# Patent

## Title
Hydraulically assisted tubing expansion

## Abstract

A method of expanding tubing comprises applying a varying fluid pressure across the wall of the tubing. The variation in pressure may be achieved by varying one or both of the fluid pressure within the tubing and the fluid pressure externally of the tubing. A body of varying volume may be located in a volume of fluid associated with the tubing. Alternatively, the volume of a body of fluid associated with the tubing may be varied by movement of a wall portion defining a boundary of the volume, which wall portion may be associated with an oscillator or a percussive or hammer device. In other embodiments a pressurised fluid source may be provided, and the fluid may be supplied at varying pressure from the source. An increase in pressure within the tubing may be accompanied by a reduction in pressure externally of the tubing.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims benefit of Great Britain patent application serial number GB 0306774.1, filed Mar. 25, 2003, which is herein incorporated by reference, this application is a continuation-in-part of U.S. patent application Ser. No. 10/805,914, filed Mar. 22, 2004 now U.S. Pat. No. 6,976,536, which is a continuation of U.S. patent application Ser. No. 10/114,923, filed Apr. 3, 2002, now U.S. Pat. No. 6,712,151, which claims benefit of Great Britain patent application Serial No. 0108638.8, filed Apr. 6, 2001, and this application is a continuation-in-part of U.S. patent application Ser. No. 10/787,993, filed Feb. 26, 2004, which claims benefit of Great Britain patent application Serial No. 0304335.3, filed Feb. 26, 2003.


BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to hydraulically assisted tubing expansion. In particular, but not exclusively, the invention relates to hydraulically assisted diametric expansion of tubing downhole.
2. Description of the Related Art
One of the most significant recent developments in the oil and gas exploration and production industry has been the introduction of technology which allows for expansion of extended sections of tubing downhole. The expandable tubing may take different forms, including but not limited to: casing, liner, sandscreen, straddles, packers and hangers. A variety of expansion methods have been proposed, including use of expansion cones or mandrels, which are forced through the tubing.
One difficulty that has been experienced with cone expansion is the requirement to apply significant forces to the cone to drive the cone through the tubing. The driving force may be applied mechanically, or hydraulically. Use of hydraulic pressure offers certain advantages, but typically requires the entire tubing to be pressurised, and also the provision of an effective seal or seals to prevent leakage of high-pressure fluid.
The sole use of fluid pressure to expand tubing, rather than mechanical expansion techniques utilising cones or other devices, is perceived to involve a degree of uncertainty, as it is difficult to predict how a particular tubular will expand in response to an internal fluid pressure which creates a force above the yield strength of the tubular. In particular, a point or area of relative weakness in the tubing wall may result in the tubing bursting or expanding in a non-uniform manner. In addition, and as noted above, use of elevated hydraulic pressure typically requires the entire tubing to be pressurised, and also the provision of an effective seal or seals to prevent leakage of high-pressure fluid.
A number of these difficulties are addressed in applicant's WO 02/081863, the disclosure of which is incorporated herein by reference, in which a tubing expansion process is described utilising a combination of both mechanical and hydraulic expansion forces. The use of a pulsed force in combination with a pulsed fluid pressure is disclosed in applicant's WO 02/103150, the disclosure of which is also incorporated herein by reference.
It is among the objectives of embodiments of the present invention to provide a method of expanding tubing, particularly in a downhole environment, which relies at least in part on hydraulic expansion forces.
SUMMARY OF THE INVENTION
According to the present invention there is provided a method of expanding tubing, the method comprising applying a varying fluid pressure to the tubing.
The varying fluid pressure preferably acts across the wall of the tubing. The variation in pressure may be achieved by any appropriate means, and one or both of the fluid pressure within the tubing and the fluid pressure externally of the tubing may be varied. A body of varying volume may be located in a volume of fluid operatively associated with the tubing. Alternatively, or in addition, the volume of a body of fluid operatively associated with the tubing may be varied by movement of a wall portion defining a boundary of the volume, which wall portion may be operatively associated with an oscillator or a percussive or hammer device. In other embodiments a pressurised fluid source may be provided, and the fluid may be supplied at varying pressure from the source or the manner in which the fluid is delivered to the tubing from the source may be such to vary the fluid pressure. An increase in pressure within the tubing may be accompanied by a reduction in pressure externally of the tubing, or a reduction of pressure externally of the tubing may occur independently of any variations in the internal pressure, which may remain substantially constant.
References herein to expansion are primarily intended to relate to diametric expansion achieved by extension of the tubing wall which may be achieved by various means, as will be described. However, embodiments of the invention may also relate to tubing which is expanded by reforming a tubing wall, for example by straightening or smoothing a corrugated tubing wall.
In one embodiment, in a downhole application, the fluid pressure externally of the tubing may be maintained at a relatively low level by providing a relatively low density fluid externally of the tubing. Thus, the hydrostatic pressure produced by the column of fluid above the tubing will be relatively low. This may be achieved by injecting gas or low density fluid into fluid surrounding the tubing. Alternatively, or in addition, a volume of fluid externally of the tubing may be at least partially isolated from the head of fluid above the tubing, for example by means of a seal or seals between the tubing and a surrounding bore or tubing wall, or by providing pumping means above the tubing.
Alternatively, or in addition, the fluid pressure internally of the tubing may be maintained at a relatively high level by providing a relatively high density fluid internally of the tubing. This feature may be utilised in other forms of tubing expansion, not reliant on a varying pressure. In particular, the use of a high density fluid will provide a relatively high hydrostatic pressure, reducing or even eliminating the need to utilise pumps to provide the desired fluid pressure in the bore. The elevated fluid pressure achieved by providing a column of high density fluid may in addition, or alternatively, be utilised for other purposes, such as driving an expansion cone or other tool through the tubing.
Tubing expansion operations are typically carried out using conventional, readily available fluids, such as seawater or completion brine, which may have a specific gravity (SG) of approximately 1.025. However, the SG of fluids used in downhole operations of course varies depending on, for example, the choice of base fluid and the presence of weight materials or other additives, and may range from 0.85 to 2.2. Thus, references herein to high and low density fluids should be related primarily to fluids utilised in conventional tubing expansion operations and other downhole operations where the fluid is selected with reference primarily to other requirements, including availability and ease of handling. Accordingly, by way of example, with reference to expansion operations which, using conventional expansion techniques, would be carried out in the presence of completion brine, a high density fluid may be one having an SG in excess of around 1.025 and a low density fluid may be one having an SG less than around 1.025. In other cases, the density of a fluid present within tubing to be expanded may be considered to be relatively high if the fluid has been selected with reference to the lower density of the fluid in the annulus surrounding the tubing. Similarly, the density of a fluid in the annulus may be considered to be relatively low if the density is lower than the density of the fluid present within the tubing to be expanded. Of course the invention is not limited to use with liquids, and in some cases one or both of the fluids, particularly where a lower density fluid is required, may be a gas such as natural gas or air, or a multiphase fluid.
The portion of tubing to be expanded may be isolated from ambient fluid by one or more appropriate seals, and a varying pressure differential may be maintained across each seal. However, in accordance with a further aspect of the invention a degree of leakage past the seals may be permissible, and in some cases may even be desirable, particularly if means for providing or creating a cycling fluid pressure is being utilised; if the frequency or rate of pressure variation is sufficiently high, a degree of leakage, and the corresponding pressure decay, will not adversely affect the expansion process and may assist in providing the desired pressure cycling when combined with an appropriate source of pressure. In particular, the method may include the step of producing a pressure pulse, and thus an elevated fluid pressure, which then reduces or decays, which may be due in part to leakage across the seal, or some other mechanism, for example the movement of a reciprocating piston. Furthermore, the ability to utilise “leaky” seals tends to facilitate use of the expansion method, as there are difficulties involved in providing a fully effective seal in many environments: when expanding tubing downhole, the tubing will often not be perfectly cylindrical, and the tubing diameter may be variable; the tubing surface is unlikely to be perfectly smooth, and may include profiles; the ambient fluid in the tubing may contain particulates and contaminants; and in preferred embodiments the seal will move relative to the tubing as the tubing is expanded, which movement would of course result in wear to one or both of the seal and the tubing, and which movement would have to overcome friction, which could be considerable if a leak-free seal was provided or required. Also, the leakage of fluid through, around or over the seal will provide lubrication, facilitating relative movement between the seal and the tubing.
The seal may take any appropriate form, but is preferably in the form of a labyrinth seal. Typically, the seal comprises a plurality of seal members, each seal member adapted to maintain a proportion of the total pressure differential across the seal. The number of seal members may be selected depending upon a number of considerations, including the form of the seal members, tubing form and condition, ambient conditions, the pressure differential to be maintained, tubing diameter, and the frequency or rate of variation of the fluid pressure. Of course such a seal configuration may also be suitable for use in situations where the fluid pressure is substantially constant, or is maintained above at least a minimum level, provided of course that means is provided for maintaining the expansion pressure at the desired level, despite leakage past the seal. Thus, perhaps five, ten, fifteen or more seal members may be provided, as appropriate. The number of seal members may be selected to provide for redundancy, such that failure or damage of one or more seal members will not adversely affect the expansion process.
The expansion may take place solely, or at least substantially, as a result of fluid pressure applied to the tubing wall. In these circumstances, using a varying fluid pressure diminishes the likelihood of uncontrolled expansion. However, the tubing may be located such that there is only a limited or controlled degree of expansion possible, for example the tubing may be located within a slightly larger bore or tubing, and in such cases, and in accordance with other aspects of the invention, a continuously elevated pressure may be utilised to achieve expansion. Expansion relying solely or predominately on fluid pressure may not necessarily produce expanded tubing of constant form or diameter, however the tubing may also be expanded or formed by other means, such as a mechanical expansion or reforming device, to achieve a desired consistent form. Of course the degree of mechanical reforming or expansion is likely to be relatively small, and such will not require application of substantial expansion forces, and thus may be carried out relatively easily and economically.
The fluid pressure may be maintained at a base pressure, for example at 70% of the yield pressure of the wall of the tubing, upon which base pressure additional pressure pulses or spikes are superimposed. The pulses or spikes will take the fluid pressure closer to the yield pressure, preferably approaching or close to the yield pressure. In certain embodiments the fluid pressure will be equal to or in excess of 100% of the yield pressure, to induce plastic deformation of the tubing.
Expansion of the tubing may be assisted by the presence of a mechanical expansion or reforming device, such as an expansion cone, mandrel or die, or a rotary expansion device. The mechanical device may exert little or no expansion force, and may merely serve to stabilise the expansion process and assist in achieving a desired expanded form, for example achieving a desired expanded diameter and avoiding ovality. Alternatively, or in addition, the mechanical expansion or reforming device may serve to retain expansion induced by the elevated fluid pressure. In one embodiment, a shallow angle cone may be advanced through the expanding tubing, the cone preferably being advanced in concert with the periods of elevated pressure. The cone angle may be selected depending upon the particular application, but for downhole tubulars of conventional form it has been found that an 11 degree cone angle results in a cone which retains expansion, that is the cone may be advanced into the tubing expanded by the elevated pressure, and is then retained in the advanced position as the tubing contracts on decay of the fluid pressure below the tubing wall yield pressure. It is anticipated that by cycling the fluid pressure at a rate of around 5 Hertz the cone will advance at a rate of approximately 6 to 8 feet per minute. Of course the rate or frequency of fluid pressure variation may be selected to suit local conditions and equipment. Such advancement may be achieved by providing separate mechanical drive means, such as a downhole tractor to push or pull the apparatus through the tubing, or simply by application of weight from surface, but may be conveniently achieved by virtue of the pressure differential over a seal coupled to the cone; as the pressure peaks, causing expansion of the tubing, the axial differential pressure acting force across the seal will also peak. Where the cone is located between seals, in particular a leading seal and a trailing seal, the leading seal may be mounted on the cone or otherwise coupled to the cone such that any pressure differential across the seal will tend to urge the cone forward. The trailing seal may be located at some point behind the cone, such that the cone is located within an isolated fluid volume between the seals. The trailing seal may be fixable or securable relative to the tubing or may be floating. The trailing seal may be retained in position mechanically or, alternatively or additionally, by fluid pressure, for example by a column of fluid above the seal, which column may be pressurised by appropriate pumps on surface. The variations in pressure are preferably applied to the isolated fluid volume between the seals, and may be created by a pulse generator located within the isolated volume, or by supplying elevated pressure fluid or pressure pulses from a source externally of the isolated volume. In other embodiments, variations in pressure may also be applied to one or both of the fluid volumes above and below the isolated volume.
While reference is made above predominately to expansion cones, similar advantages and effects may be achieved using other forms of expansion devices.
Of course the presence of fluid will facilitate movement of any expansion device present relative to the tubing, in particular by serving as a lubricant between the contacting surfaces of the expansion device and the tubing. The fluid may be selected for its lubricating properties. This is particularly the case in embodiments where the fluid surrounding the expansion device is at least partially isolated from the ambient fluid, and as such a smaller volume of fluid selected for its particular properties may be provided. Leakage past isolating seals may be accommodated by providing a larger initial volume, or by supplying further fluid to the volume. Of course the fluid may be selected with properties other than lubrication in mind, for example the fluid may comprise or include a relatively viscous element, for example a grease, to minimise the rate of leakage and pressure decay.
In other embodiments, the fluid may contain material or particles intended to facilitate movement between the expansion device and the tubing, such as large numbers of small spherical particles, which will act as bearings and provide for a relatively large area rolling contact between the expansion device and the tubing. Such particles may be of any appropriate material, such as titanium carbide. It is believed that the spherical grain structure of titanium carbide facilitates in the reduction of friction between the surfaces. In certain embodiments, such particles may be provided in a fluid suspension, the fluid being selected for its lubricating properties. Of course the use of such particles to facilitate relative movement of contacting surfaces is not limited to use with an expansion device, and may be utilised in any application where it is useful to reduce friction between surfaces.
Downhole expansion may be accomplished either top down or bottom up, that is expansion process moves downwardly or upwardly through the tubing.
Where an expansion or reforming device is provided, one or both of the tubing and the device may be vibrated, as discussed in greater detail below. Thus, this embodiment comprises the additional steps of:

    
    
        vibrating at least one of the tubing and the expansion device; and
        translating the expansion device relative to the tubing.
    
    


The vibration of at least one of the tubing and the expansion device preferably acts to reduce friction between the tubing and the device.
In conventional tubing expansion operations an expansion device which slides relative to the tubing to be expanded, such as a cone or mandrel, will tend to progress through the tubing incrementally in a series of small steps. From a static condition, the load on the cone is increased until the load is sufficient to drive the cone through the tubing. In addition to the forces required to expand the tubing diametrically, it is also necessary to overcome the static friction between the contacting surfaces of the cone and the tubing before the cone will move relative to the tubing. Once static friction has been overcome, frictional resistance to movement typically decreases sharply due to the lower dynamic friction between the contacting surfaces, such that the initial movement of the cone will tend to be relatively rapid. As the cone moves forward rapidly relative to the tubing, the driving force being applied to the cone will tend to fall, the inertia of the cone-driving arrangement being such that the cone-driving arrangement will typically fail to keep pace with the cone. Thus, after the initial rapid movement, the cone will tend to stall as the driving force decreases. The driving force applied to the cone then increases once more, moving the cone forward again once static friction between the cone and tube is overcome. For brevity, this form of movement will hereinafter be referred to as “stick-slip”.
With this aspect of the present invention, the vibration of one or both of the expansion device and the tubing is intended such that there will be little or no static friction experienced between the contacting surfaces, and the conventional stick-slip progression of the expansion device relative to the tubing should be avoided. The driving force necessary to drive the expansion device through the tubing should therefore remain relatively constant, as the frictional forces remain at a relatively constant, and relatively low, level.
Furthermore, the reduction in friction between the expansion device and the tubing should tend to decrease the wear experienced by the expansion device, which in conventional expansion operations may place limits on the length of tubing which can be expanded in a single expansion operation.
The frequency and amplitude of vibration may be selected to suit each particular application. Furthermore, the direction of vibration may be selected as appropriate: for example, the vibration may be random, multi-directional, axial, transverse or rotational. In one embodiment of the invention the vibration is substantially perpendicular to the surface of the expansion device, and in another embodiment the vibration takes the form of torsional oscillations.
Where the expansion device is vibrated, all or a major portion of the device may be subject to vibration. Alternatively, only a selected portion of the device may be subject to vibration, for example only a surface portion of the device, or only a selected area of the surface of the device, may be subject to vibration. Portions of the expansion device may also experience different degrees or forms of vibration.
If the tubing is vibrated, all or a substantial portion of the tubing may be vibrated. Alternatively, only a selected portion of the tubing may be vibrated. For example, only a portion of the tubing at or adjacent the expansion device may be vibrated, or only a surface portion of the tubing may be vibrated.
The vibration of the expansion device or tubing may induce physical movement of the device or tubing. Alternatively, or in addition, the vibration of the device or tubing may induce contraction and expansion of all or a portion of the device or the tubing. For example, the vibration may take the form of one or more waves traveling through the device or tubing.
The vibration may be induced or created locally relative to the expansion device or the tubing being expanded, or may be created remotely, for example a wave form oscillation may be created remote from the expansion device location, and then travel along or through the tubing wall, or travel to the expansion location via another medium.
The vibration may be created by any appropriate means, including: an oscillating or otherwise moving mass; creating a varying or cyclic restriction to fluid flowing through the expansion device or tubing; an electromagnetic oscillator; varying the pressure of fluid operatively associated with the device or tubing; creating pressure pulses in a fluid; or injecting gas or liquid or a mixture of both into fluid operatively associated with the device or tubing.
The source of vibration or oscillation may be directly or indirectly coupled to one or both of the expansion device and the tubing.
The vibration may be of a constant, varying or substantially random nature, that is the amplitude, direction, frequency and form of the vibration may be constant, varying or random.
The vibration or oscillation may be of high frequency, for example ultrasonic. Such vibration may not be apparent as physical movement, as the vibration may be at a molecular or macromolecular level, or at least at a level below that of readily detectable physical movement of the device or tubing. Such vibration may be induced electro magnetically, for example by a varying electromagnetic field, or a varying or alternating current or voltage. Alternatively, or in addition, the vibration or oscillation may be or relatively low frequency, for example in the range of 1 to 100 Hz. If desired, the vibration may comprise a plurality of different components, for example a low frequency component and a high frequency component.
The vibration may be selected to coincide with a natural frequency of the expansion device or the tubing, or another element of apparatus. Alternatively, the vibration may be selected to avoid such natural frequency or frequencies.
The expansion device may be translated relative to the tubing by any appropriate means. The device may be mounted on a support which allows the device to be pushed, pulled or otherwise driven through the tubing. The support may extend from a downhole location to surface, where a pushing, pulling or torsional force may be applied. Alternatively, the expansion device may be coupled to a tractor or other driving arrangement located downhole. Alternatively, or in addition, fluid pressure may be utilised to move the device relative to the tubing. Due to the relatively low forces required to move an expansion device through tubing in the various embodiments of the invention, various means for providing motive force are available which would not provide sufficient force in a conventional tubing expansion operation. Thus, for example, where tubing expansion takes place predominantly as a result of applied fluid pressure, a tractor may provide sufficient motive force to translate the expansion apparatus relative to the tubing; in a conventional tubing expansion operation, it is most unlikely that sufficient motive force could be provided by a tractor.
The expansion device may take any appropriate form and may utilise any appropriate expansion mechanism, or a combination of different expansion mechanisms. An expansion cone or mandrel may be utilised with an expansion surface adapted for sliding or rolling contact with the tubing wall. The cone may be adapted for axial movement relative to the tubing, but may also be adapted for rotation. Alternatively, or in addition, a rotary expander may be utilised, that is a device which is rotated within the tubing with at least one expansion member, typically a roller, moving around the surface of the tubing and creating localised compressive yield in the tubing wall, the resulting reduction in wall thickness leading to an increase in tubing diameter.
The expansion device may define a fixed diameter, or a variable diameter. The device may be compliant, that is the device has a degree of flexibility to permit the device to, for example, negotiate sections of the tubing which cannot be expanded to a desired larger diameter or form. Alternatively, the expansion device may define a fixed diameter and be non-compliant. In certain embodiments, the expansion device may feature both fixed and compliant elements.



BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic illustration of tubing being expanded downhole in accordance with a preferred embodiment of the present invention; and
FIG. 2 is a schematic illustration of tubing being expanded downhole in accordance with a further embodiment of the present invention.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 of the drawings illustrates a tubing in the form of a bore lining casing 10 located in a drilled bore 12, such as may be utilised to gain access to a subterranean hydrocarbon reservoir. The casing 10 is run into the bore 12 in a smaller diameter first condition, of diameter D1, and is subsequently expanded to a larger second diameter D2.
Expansion of the casing 10 is achieved using expansion apparatus 14 mounted on the lower end of a string of drill pipe 16, which extends to surface. The expansion apparatus 14 comprises a semi-compliant expansion cone 18, that is a cone of relatively hard material which defines an outer expansion surface 20 and which defines a maximum expansion diameter corresponding to the expanded tubing diameter D2. However, the cone 18 is arranged such that the expansion surface may be deflected radially inwardly to a limited extent to accommodate situations where, for example, the casing 10 cannot be expanded to the diameter D2. A variable volume pulse generator 22 is mounted to the cone 18 and is supplied with power via a control line (not shown) that extends to surface.
The volume of fluid surrounding the cone 18 and the oscillator 22 is isolated from the remaining fluid in the casing 10 by seals 24, 26, the leading seal 24 being mounted on the leading end or nose of the cone 18, while the trailing seal 26 is mounted to the trailing end of the oscillator 22. Each seal 24, 26 comprises a plurality of seal members 24a, 24b, 24c, 26a, 26b, 26c as will be described, and in use the seal members 24a-c, 26a-c permit a degree of leakage thereacross. In this example, each seal member is in the form of a split ring, of a somewhat similar form to a piston ring. Thus, a small volume of fluid may pass between the ends of each seal member. However, the number of seal members provided is such that only minimal leakage occurs past each seal 24, 26. Of course other embodiments of the invention may comprise different forms of seal member, for example porous members or members which are intended to allow a degree of leakage between the seal member surface and the tubing surface.
In use, the volume of fluid V1 in the casing 10 above the seals 26 is at pressure P1. The volume V1 is filled with a relatively high density fluid, resulting in a relatively high hydrostatic pressure above the seals 26. In addition, pumps may be utilised to further increase the pressure above the seals 26.
The volume of fluid V3 beneath the leading seal 24 is isolated from the high density fluid and is at a significantly lower pressure P3 than P1.
The volume of fluid V2 between the seals 24, 26 is maintained at an elevated base pressure P2, which pressure is achieved by means of pumps, which will typically be located on surface, and which communicate with the volume V2 via the drill pipe string 16 and a one-way valve provided in the string 16. The base pressure P2 may be the same as or more than the pressure P1 above the seal 26.
Each individual seal member 24a, 24b, 24c, 26a, 26b, 26c will only maintain a pressure differential which is less than the pressure differential between volumes V1 and V2 or V2 and V3. However, collectively the seal members 24a-c, 26a-c are effective to maintain the rate of leakage or pressure decay at a relatively low level.
The pressure P2 is selected such that the differential pressure across the wall of the casing 10 is below the yield pressure of the casing 10, for example the pressure P2 may be 70% of the yield pressure. However, operation of the pulse generator 22 creates pressure pulses that exceed the yield pressure of the casing 10, such that the casing 10 will tend to expand when exposed to the pressure pulses.
The weight of the string 16 and the expansion apparatus 14, and the fluid pressure forces acting on the apparatus 14, and thus on the cone 18, also results in a mechanical expansion force being applied to the casing 10 by the cone 18, such that the cone 18 will tend to advance and expand a short length of the casing 10 with each pressure pulse. In particular, the pulsing pressure P2 creates a corresponding differential pressure pulse across the seal 24, and thus creates a pulsing axial force tending to advance the cone 18. Of course this pulsing force will coincide with the maximum pressure, above the casing yield pressure, within the volume V2, when the force required to advance the cone 18, and thus mechanically expand the casing 10, will be at a minimum.
If desired, the pressure P1 above the expansion apparatus 14 may also be pulsed, to apply an additional motive force to the apparatus 14, and to counteract any differential pressure experienced across the seal 26 which might tend to urge the apparatus in the opposite direction.
The cone angle is selected such that the forces acting between the cone surface and the casing 10 will retain the forward travel of the cone 18 following a pressure pulse. In this manner, the casing 10 may be extended in a series of small steps. However, expansion may still take place relatively rapidly. For example, with the pressure between the seals pulsing at 5 hertz, the cone will progress at a rate of approximately six to eight feet per minute.
The presence of fluid around the cone 18 minimises friction between the contacting surfaces of the cone 18 and casing 10, and furthermore the small degree of leakage across the seal members also serves to provide lubrication for movement of the seals 24, 26 through the casing 10.
In addition to the pressure pulses which may be present in the pressure P1 and P2 as noted above, a further pressure variation may be applied to the casing 10 or apparatus 14 with a view to inducing vibration in one or both of the casing 10 or apparatus 14. Such vibration may be utilised to reduce the friction between the apparatus 14 and the tubing 10. This vibration may be the result of further applied fluid pressure pulses, typically of relatively high frequency. Alternatively, the rate of variation of pressure P2 may be selected to provide both expansion and friction-reducing vibration. These features of the invention are more fully described in our application entitled “Tubing Expansion”, being filed concurrently herewith.
Reference is now made to FIG. 2 of the drawings, which illustrates expansion apparatus 114 in accordance with a further embodiment of the present invention. The apparatus 114 shares many features with the apparatus 14 described above, and operates in a broadly similar manner.
In addition to the leading and trailing seals 124, 126, swab cups 50 are provided ahead of the leading seal 124, which swab cups 50, in addition to a sealing function, serve to condition the inner surface of the casing 110 ahead of the seal 124, and also assist in stabilising the expansion cone 118.
The oscillator 122 is in the form of reciprocating piston pump, a rotary drive 52 being converted to axial movement of the pump piston 54 by an appropriate transfer arrangement 56, such as those described in WO 02/14028, U.S. Pat. Nos. 5,042,385 and 5,513,709, the disclosures of which are incorporated herein by reference.
Upward movement of the piston 54 draws fluid from the volume beyond the swab cup 50 into the piston cylinder 58 via a conduit 60 incorporating a one-way valve 62. Downward movement of the piston 54 pumps the fluid from the cylinder 58 through a further one-way valve 64 and then through a plurality of conduits 66 to fluid outlets 68 provided in the cone surface 120.
In use, the fluid pressure above the seal 124, that is the pressure between the seals 124, 126 and also above the trailing seal 126, is maintained at a base pressure corresponding to approximately 70% of the yield pressure of the casing 110, in this example this being around 3000 psi (the yield pressure of the casing 110 is 3700 psi). The oscillator 122 is then operated to pump fluid into the volume V02 between the seals 124, 126 to create short duration 4000 psi pressure pulses within the volume V02, during which the fluid pressure in the small volume around the cone 118 exceeds the casing yield pressure. With each pressure pulse the casing 110 expands by a small degree, in this example, the expansion resulting in a 10 cc increase the volume V02.
A substantially constant weight or force is being applied to the cone 118, for example by provision of a downhole tractor coupled to the string, while the pressure in the volume V02 is pulsed, and at each pulse the cone 118 will advance a short distance to occupy the newly expanded casing 118. The main proportion of the expansion is a result of plastic deformation of the casing 110, while a smaller degree of deformation is elastic, such that the casing 110 will tend to contract to some extent with the decay of the pressure within the volume V02 from the peak pressure produced at each pulse. However, the cone angle is relatively shallow (the cone angle is shown somewhat exaggerated in the Figure) such that the cone 118 will tend to retain any elastic deformation. Thus, following completion of an expansion operation, it may be necessary to apply a tension to the cone 118 while the pressure in the volume V02 is being pulsed in order to remove the cone 118, if this is desired or necessary: in some cases the cone 118 may be left in the casing 110.
As will be apparent to those of skill in the art, the operation of the oscillator 122 combined with the application of weight to the cone 118 will result in relatively rapid expansion of the casing 110.
Those of skill in the art will recognise that the above described embodiments are merely examples of the present invention, and that various modifications and improvements may be made thereto, without departing from the scope of the invention.

## Claims

1. A method of expanding tubing, the method comprising:
applying a varying fluid pressure to the tubing;
providing an expansion device; and
vibrating at least one of the tubing and the device.

2. The method of claim 1, wherein the tubing is expanded downhole.

3. The method of claim 1, wherein the varying fluid pressure acts across a wall of the tubing.

4. The method of claim 1, wherein the pressure within the tubing is varied.

5. The method of claim 1, wherein the pressure externally of the tubing is varied.

6. The method of claim 1, further comprising pumping fluid into a volume of fluid operatively associated with the tubing.

7. The method of claim 1, further comprising locating a body of varying volume in a volume of fluid operatively associated with the tubing.

8. The method of claim 1, further comprising moving a wall portion defining a boundary of a volume of fluid operatively associated with the tubing.

9. The method of claim 1, further providing a pressurized fluid source.

10. The method of claim 9, wherein fluid is supplied at varying pressure from the source.

11. The method of claim 10, wherein fluid is delivered to the tubing from the source in a manner so as to vary the fluid pressure.

12. The method of claim 1, wherein an increase in pressure within the tubing is accompanied by a reduction in pressure externally of the tubing.

13. The method of claim 1, wherein fluid pressure externally of the tubing is maintained at a relatively low level by providing a relatively low density fluid externally of the tubing.

14. The method of claim 13, further comprising injecting a low density fluid into fluid surrounding the tubing.

15. The method of claim 1, wherein a volume of fluid externally of the tubing is at least partially isolated from a head of fluid above the tubing.

16. The method of claim 1, wherein fluid pressure internally of the tubing is maintained at a relatively high level by providing a relatively high density fluid internally of the tubing.

17. The method of claim 1, wherein a cycling fluid pressure is applied to the tubing.

18. The method of claim 1, wherein a portion of tubing to be expanded is at least partially isolated from ambient fluid by at least one seal, and a varying pressure differential is maintained across the at least one seal.

19. The method of claim 18, wherein a degree of leakage occurs across the at least one seal.

20. The method of claim 19, wherein leaking fluid lubricates the seal.

21. The method of claim 20, further comprising producing a pressure pulse, and an associated elevated fluid pressure, which then decays as leakage occurs across the seal.

22. The method of claim 18, wherein the seal is moved relative to the tubing as the tubing is expanded.

23. The method of claim 1, wherein tubing expansion takes place substantially as a result of differential fluid pressure applied across the tubing wall.

24. The method of claim 1, wherein the tubing is constrained such that only a limited degree of expansion is achievable.

25. The method of claim 24, wherein the tubing is located within a slightly larger bore.

26. The method of claim 1, wherein the tubing is mechanically formed during expansion.

27. The method of claim 1, wherein fluid pressure within the tubing is maintained at a base pressure, upon which base pressure a pressure increase is superimposed.

28. The method of claim 27, wherein pressure pulses are superimposed on the base pressure.

29. The method of claim 28, wherein the pressure increase takes the pressure acting on the tubing wall to within 10% of the yield pressure of the tubing wall.

30. The method of claim 28, wherein the pressure increase takes the pressure acting on the tubing wall to within 5% of the yield pressure of the tubing wall.

31. The method of claim 27, wherein the pressure increase takes the pressure acting on the tubing wall to at least the yield pressure of the tubing wall.

32. The method of claim 1, wherein a mechanical device is advanced through the tubing to occupy an increased volume within the tubing created at least in part by the varying fluid pressure.

33. The method of claim 32, wherein the device is advanced in stepwise fashion in concert with a series of variations in fluid pressure.

34. The method of claim 1, wherein a mechanical expansion force is applied to the tubing wall.

35. The method of claim 1, wherein the expansion device retains expansion induced at least in part by fluid pressure.

36. The method of claim 35, wherein during periods of lower pressure the expansion device retains expansion produced during periods of elevated fluid pressure.

37. The method of claim 35, wherein the expansion device comprises a shallow angle cone that is advanced through the tubing to retain expansion.

38. The method of claim 1, wherein the expansion device is translated relative to the tubing by fluid pressure.

39. The method of claim 1, wherein the expansion device is located between a pair of seals.

40. The method of claim 1, wherein a leading seal is provided on the expansion device and the device is translated relative to the tubing by a pressure differential across the seal.

41. The method of claim 1, wherein the varying pressure is applied to a substantially isolated volume of fluid located between a pair of seals.

42. The method of claim 1, wherein the expansion device is provided within a substantially isolated volume located between a pair of seals.

43. The method of claim 41, wherein the varying pressure is created by at least one of: a pulse generator operatively associated with the isolated volume; and by supplying at least one of elevated pressure fluid and pressure pulses from a source externally of the isolated volume.

44. The method of claim 1, wherein fluid operatively associated with the tubing is selected for its lubricating properties.

45. The method of claim 1, wherein fluid operatively associated with the tubing is selected for its flow characteristics.

46. The method of claim 1, wherein a multitude of bearing particles are provided in fluid operatively associated within the tubing.

47. The method of claim 1, further comprising providing a mechanical device for engaging the tubing and supplying fluid to contacting surfaces of the device and the tubing.

48. The method of claim 1, further applying a motive force to the expansion device to translate the expansion device relative to the tubing.

49. The method of claim 48, wherein the expansion device is translated by being pulled through the tubing.

50. The method of claim 48, wherein the expansion device is translated by being pushed through the tubing.

51. The method of claim 48, wherein the motive force comprises a fluid pressure force.

52. The method of claim 48, wherein the motive force comprises a mechanical force.

53. The method of claim 52, wherein the motive force is provided by a downhole tractor.

54. An apparatus for expanding tubing downhole, the apparatus comprising:
a pressurizing system for applying a varying fluid pressure to the tubing;
an expansion device; and
a system for vibrating at least one of the expansion device and the tubing.

55. The apparatus of claim 54, wherein the pressurizing system is adapted to create a fluid pressure differential across a wall of the tubing.

56. The apparatus of claim 54, wherein the pressurizing system is adapted to vary the pressure within the tubing.

57. The apparatus of claim 54, wherein the means is adapted to vary the pressure externally of the tubing.

58. The apparatus of claim 54, wherein the pressurizing system comprises means for increasing the pressure within the tubing while reducing the pressure externally of the tubing.

59. The apparatus of claim 54, further comprising means for isolating a portion of tubing to be expanded from ambient fluid.

60. The apparatus of claim 59, wherein said isolating means comprises at least one seal.

61. The apparatus of claim 60, wherein said isolating means comprises at least two spaced seals for containing a volume of fluid therebetween.

62. The apparatus of claim 60, wherein said seal is adapted to permit a degree of leakage thereacross.

63. The apparatus of claim 60, wherein the seal comprises a plurality of seal members, each seal member adapted to maintain a fluid pressure differential thereacross.

64. The apparatus of claim 63, wherein the seal comprises at least five seal members.

65. The apparatus of claim 63, wherein the number of seal members is selected to provide for redundancy.

66. The apparatus of claim 63, wherein the seal comprises a labyrinth seal.

67. The apparatus of claim 54, wherein said pressurizing system comprises means creating a cycling fluid pressure.

68. The apparatus of claim 54, wherein the pressurizing system is adapted to produce at least one pressure pulse.

69. The apparatus of claim 54, wherein the pressurizing system is adapted to maintain fluid pressure within the tubing at a base pressure below the yield pressure of the wall of the tubing and superimpose pressure pulses thereupon, taking the fluid pressure to at least the yield pressure of the wall of the tubing, to induce plastic deformation of the tubing.

70. The apparatus of claim 54, wherein the expansion device comprises an expansion cone.

71. The apparatus of claim 54, wherein the expansion device comprises a rotary expansion device.

72. The apparatus of claim 54, wherein the expansion device is adapted to stabilize a tubing expansion process.

73. The apparatus of claim 54, wherein the expansion device is adapted to assist in achieving a desired expanded tubing form.

74. The apparatus of claim 54, wherein the expansion device is adapted to retain expansion induced by elevated fluid pressure.

75. The apparatus of claim 54, wherein the expansion device comprises a shallow angle cone.

76. The apparatus of claim 75, wherein the cone angle no more than 11 degrees.

77. The apparatus of claim 54, wherein the expansion device is adapted to be advanced through expanding tubing in concert with periods of elevated pressure.

78. The apparatus of claim 54, further comprising drive means for translating the expansion device through the tubing.

79. The apparatus of claim 54, further comprising means for translating the expansion device relative to the tubing.

80. The apparatus of claim 79, wherein the translating means is a tractor.

81. The apparatus of claim 54, wherein the expansion device is provided in combination with at least one seal adapted to contain a pressure differential thereacross and induce a translating force.

82. The apparatus of claim 54, wherein the expansion device is located between a pair of seals.

83. The apparatus of claim 82, wherein the expansion device is located between a leading seal and a trailing seal, the leading seal being coupled to the expansion device such that a pressure differential across the seal tends to urge the expansion device forward.

84. The apparatus of claim 82, wherein the pressurizing system is provided between the seals.

85. The apparatus of claim 84, wherein the pressurizing system is in the form of a pulse generator.

86. The apparatus of claim 82, wherein the pressurizing system is adapted to supply elevated pressure fluid from a source externally of a volume between the seals.

87. The apparatus of claim 54, further comprising means for supplying fluid.

88. The apparatus of claim 54, in combination with a fluid to be pressurized.

89. The apparatus of claim 88, wherein the fluid comprises a lubricant.

90. The apparatus of claim 88, wherein the fluid has a viscosity selected to minimize leakage past seals associated with the apparatus.

91. A method of expanding tubing by extending a wall of the tubing, the method comprising:
isolating a portion of tubing containing an expansion device;
applying a base pressure to the isolated portion of tubing, the base pressure creating a differential pressure across a wall of the tubing below the yield pressure of the tubing wall;
applying pressure pulses to the isolated portion of tubing in excess of said base pressure such that the tubing is expanded; and
translating the expansion device to occupy the expanded tubing.

92. A method of expanding tubing, the method comprising:
applying a varying fluid pressure to tubing having an internal volume, the varying fluid pressure serving at least in part to increase said volume; and
advancing a mechanical device through the tubing to occupy said increased volume.

93. The method of claim 92, wherein the device is advanced in stepwise fashion in concert with a series of variations in fluid pressure.

94. The method of claim 93, wherein during periods of lower pressure the mechanical expansion device retains expansion produced during periods of elevated fluid pressure.

95. An apparatus for expanding tubing downhole, the apparatus comprising:
a pulse generator configured to generate and apply a varying fluid pressure to the tubing such that the tubing is expanded, and
at least one seal for isolating a portion of tubing to be expanded from ambient fluid, said at least one seal being adapted to permit a degree of leakage thereacross.

96. The apparatus of claim 95, wherein a plurality of seal members are provided, each seal member adapted to maintain a fluid pressure differential thereacross.

97. The apparatus of claim 96, wherein at least five seal members are provided.

98. The apparatus of claim 95, wherein the at least one seal comprises a labyrinth seal.

99. An apparatus for expanding tubing downhole, the apparatus comprising:
pressurizing system for applying a varying fluid pressure to the tubing; and
an expansion cone adapted to retain expansion induced by elevated fluid pressure, the expansion cone includes a plurality of fluid outlets on a sloped surface thereof for communicating pressurized fluid from the pressuring system to an inner diameter of the tubing.

100. The apparatus of claim 99, wherein the expansion device comprises a shallow angle cone.

101. The apparatus of claim 99, wherein the cone angle no more than 11 degrees.

102. A method of expanding tubing, the method comprising:
applying a varying fluid pressure to the tubing, wherein a portion of tubing to be expanded is at least partially isolated from ambient fluid by at least one seal, and a varying pressure differential is maintained across the at least one seal, and wherein the at least one seal is arranged to provide for a degree of leakage thereacross and lubricates the at least one seal; and
producing a pressure pulse, and an associated elevated fluid pressure, which then decays as leakage occurs across the seal.

103. An apparatus for expanding tubing downhole, the apparatus comprising:
a pressurizing system configured to apply a varying fluid pressure to the tubing such that the tubing is expanded; and
at least one first seal member disposed proximate an end of the pressurizing system and at least one second seal member disposed proximate another end of the pressurizing system, wherein the seal members are configured to isolate a portion of tubing to be expanded from ambient fluid, wherein each seal member is configured to leak.

104. An apparatus for expanding tubing downhole, the apparatus comprising:
a pressurizing system configured to apply a varying fluid pressure to the tubing such that the tubing is expanded, wherein the pressurizing system comprises a member for increasing the pressure within the tubing while reducing the pressure externally of the tubing; and
at least one first seal member disposed proximate an end of the pressurizing system and at least one second seal member disposed proximate another end of the pressurizing system, wherein the seal members are configured to isolate a portion of tubing to be expanded from ambient fluid.

105. The apparatus of claim 104, further comprising a reciprocating pump operatively associated with at least one one-way valve.

106. An apparatus for expanding tubing downhole, the apparatus comprising:
a pressurizing system configured to apply a varying fluid pressure to the tubing such that the tubing is expanded;
at least one first seal member disposed proximate an end of the pressurizing system and at least one second seal member disposed proximate another end of the pressurizing system, wherein the seal members are configured to isolate a portion of tubing to be expanded from ambient fluid; and
a member for reducing the fluid pressure externally of the tubing.

107. The apparatus of claim 106, wherein said member for reducing the fluid pressure externally of the tubing comprises an injection member configured to inject a gas into the fluid surrounding the tubing.