pump or different pumps (not shown). 
   The heating device  22  has an elongated construction and is preferably a resistive heating element for heating the tubular sleeve  14 . The temperature of the heating device  22  is properly controlled to a melting point of the tubular sleeve  14  during operation. The heating device  22  also has a central hole (not shown) for allowing passage of the connecting member  32  and the inflating member (not shown). 
   The tubular sleeve  14  shown in the drawings is expandable and undergoes an expansion process during operation as shown in  FIGS. 4 and 5 . It should be noted that the tubular sleeve  14  can be made of a non-expandable material and undergoes an unfolding process only without expanding. Alternatively, the tubular sleeve  14  can be made to undergo both unfolding and expansion process during operation. As previously set forth, the terms “deform”, “deformable” or “deformation” used throughout the present disclosure cover all three situations. 
   In case the tubular sleeve  14  is made of an expandable material, the tubular sleeve  14  can be expanded with or without heating depending on the construction of the tubular sleeve  14 . When the tubular sleeve  14  is made of a rigid composite tube, heating is generally required for expanding the tubular sleeve  14 . However, when the tubular sleeve  14  is in the form of fibers and woven with structural fibers, heating is generally not necessary and such tubular sleeve  14  is easier to roll on a drum. 
   When the tubular sleeve  14  is of a composite structure, the tubular sleeve  14  may have one of the following constructions, for example: 
   1. A sleeve of carbon/thermoplastic braids wherein the braids are soft/expandable and each wire of these braids is made with carbon fibers and thermoplastic fibers. The thermoplastic can be melted after being expanded. 
   2. A multilayer sandwiched sleeve with carbon and thermoplastics braids wherein the thermoplastic fibers and carbon fibers are braided separately. 
   3. A sleeve of carbon braids wrapped by thermoplastic bands/wires wherein the sleeve includes a layer of carbon braids, which is surrounded by a thermoplastic band or wire. 
   4. A pre-made composite carbon/thermoplastic sleeve wherein the thermoplastic and carbon fibers form a solid composite cylinder, which can have a circular cross-section. The fibers are set at a correct angle to allow deformation when the thermoplastic is melted. Fibers can also be set perpendicular to the cylinder axis. The cylinder can be folded on several generating lines. When the thermoplastic is soft enough, the deformation is performed by unfolding the sleeve. 
   5. A bi-axial composite sleeve wherein the sleeve is made with expandable fibers in one axis. 
   The preferred thermoplastic materials used in the composition of the tubular sleeve  14  include nylon materials such as polyamide 6 (PA6), polyamide 6,6 (PA6,6), or polyamide 12 (PA12), or even polyethersulfone (PES), polyphenylene sulfide (PPS), polyvinylidene fluoride (PVDF), polyetherimide (PEI) or PEEK thermoplastics. The carbon fibers are structural fibers to provide a structural support for the thermoplastic matrix. The fibers can be set with a low angle relative to the sleeve axis. As the tubular sleeve  14  is deformed, the angle is increased. Alternatively, the fibers can be rolled perpendicular to the sleeve axis so that the sleeve is folded before application and is unfolded, rather than expanded, during application. 
   Referring to  FIGS. 1 through 7 , the method of using the casing apparatus  10  for casing or repair a well is now described.  FIG. 1  shows a running-in step, where the casing apparatus  10  including the setting tool  12  and the tubular sleeve  14  is lowered down into the well  26  to a desired depth adjacent to a section or zone of the well  28  to be cased or repaired. 
   Next, in an anchorage step as shown in  FIG. 2 , the anchoring device  18  is inflated by injecting fluid or air through the running tool  34 , the connecting member  32 . The anchoring device  18  is inflated to engage the well  26  so as to hold the lower end  28  of the tubular sleeve  14  in place. The anchoring device  18  may also be a mechanical expandable anchor. 
   In the anchorage step, the tensioning device  16 , which holds the upper end  24  of the tubular sleeve  14 , is operated to adjust the tension of the tubular sleeve  14  and maintain a proper tension in the longitudinal direction of the tubular sleeve  14 . The tensioning device  16  and the anchoring device  18  keep the tubular sleeve  14  in place without being moved in the longitudinal direction by the moving device  20  during and/or following the deformation process. The tensioning device  16  may maintain a constant or variable tension of the tubular sleeve  14  during the deformation process, depending on the applications. 
   The tensioning device  16  may in some embodiments, be made of buoyant elements. The density of those elements and/or the volume of those elements can be selected to adjust the tension of the tubular sleeve  14  depending on the well fluid and the weight of the parts of the casing apparatus. 
   Next, as shown in  FIG. 3 , the moving device  20  is inflated to an inflated condition. The inflated condition of the moving device  20  is properly set to adapt for the thickness of the tubular sleeve  14  and the diameter of the well  26  to ensure that a proper pressure is applied to the tubular sleeve  14 . 
   In this moving device inflation step, the heating device  22  is switched on for heating the tubular sleeve  14  to a melting point. Since the heating device  22  is disposed above the moving device  20 , any part of the tubular sleeve  14  is heated before being deformed by the moving device  20 . 
   In some cases, for some thermoplastic materials, heating may take place after the deformation process. Therefore, the heating device  22  may be disposed below the moving device  20  and heating is applied to the tubular sleeve  14  after that tubular sleeve  14  is deformed. 
   Referring to  FIG. 4  which shows the start of the deformation process of the tubular sleeve  14 , when the lower end  28  of the tubular sleeve  14  is heated and is ready for deformation, the cable  36  pulls upward the heating device  22  and the properly inflated moving device  20 . As the moving device  20  is moved past the part of the tubular sleeve  14  that has been heated, the moving device  20  deforms the heated part of the tubular sleeve  14  radially against the well  26 . 
   Preferably, the heating device  22  and the moving device  20  are moved at a lower speed that ensures that the part of the tubular sleeve  14  to be deformed by the moving device  20  is sufficiently heated and deformed. As the moving device  20  is moved from the lower end  28  to the upper end  24 , the tubular sleeve  14  is progressively deformed from the lower end  28  to the upper end  24  until the entire sleeve  14  is deformed. At the same time, the tubular sleeve  14  is progressively cooled down and sets-up from the lower end  28  to the upper end  24 . As with most thermoplastic materials, as they are cooled down, they naturally recover mechanical properties, and as such, they set-up. 
   In those embodiments where the sleeve  14  is passed through a tubing, a well patch (such as Patch Flex), or any other inner diameter casing restriction, the heating device  22  and the moving device  20  may be moved at a speed that ensures the tubular sleeve  14  expands at the same expansion rate as casing restriction. This feature allows setting of the sleeve after passing through tubing or after passing through any inner diameter casing restriction. 
   While in this illustrative example, the heating device  22  is moved together with the moving device  20  to apply heat and pressure to the tubular sleeve  14  in substantially the same time, it is within the contemplation of the present disclosure that the heating device  22  can be moved independently of the moving device  20  and heat the entire tubular sleeve  14  before the deformation process begins. It is also within the contemplation of the present disclosure that the heating device  22  may be made stationary. 
   As previously described, the moving device  20  can be partially or fully inflated to adapt for the thickness of the sleeve  14  and the diameter of the well  26 . Additionally, the inflated conditions of the moving device  20  can be adjusted during the deformation process to apply a variable pressure on the tubular sleeve  14 . One of the advantages is that only one tubular sleeve  14  is needed to case or repair a zone which does not have a constant diameter. The moving device  20  can be partially inflated in a section having a smaller diameter and can be fully inflated in a section having a larger diameter. 
   Referring to  FIG. 5 , upon completion of the deformation process, the linking cable  30  is broken to separate the anchoring device  18  from the tubular sleeve  14 . The linking cables  30  may breakable by connection to a mechanical weak point. Finally, as shown in  FIG. 6 , the anchoring device  18  and the moving device  20  are deflated and removed from the well  26 , thereby completing the casing or repairing process. 
   It should be noted that while the tubular sleeve  14  has been described as being made of a thermoplastic material in the present disclosure, the tubular sleeve  14  can be made of a thermosetting material. Therefore, hardening the tubular sleeve  14  during the deformation process can be achieved by applying a cross-liking agent, radiation or ultraviolet, etc, other than heating or cooling. Therefore, a nozzle for spraying the cross-linking agent, a radiation source or an ultraviolet source may be incorporated in the setting tool  12  to facilitate polymerization of the tubular sleeve  14 . 
   The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. Accordingly, the protection sought herein is as set forth in the claims below.