Abstract:
A tubular string is advanced with a bottom hole assembly as the hole is drilled and reamed in a desired direction with the aid of directional drilling equipment adjacent the bit. When the advanced tubular forms the desired lap to the existing tubular, the assembly can be configured to cement the tubular and expansion can then be accomplished to fill the annular space and enhance the cement bonding. The expansion equipment can create a bottom bell on the expanded tubular and expand the top end into a bell of the existing tubular so that a monobore is created as the process is repeated with each added string. Numerous variations are contemplated for each single trip including but not limited to the direction of expansion, whether cementing or expansion occurs first, reforming folded tubing in the hole as well as the nature of the expansion tool and pressure control when drilling.

Description:
FIELD OF THE INVENTION 
       [0001]    The field of the invention is generally drilling and completion optimization and more specifically the combination of multiple functions in a single trip such as liner or casing directional drilling with cementing and expansion capabilities to form a monobore. 
       BACKGROUND OF THE INVENTION 
       [0002]    Drilling a hole and advancing casing or liner as the hole is drilled and reamed are known as described in U.S. patent and published applications: U.S. Pat. Nos. 5,845,722; 6,196,336; 6,419,033; 2003/0056991; 2003/0106688; U.S. Pat. Nos. 5,348,095; 6,371,203; 2002/0040787; 2002/0189863; 2004/0011534; 2005/6854533; 2007/0144784; 2007/0175665; 2007/0267221; 2008/0135289; 2009/0090508 and 2010/7784552. 
         [0003]    Some of the art also has a focus on hole orientation while drilling such as US Publication 2009/0056938 and 2005/0126825. Casing drilling with expansion is discussed in US Publication 2007/7287603. Other prior art discusses drilling a wellbore and forming a monobore, such as US Publication 2006/0196663; 2011/0114336; 2010/0032167 and 2008/7383889. Drilling and cementing is discussed in UP Publication 2009/0107675. Expanding and cementing is covered in US Publication 2012/0061097. Using folded tubulars and reforming them in a wellbore coupled with further expansion as a possibility is discussed in 2011/0265941. 
         [0004]    The present invention seeks to make drilling and completion more efficient by enabling in some embodiments the drilling and reaming of a borehole while advancing casing, liner or a patch with the further ability to expand and cement in either order. The expansion device can be run top down or bottom up when using a swage that can be built to multiple diameters for creating a bottom bell on the tubular advanced with the bottom hole assembly (BHA), expand the tubular and fixate the tubular to an existing tubular through which the expanded tubular has just been run. Cementing can be accomplished before or after expansion and expansion can be accomplished with an inflatable instead of a swage. A monobore can be created with an expansion tool that adapts to several diameters. The BHA can be driven by a fluid motor such as a Moineau pump and supported by rigid or coiled tubing. The tubular can be solid, with single or multiple walls or slotted. The swage can be advanced with a hydraulic anchor/stroker tool alone or with force delivered through the running string or combinations of the two. Steering tools can be incorporated in the BHA as well as sensors to determine the location of the string being advanced. Drilling pressure at the bit can be controlled with adjustable chokes associated with the tubular being drilled in. The swage can be used as a tubular support during running in and drilling. A folded liner can be advanced and then made round with a swage or by application of internal pressure. The string can be rotated during cementing to distribute cement with the downhole motor to do the rotation if coiled tubing is used for the running string. Expansion can also be accomplished with roller expanders, conical swages or internal pressure in the string. Expansion direction can be top down or bottom up. Cementing can occur bottom up or top down and can occur before or after expansion. Expansion can also occur at one end or another first and then proceed from the opposite end or with a middle section expanded first followed by opposed ends. Top down expansion can be aided by adding string weight by setting down weight at the surface. Those skilled in the art will better appreciate these and other aspects of the present invention from a review of the detailed description of the preferred embodiment and the associated drawings while recognizing that the full scope of the invention is to be found in the appended claims. 
       SUMMARY OF THE INVENTION 
       [0005]    A tubular string is advanced with a bottom hole assembly as the hole is drilled and reamed in a desired direction with the aid of directional drilling equipment adjacent the bit. When the advanced tubular forms the desired lap to the existing tubular, the assembly can be configured to cement the tubular and expansion can then be accomplished to fill the annular space and enhance the cement bonding. The expansion equipment can create a bottom bell on the expanded tubular and expand the top end into a bell of the existing tubular so that a monobore is created as the process is repeated with each added string. Numerous variations are contemplated for each single trip including but not limited to the direction of expansion, whether cementing or expansion occurs first, reforming folded tubing in the hole as well as the nature of the expansion tool and pressure control when drilling. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is an assembly drawing of the system of the present invention using a mechanical swage; 
           [0007]      FIG. 2  is an alternative to  FIG. 1  using internal pressure to accomplish expansion rather than a swage assembly; 
           [0008]      FIG. 3  is another view of the assembly of  FIG. 1 ; 
           [0009]      FIG. 4  shows a tubular to be run in suspended from the surface; 
           [0010]      FIG. 5  is the view of  FIG. 4  with the bottom hole assembly extended through the tubular to latch the tubular to the BHA; 
           [0011]      FIG. 6  is the view of  FIG. 5  with the assembly advanced to hole bottom; 
           [0012]      FIG. 7  is the view of  FIG. 6  with the reamer extended; 
           [0013]      FIG. 8  is the view of  FIG. 7  with the desired lap obtained, the reamer collapse and the anchor set to attach the assembly to the existing tubular; 
           [0014]      FIG. 9  is the view of  FIG. 8  showing cement delivery and expansion; 
           [0015]      FIG. 10  is the view of  FIG. 9  showing expansion that makes the annular space smaller and redistributes the cement; 
           [0016]      FIG. 11  is the view of  FIG. 10  showing expansion at the lap to the existing liner to connect them followed by circulation to remove excess cement; 
           [0017]      FIG. 12  schematically illustrates the bottom up expansion configuration; 
           [0018]      FIG. 13  schematically illustrates the top down expansion configuration; 
           [0019]      FIG. 14  is an alternative to  FIG. 12  where the string is pulled to expand with the stroking tool available for backup purposes only; 
           [0020]      FIG. 15  illustrates expansion of the tubular with internal pressure; 
           [0021]      FIG. 16  is a section through a single wall cemented tubular; 
           [0022]      FIG. 17  is a section through a single wall tubular that is not cemented; 
           [0023]      FIG. 18  is a section through a dual wall tubular that is not cemented; 
           [0024]      FIG. 19  is a section view illustrating the operation of the adjustable choke  18  shown in  FIG. 3  with a previous casing in position; 
           [0025]      FIG. 20  is the view of  FIG. 18  illustrating the adjustable choke in an open hole situation; and 
           [0026]      FIG. 21  shows one way of folding the tubular for run in before expansion into a rounded shape. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0027]    Referring to  FIGS. 1 and 3 , the bottom hole assembly (BHA)  16  has a pilot bit  9  and steering unit  10  that are spaced apart from an expandable reamer  8 . Continuing in the uphole direction there is a stroker/thruster  7  which is a hydraulically actuated piston that works in tandem with an anchor  1  to selectively move the swage assembly  6  through the casing or liner  11 . A running tool  2  selectively retains the tubular  11  for running in and drilling so that tubular  11  moves with the advancing bit  9 . The running tool  2  is connected through drill pipe  3  to a mud motor  4  for rotation of the bit  9 . The entire assembly is supported from the surface with rigid or coiled tubing that is not shown. An indication tool  5  is part of the tool string for drilling and senses an indication point  14  on the tubular  11  to properly align the internal components with the surrounding tubular  11  for actuation of the running tool to connect them together so that there will be tandem movement of the advancing bit  9  and the tubular  11 . Below the expander  6  is cement valve  13  which is selectively opened when and if it is desired to cement. This ported sub is normally closed so that fluid from the surface can be used to extend the blades on the reamer  8  and provide nozzle fluid to the pilot bit nozzles to remove cutting as more hole is made by bit  9 . Working in association with the cement valve assembly  13  is the open hole packer  15  that is preferably a cup type seal that opens in an uphole direction to redirect cement  24  by opening up as shown in  FIG. 1 . This type of seal can be multiple rows of overlapping metals that can slide relatively to each other as the delivered cement  24  exits from ports  32 . Such ports  32  can be opened with a dropped ball on a seat that shifts a sleeve (not shown) or internal pressure levels through an orifice that shifts a sleeve using differential pressure or other mechanisms to selectively open the ports  32  at the onset of cementing. The ports  32  can also be configured with one way valves to prevent return of the delivered cement  24  once it passes through the ports  32 . 
         [0028]      FIG. 1  also shows the existing tubular  34  that preferably has a bell  36  formed at its lower end so that the tubular  11  can be expanded into bell  36  for a sealed connection between the two so that a monobore can be created as the process is repeated with additional tubulars  11 . As will be explained below the swage assembly or expander  6  can be built to different dimensions so that the onset of movement through the tubular  11  is at a larger dimension for the expander  6  to create the bell  36  as is shown more clearly in  FIG. 11 . Note that the anchor  1  grips tubular  34  above the bell  36  to enable the stroker  7  to advance the swage assembly  6  through the tubular  11 . As an alternative the swage assembly  6  can be advanced with a pulling force on the drill string (not shown) and the stroker  7  and anchor  1  can be part of the assembly for backup purposes only. 
         [0029]    The open hole packer  15  is there to keep the cement  24  from moving downhole toward the reamer  8  and the bit  9 . Low pressure open hole packer  12  is secured to the lower end of the tubular  11  and is there for the purpose of preventing cement  24  backup out of the annular space  38  as an alternative to check valves associated with openings  32 . The packer  12  can also be of the multi-layered cup shape petal design where the petals move relatively to each other to open. Cement delivery merely displaces the cup shape inwardly as the cement  24  passes and thereafter the weight of the cement above the packer  12  urges its overlapping layers outwardly so that the cement  24  is prevented from reversing direction. 
         [0030]    At the top of the tubular  11  and extending into the annular space  38  is a schematically illustrated choke that can be used to control the fluid pressure at the bit  9  when more hole is made within a desired pressure range to enhance the rate of penetration and to minimize formation damage. Alternatively, such pressure control at the bit  9  could also be accomplished at the well surface. 
         [0031]    The major components of the assembly having been described a preferred sequence of operation will now be reviewed followed by possible variations and other options.  FIG. 4  illustrates the rig floor  20  with slips  19  holding the casing or liner sting  11  inside an existing tubular  40  that has been cemented with cement  42 . Packer  12  is shown at the lower end of the tubular string  11 . In  FIG. 5  the BHA  16  is installed so that the anchor  1  extending out beyond the top of the tubular string  11 . The indication tool  5  senses the indication point  14  to get this needed alignment. In  FIG. 6  the running tool  2  is actuated to grab the tubular string  11  so that the slips  19  at the rig floor  20  can be released and the drill string (not shown) can be used to support the tubular string  11 . The bit can then be run to hole bottom, if it is not already there. 
         [0032]      FIG. 8  shows the reamer  8  with blades extended which can be accomplished by the circulating fluid pressure that is directed to the nozzles of the bit  9 . At this point drilling with bit  9  can take place while reaming with reamer  8  and advancing the tubular string  11  at the same time. In  FIG. 9  the drilling has advanced the tubular string so that its top end overlaps the lower end  21  at bell  36 . The anchor  1  is activated above the bell  36  and the reamer is deactivated so that expansion or cementing, if desired, can now take place. 
         [0033]    In  FIG. 9  the expander  6  is built and moved into contact with the lower end of the tubular string  11  to close it off from the cement  24  that is delivered through the now opened cement valve  13 . Delivery of the cement  24  opens up the open hole packer  15  so that the cement is redirect up into the annulus  23  in the direction of the arrows. At this time the open hole packer  12  also opens under the weight of the delivered cement  24  to keep the cement  24  from reversing direction and going back toward cement valve  13 . The running tool  2  can now be released. 
         [0034]      FIG. 10  shows the swage  6  making the bell  36  at the lower end of the tubular string  11  followed by being reconfigured to expand the balance of tubular string  11  to the desired diameter so that the recess shoe gap  25  will close when the swage assembly  6  gets to that location. The measured amount of cement  24  is pushed uphole in the annulus  23  as the annulus  23  gets smaller due to the tubular string  11  expansion toward the borehole wall  22 . The packer  12  is active to keep the cement  24  from moving downhole. A caliper log (not shown) can be used in conjunction with the cement delivery step. Preferably the expansion of the tubular string  11  moves the cement  24  to or through the recess shoe gap  25  which is then closed with the expander  6  against the bell  36 . The adjustable choke  18  can then serve as a seal for gap  25  or some other sealing member or a metal to metal contact can then seal the tubular string  11  to the tubular above such as  40  or a previously expanded tubular string.  FIG. 11  shows the end of the swaging and the removal of the BHA  16  while using fluid circulated through the bit  9  in the vicinity of the upper end of the tubular string  11  now joined to the tubular above to remove excess cement that got through the gap  25  before that gap was closed by the swage assembly  6 . The assembly is then pulled out of the hole and a new tubular string is made ready and the process is repeated. If there is still cement in the tubular string  11  near the former gap  25  that is now closed, the bit  9  will simply drill through it. 
         [0035]      FIGS. 12 and 13  illustrate the tool arrangement for bottom up and top down respectively. As previously described for bottom up, the running tool  2  and the associated components grab the tubular string  11  with the anchor  1  located above the running tool  2  and the swage  6  and thruster  7  located near the lower end. To do top down requires the running tool  2  to be below the expander  6  with the anchor  1  and the stroker  7  and the expander  6  above as shown in  FIG. 13 . As soon as tubular string  11  is affixed to the bell of the string above, the running tool  2  can release the tubular string  11 . It should be noted that the initial expansion may or may not fully seal to the bell  36  of the string above depending if there is to be a cementing step thereafter. Gaps can be left open and then closed with the expander after cement  24  delivery. Expanding top down also reduces risk of getting stuck as the BHA is more easily pulled out with a tensile force on the drill string without any need to collapse the expander  6  as it is being driven top down in  FIG. 13 . As another alternative in  FIG. 14 , the expander  6  and thruster  7  can be located below the running tool  2  and the expansion can take place bottom up with a pulling force on the drill string (not shown) with the thruster  7  being there for backup purposes in the event excessive force would otherwise have to be applied to advance the expander  6 . Normally in the bottom up expansion the stroker  7  advances the expander  6  while the drill string with anchor  1  is braced against the existing tubular above. When the tubular string  11  is secured to the existing string, then the running tool  2  is released. This allows the drill string with the bit  9  to then be removed. Alternatively for bottom up expansion the tubular string  11  can have a hanger near its lower end to hold it in place as the expander  6  is built to the desired expansion diameter the expander  6  moved with the stroker  7  through the tubular string  11 . Alternatively the fixation can be at the lower end of the tubular string  11  and the expansion accomplished with a pulling force on the drill string (not shown). 
         [0036]    The assembly can also be centered using an inflatable in the recently reamed section before building the expansion assembly  6 . 
         [0037]    In a top down expansion the chances of getting the expander  6  stuck are reduced as the expander  6  can be reconfigured to a smaller dimension and simply pulled out of the tubular string  11  or it can be retracted without having its swaging dimension reduced first. Top down also affords the option of building the expander  6  outside the tubular string  11  to the initial desired dimension. Again, extraction of the expander  6  with top down is far simpler than a bottom up expansion. 
         [0038]    The expander  6  is preferably buildable to multiple dimensions so that it can make an end bell for a monobore completion and then be reconfigured to the desired dimension for completion of the expansion of the tubular string  11 . 
         [0039]    The open hole packer  12  can serve the function of a hanger. The drill string can be rigid pipe or coiled tubing. Alternatively the bit  9  can be attached to the tubular string  11  directly when the tubular string happens to be casing. The expansion process can also be initiated and monitored with sensors to detect the proper positioning of the tubular string  11  with respect to the existing tubular to which it will be attached by expansion and the sensors can monitor the progress of the expansion to determine when it is time to reconfigure the expansion assembly  6  after the tubular sting  11  is attached to the existing tubular above. The tubular string can be solid wall or slotted to facilitate the expansion. 
         [0040]    The bypass  17 , see  FIG. 3  along with the adjustable choke  18  can work together with the choke  18  bypassing pressure in both directions with additional bypass flow through  17  for control of the effective density on the formation at the bit  9  taking into account the pressure drop in the annulus above. 
         [0041]    The expander  6  when placed below the tubular string  11  for running in can support the tubular string  11  for running in the hole before drilling resumes. 
         [0042]    The tubular string need not have a circular cross section when running in. It can be fluted, as in  FIG. 21  or flat and then when located at a desired location can be made round and subsequently further increased in a mechanical expansion with the expander  6 . A higher expansion ratio can be attained with a folded string. Internal pressure can be used to unfold the string and bring its profile to round as shown in  FIG. 15  with the internal volume  50  pressurized against a seal  52 . Roller expanders can also be used for reforming the folded tubular or a combination of the above described techniques. The folder tubular string  11  can be expanded top down and the cement can be delivered top down through the gap such as  25  in  FIG. 10 . Bottom up expansion of the folded tubular string is also contemplated. Either end can be expanded first to make a bell and then the rest of the folded string can be expanded to a different dimension by going in either direction. Alternative a middle portion of the tubular string  11  can be expanded first for fixation followed by expansion of the bottom portion and then the top portion or vice versa. 
         [0043]    Those skilled in the art will appreciate that the present invention allows for tubular sting expansion in the context of liner drilling with a drill string or with a casing drilling application. A monobore or some other type of completion can be achieved. In some applications cementing would be optional. Cementing can be done before or after expansion and in the same trip. The drilling can be steerable so that liner and casing can be advanced into a properly oriented bore and expanded and if desired cemented in the same trip. In some applications such as when setting a patch the cement can be allowed to flow toward the bit and the reamer. Expansion that takes place after cementing increases the cement bond and saves money by reducing the amount of cement needed for the completion. In some applications the cementing can be optional, which saves additional sums. Expansion increases the internal tubular diameter to allow greater flow capacities and less pressure drop for a given flow rate. Future drilling out of the cement such as when making a lateral can also be reduced when expansion results in a thinner layer of cement in the surrounding annulus. Use of known components of known integrity can be used such as reamer blades that can be retracted for removal of the drill string to get the next tubular string section to be advanced into the wellbore. The roller expander can be used instead of a cone type expander to get the various dimensions to build an end bell at a lower end and to expand the bulk of the string length as well as to secure the string to an existing tubular at an opposite end. 
         [0044]    Top down expansion can also be accomplished with string weight added to the expander as an expansion option. In a bottom up expansion the movement of the expander can distribute the cement and while pushing up the cement take voids out of the cement. 
         [0045]    A single wall tubular such as casing  60  can be used with cement  62  as shown in  FIG. 16 .  FIG. 17  shows a single wall tubular  70  used without cement.  FIG. 18  shows wall layers  80  and  82  where layer  82  is more ductile than layer  80  used in a borehole without cementing. 
         [0046]    It is also desirable to rotate the tubular string  11  which can be done by rotation of the drill string if the drill string is rigid. The fluid motor  4  can also be selectively engaged to the tubular string with a swivel mount for the motor  4  to allow relative rotation as shown schematically by  54  in  FIG. 15 . 
         [0047]    In the case of casing drilling the expander  6  can be carried within the casing and then when drilling to the needed depth the expander  6  can latch the bit  9  and be extended out the lower end of the casing so that it can be built and conduct the expansion bottom up while retrieving the bit and reamer behind it. Alternatively the expander  6  can be supported above the casing string using a running tool and an anchor with a stroker for expansion in a top down direction. The configuration for cementing can be as previously described. 
         [0048]    Seals  12  or  15  can be inflatable seals actuated with the delivered cement  24 . 
         [0049]    “Cement” as used herein is intended to encompass all materials capable of sealing tubulars downhole. 
         [0050]      FIGS. 19 and 20  schematically show the one way flow action of the choke  18  within a bell at the lower end of an existing tubular as in  FIG. 19  and arrows  100  or in open hole with arrows  102 . 
         [0051]    The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below: