Patent Publication Number: US-10316627-B2

Title: Assembly and method for creating an expanded tubular element in a borehole

Description:
CROSS REFERENCE TO EARLIER APPLICATIONS 
     The present application is a National Stage application of PCT/EP2015/068373 filed on Aug. 10, 2015, which claims priority of European application No. 14180767.7 filed Aug. 13, 2014. 
     BACKGROUND OF THE INVENTION 
     The present invention relates to an assembly and a method for creating an expanded tubular element in a borehole. The borehole may extend into an earth formation, for instance for the exploration or production of hydrocarbons. 
     Wellbores for the production of hydrocarbons are generally provided with steel casings and/or liners to provide stability to the wellbore wall and to prevent uncontrolled flow of fluid between the wellbore and the surrounding earth formation. A casing generally extends from surface into the wellbore, whereas a liner may extend only a lower portion of the wellbore. However in the present description the terms “casing” and “liner” are used interchangeably and without such intended difference. 
     In a conventional wellbore, the wellbore is drilled in sections whereby each section is drilled using a drill string that has to be lowered into the wellbore through a previously installed casing. In view thereof the wellbore and the subsequent casing sections decrease in diameter with depth. The production zone of the wellbore therefore has a relatively small diameter in comparison to the upper portion of the wellbore. In view thereof it has been proposed to drill a “mono diameter” wellbore whereby the casing or liner to be installed is radially expanded in the wellbore below a previous casing, after lowering to the required depth. Subsequent wellbore sections may than be provided with expandable liners, wherein each liner is expanded to substantially the same inner diameter as the previous liner or casing. If subsequent liner sections are expanded to the same diameter as the previous section, the wellbore inner diameter may remain substantially constant along at least a part of its length. 
     Subsequent wellbore section may therefore be drilled at a diameter larger than in the conventional wellbore, which may allow the wellbore to have a larger inner diameter at target depth than a conventional wellbore. 
     US-2006/0065403-A1 discloses an assembly for expanding a tubular element in a wellbore, whereby the tubular element is suspended during running-in into the wellbore on an expansion string having an expander at its downhole end, and whereby the tubular element passes through an existing casing in the wellbore. There is a risk that the lower end of the tubular element is prematurely expanded by the expander, for example if the weight of the tubular element causes the tubular element to slip downward relative to the expansion string and consequently partly expand. Such unintended expansion may hamper, or even prevent, introduction of the tubular element through the existing casing. 
     US patent application US2009/0139732 discloses a downhole swaging system with an expandable secondary swage, which is expanded if a primary swage encounters an increased resistance to swaging generated by a load ring or a section of increased thickness or strength of the expandable tubular. The known load ring or section of increased resistance are located at a location along the length of the expandable tubular where the secondary swage needs to be expanded and they are not arranged at a lower end or the expandable tubular and do not support the expandable tubular during descend into a borehole prior to the expansion process. 
     Other downhole well tubular expansion systems are disclosed in US patent applications US2009/139732 and US2012/298379, International patent applications WO2012/104257 and WO2014/151314 and in European patent application EP 1717411. 
     These known assemblies are not provided with a starter joint. There is a need for an improved assembly for supporting and expanding a expandable tubular wherein the expansion string may be locked to a starter joint during transport to the rig and during make-up of the tubular element on the rig floor, which starter joint transfers the weight of the tubular element to the expansion string without the tubular element being prematurely expanded, and may furthermore transfer rotary torque from the expansion string to the tubular element required for making-up and breaking-out of the on-off sub connection and for reaming with the expansion assembly while running into the borehole and which may also transfer a downward force from the expansion string to the tubular element to enable the tubular element to be pushed into the borehole in case obstructions are encountered on the way down. 
     It is an object of the invention to provide an improved assembly for lowering and expanding a tubular element in a borehole. 
     SUMMARY OF THE INVENTION 
     The invention provides an assembly for lowering and expanding a tubular element in a borehole, the assembly comprising:
         an expander arranged at a downhole end of an expansion string for radially expanding the tubular element in the borehole by upward movement of the expansion string through the tubular element;   a starter section arranged at a downhole end of the tubular element and comprising an internal upset having an upset inner diameter smaller than the initial inner diameter of the unexpanded tubular element; and   support means protruding from an outer surface of the expansion string below the internal upset for supporting the internal upset of the starter section to transmit at least part of the weight of the unexpanded tubular element via the internal upset and the support means to the expansion string when the assembly is lowered into the borehole, the internal upset being adapted to be radially expanded by the support means upon upward movement of the expander through the tubular element.       

     The invention also relates to a method for lowering and expanding a tubular element in a borehole, the method comprising the steps of:
         arranging a starter section at a downhole end of the tubular element, the starter section comprising an internal upset having an upset inner diameter smaller than the initial inner diameter of the unexpanded tubular element;   arranging an expansion string extending within the tubular element, the expansion string comprising an expander for radially expanding the tubular element in the borehole by upward movement of the expander through the tubular element and support means protruding from an outer surface of the expansion string below the internal upset for supporting the internal upset;   lowering the assembly into a borehole while transmitting at least a portion of the weight of the tubular element via the internal upset and the support means to the expansion string; and   radially expanding the internal upset by the support means upon upward movement of the expander through the tubular element.       

    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be described hereinafter in more detail and by way of example with reference to the accompanying schematic drawings in which: 
         FIG. 1  shows an exemplary embodiment of the assembly according to an embodiment of the invention; 
         FIG. 2 a    shows a portion of an expansion string of the exemplary embodiment; 
         FIG. 2 b    shows a starter joint of the exemplary embodiment; 
         FIG. 3  shows the starter joint with some design parameters indicated; and 
         FIG. 4  shows a modified version of the starter joint. 
     
    
    
     In the detailed description and the figures, like reference numerals relate to like components. 
     DETAILED DESCRIPTION OF DEPICTED EMBODIMENTS 
     The present disclosure involves an assembly for lowering and expanding a tubular element in a borehole on an expansion string, wherein at least part of the weight of the tubular element is transmitted to the expansion string via an internal upset and support means. 
     The weight carrying capacity of the expansion string is increased by virtue of the support means and the internal upset cooperating to carry at least a portion of the weight of the tubular element. The internal upset is expanded itself at the onset of the expansion process and thereby does not form an obstruction in the tubular element as expansion proceeds. 
     To allow the support means to pass easily through the unexpanded tubular element during the expansion process, suitably the support means has an outer diameter substantially equal to an inner diameter of the tubular element prior to radial expansion thereof, the support means being arranged upwardly from the expander. 
     To promote radial expansion of the internal upset by the support means, the internal upset advantageously rests on a support surface of the support means, the support surface extending inclined relative to a longitudinal axis of the expansion string. 
     The tubular element may be supported by a starter section during descent into the borehole. The starter section may take the form of a starter joint. The starter joint may overcome other drawbacks of the prior art as well. 
     In an exemplary embodiment, the support means comprises a series of external splines provided to the expansion string, the external splines being arranged to cooperate with a series of internal splines provided to the starter section to form a splined connection that rotationally locks the expansion string to the starter section. 
     To further increase the weight carrying capacity of the expansion string, the internal splines may be supported by an upper portion of the expander. 
     Suitably the expansion string includes a mandrel and a torque retainer ring extending around the mandrel, wherein the external splines are provided to the torque retainer ring. 
     The internal upset may comprise, for example, an annular internal upset extending along the inner circumference of the tubular element. Furthermore, the annular internal upset may extend into an annular recess formed in the expansion string so as to allow the tubular element to be pushed in downward direction by the expansion string. 
     Suitably the expansion string comprises a near-cone centralizer for centralising the expansion string in the tubular element, wherein a lower portion of the near-cone centralizer defines a boundary of the annular recess. The expansion string further may comprise a far-cone centralizer for centralising the expansion string in the tubular element, the far-cone centralizer being arranged upwardly from the near-cone centralizer. A debris catcher may be arranged at an upper portion of the expansion string. 
     In an exemplary embodiment the expansion string is at the upper end thereof connected to a drill pipe by means of an on-off sub that is adapted to be disconnected by rotation of the drill pipe relative to the expansion mandrel. 
     The starter section suitably comprises a lower section of the tubular element, said lower section being connected to an upper section of the tubular element in releasable manner 
     In order to anchor the tubular element after expansion thereof against another tubular element in the borehole, the starter section may be provided at its outer surface with a layer of friction material for enhancing friction between the starter section and the other tubular element. 
     Suitably the starter section comprises an outwardly flaring lower part arranged to be supported by the expander so as to transmit another portion of the weight of the tubular element via the outwardly flaring lower part and the expander to the expansion string. In this manner the weight carrying capacity of the assembly may be enhanced. 
     In order to further reduce the risk of premature expansion of the tubular element, the outwardly flaring lower part of the starter section may comprise a material of higher yield strength than a material of a remainder part of the starter section. Suitably the tubular element after radial expansion thereof forms an expanded liner or an expanded casing in the borehole. 
       FIG. 1  shows an assembly including a tubular element  1  adapted to be radially expanded in a wellbore and an expansion string  2  for radially expanding the tubular element. The expansion string  2  may comprise a mandrel  4 , a far-cone centralizer  6 , a debris catcher  7  and an on-off sub  8  having lower and upper parts  8   a,    8   b.  The on-off sub  8  connects the expansion string to the lower end of a drill pipe  10 , and may be adapted to be disconnected by rotation of the drill pipe  10  relative to the mandrel  4 . Expander  14  for expanding the tubular element  1  is arranged near a downhole end of the expansion string  2 . 
     The mandrel  4  may be provided with a lock nut  12 , the expander in the form of expansion cone  14 , a torque retainer ring  16  and a near-cone centralizer  18 . Each of the expansion cone  14 , the torque retainer ring  16  and the near-cone centralizer  18  has a respective central passage  19 ,  20 ,  21  through which the mandrel  4  extends in slidable manner. The lock nut  12  is screwed to the mandrel  4  to lock the assembly of expansion cone  14 , torque retainer ring  16  and near-cone centralizer  18  in place whereby the near-cone centralizer abuts against a shoulder  22  of the mandrel  4 . The expansion cone  14  may be rotationally locked to the torque retainer ring  16  by a castellated connection  24 . The torque retainer ring  16  may be rotationally locked to the near-cone centralizer  18  by a castellated connection  26 . The near-cone centralizer  18  may be rotationally locked to the shoulder  22  of mandrel  4  by a castellated connection  28 . 
     Alternatively the torque retainer ring  16  may be directly rotationally locked to the mandrel  4  by means of key slots in the torque retainer ring  16  and the mandrel  4 , and keys fitting in such key slots. This way the castellated connections  26 ,  28  may be eliminated. 
     The expansion cone  14  has a nose portion  30  of diameter substantially equal to the inner diameter of the unexpanded tubular element  1 . From the nose portion  30 , the diameter of the expansion cone  14  gradually increases in downward direction to a diameter corresponding to a desired expansion ratio of the tubular element  1 . The nose portion  30  is provided with an annular seal  32  of resilient material. 
       FIG. 2 a    shows the mandrel  4  with related components in more detail. An annular recess  34  may be formed between the torque retainer ring  16  and the near-cone centralizer  18 , for instance at the level of the castellated connection  26 . The torque retainer ring  16  may be provided with a series of external splines  36  regularly spaced along the outer circumference of the torque retainer ring. Each external spline  36  may have an upper surface  38  extending inclined relative to a longitudinal axis  39  of the mandrel  4 . The respective upper surfaces  38  define the lower boundary of the annular recess  34 . The upper boundary of the annular recess  34  is defined by a tapered lower surface  40  of the near-cone centralizer  18 . 
       FIG. 2 b    shows a starter section of the tubular element  1  in the form of starter joint  42 . The starter joint  42  may form a lower portion of the tubular element  1 . The starter joint  42  may for instance be adapted to be connected to an upper portion of the tubular element  1  (not shown) by pin member  43 . The pin member may be a male part of a threaded connection, connectable to a corresponding box member of the upper portion of the tubular element. 
     The starter joint  42  may be provided with a series of internal splines  44  regularly spaced along the inner circumference of the starter joint  42 . Slots  46  may be defined between the respective internal splines  44 . The slots  46  are arranged to receive the external splines  36  of the torque retainer ring  16  so as to form a splined connection. Each slot  46  has an upper surface  47  extending at the same inclination as the upper surfaces  38  of the external splines  36 . 
     The starter joint  42  may be provided with an annular internal upset  48  that fits into the annular recess  34 . The lower boundary of the internal upset  48  is formed by the respective upper surfaces  47  of the slots  46 . An annular indentation  50  is formed in the outer surface of the starter joint  42  at the level of the internal upset  48  so that the wall thickness of the starter joint  42  remains substantially constant along its length. 
     In an embodiment, the starter joint  42  has an outwardly flaring lower section  52  adapted to receive an upper part of the expansion cone  14 , as shown in  FIG. 1 . The largest outer diameter of the lower section  52  is less than, or equal to, the largest outer diameter of the expansion cone  14 . Also, the starter joint  42  may have an upper section  53  of inner diameter substantially equal to an initial inner diameter of the tubular element  1  prior to expansion thereof. 
     During operation, the starter joint  42  may be made-up with the expansion string  2  as follows. The near-cone centralizer  18  is fitted to the mandrel  4  so that the near-cone centralizer  18  abuts against shoulder  22  and is rotationally locked to the mandrel  4  by castellated connection  28 . Then the upper portion  53  of the starter joint  42  is extended over the near-cone centralizer  18  until the annular internal upset  48  contacts the tapered lower surface  40  of the near-cone centralizer  18 . Subsequently the torque retainer ring  16  is inserted into the starter joint  42  such that the external splines  36  slide into the slots  46  of the starter joint  42  until the upper surfaces  38  of the external splines  36  abut against the annular internal upset  48 . In this position the torque retainer ring  16  is rotationally locked to the near-cone centralizer  18  by castellated connection  26 . 
     Subsequently the expansion cone  14  is inserted into the starter joint  42  and fitted to the mandrel  4  until the nose portion  30  of the expansion cone  14  abuts against the torque retainer ring  16 . In this position the expansion cone  14  is rotationally locked to the torque retainer ring  16  by castellated connection  24 . Then the lock nut  12  is screwed to the mandrel  4  so as to axially lock the expansion cone  14 , the torque retainer ring  16  and the near-cone centralizer  18  to the mandrel  4 . The length of the internal splines  44  is such that these abut against the nose portion  30  of the expansion cone  14  after the lock nut  12  has been fastened. Subsequently the mandrel  4  is connected to the far-cone centralizer  6 , the debris catcher  7  and the lower part  8   a  of the on-off sub  8  as shown in  FIG. 1 . Finally a joint of the tubular element  1  is connected to the pin member  43  of the starter section. The internal upset  48  prevents the expansion string  2  from dropping out of the tubular element and starter joint  42  during this phase. 
     In a next step the expansion string  2  is lowered into the wellbore whereby the remaining upper portion of the tubular element is formed by adding tubular sections to the tubular element  1  in correspondence with the total length of the tubular element required in the wellbore. Meanwhile the tubular element  1  is supported and locked against rotation by a support device (not shown) at a drilling rig above the wellbore. 
     Subsequently upper part  8   b  of the on-off sub  8  may be connected to the bottom of drill pipe  10 . Sections of drill pipe are added to form drill pipe  10 . The drill pipe  10  is lowered into the tubular. Then the on-off sub  8  is made-up, for instance through right-hand rotation of the drill pipe sections. Upon lifting up the assembly on the drill pipes, the top of the tubular element  1  is released from the support device. 
     Subsequently the tubular assembly is run into the wellbore by adding drill pipes in correspondence with the depth of the wellbore. During running-in the assembly into the wellbore the weight of the tubular element  1  is transferred to the expansion string  2  via the contact between the internal upset  48  and the external splines  36 , via the contact between the internal splines  44  and the nose portion  30  of the expansion cone  14 , and via the contact between outwardly flaring lower portion  52  of the starter joint  42  and the expansion cone  14 . 
     Rotary torque required for making-up the on-off sub  8 , or for reaming the wellbore while running the assembly into the wellbore, is transferred from the mandrel  4  via the castellated connection  28  to the near-cone centralizer  18 , then via the castellated connection  26  to the torque retainer ring  16 , then via the splined connection to the starter joint  42 , and then via the pin member  43  and the corresponding box member to the remaining upper portion of the tubular element  1 . 
     If the expansion cone  14  may get stuck in the tubular element  1  during the expansion process, for example while the expansion cone is located in an overlap section wherein the tubular element  1  overlaps a previous liner or casing, the drill pipe may be disconnected from the expansion string  2  by breaking out the on-off sub. At this stage the external splines  36  of the torque retainer ring  16  may no longer be in contact with the internal splines  44  of the starter joint  42 . In such instance the break-out torque for breaking out the on-off sub is transmitted from the drill pipe via the on-off sub to the mandrel  4 , then via the castellated connections  28 ,  26 ,  24  to the expansion cone  14 , and finally via the face of the expansion cone  14  to the tubular element  1 . 
     If the tubular element needs to be pushed in downward direction to overcome friction between the tubular element  1  and the wellbore wall, for example during running-in the expansion assembly into a high inclination borehole, the required downward force is transmitted from the drill pipe and mandrel  4  via the near-cone centralizer  18  to the annular internal upset  48  of the starter joint  42  and hence to the stuck point of the tubular element  1 . 
     Once the expansion assembly has reached the target depth in the wellbore, the expansion process is started by applying a selected upward force to the drill pipe to move the expansion string  2  upwardly while the tubular element  1  is held stationary, for example by anchoring the tubular element  1  to another tubular element arranged in the wellbore. In this manner the external splines  36  of the torque retainer ring  16  expand the internal upset  48  of the starter joint  42  until the internal upset becomes flush with the outer diameter of the nose portion  30  of the expansion cone  14 . The inclined upper surfaces  38  of the external splines  36  and the correspondingly inclined upper surfaces  47  of the slots  46  induce the onset of expanding the internal upset. Simultaneously, the expansion cone  14  expands the lower section  52  of the starter joint  42  followed by the splined portion of the starter joint, and subsequently the remainder of the tubular element  1 . 
     In view of the relatively high local contact stresses that may occur between the expansion cone  14  and the edges of the internal splines  44  during expansion, the inner surface of the starter joint  42  may be provided with a dedicated coating, for instance a solid lubricant. A suitable example of such coating is Manganese Phosphate overlayed by a layer of a teflon based material, for example Xylan™ coating. A solids free coating, e.g. Rust Preventing Solid Lubricant film, may be used in combination with such coating. 
     The load carrying capacity of the starter joint  42  is selected such that the force required to release the expansion string  2  from the starter joint  42  exceeds the buoyant weight of the tubular element  1  in a vertical borehole. In this manner premature plastic deformation of the starter joint  42  is prevented. Such premature plastic deformation could otherwise result in an increase of the maximum diameter of the lower section  52  of the starter joint  42  to the extent that the starter joint  42  cannot pass through another tubular element already installed in the wellbore. 
       FIG. 3  indicates some design parameters that may be used to achieve the required minimum force to release the expansion string  2  from the starter joint  42 . The starter joint  42  has a reference wall thickness t 0  substantially equal to that of the remainder of the tubular element  1 . The started joint may be manufactured from the same expandable material as the remainder of the tubular element  1 . 
     A suitale material may be for example VM-50 expandable tubular, marketed by Vallourec (France). VM 50 P110 is nickel based, and made of an austenitic Corrosion Resistant Alloy. The main alloying elements may be 54% Ni, 20% Cr and 9% Mo. 
     The push-down force capability, i.e. the capability of pushing the tubular element  1  downwardly via the expansion string  2 , is dependent on the dimensions of the internal upset  48 : h, t u  and α. The rotational torque transmission capability via the splined connection is dependent on the dimensions of the splines: l, w and h. The weight carrying capacity of the starter joint  42  is dependent on the dimensions of the internal upset  48 : h, ß, the cross-sectional area and number of external and internal splines  36 ,  44 , and the maximum diameter of the lower section  52  of the starter joint. 
     Furthermore, the friction factor at the interface between the expansion cone  14  and the lower section  52  can be increased to increase the weight carrying capacity, for example by application of a high-friction copper coating at the interface. 
     The weight carrying capacity obtained by the internal upset  48 , the splines  36 ,  44  and the lower section  52  enables a maximum length of the tubular element  1  to be carried into the wellbore whereby the buoyant weight of the tubular element in a vertical hole is less than the expansion force required to expand the tubular element  1 . 
     A safety margin may be applied to compensate for variations in friction factor at the interface between the expansion cone  14  and the lower section  52  of the starter joint  42 , and to compensate for reduction of the material yield strength with increasing temperature. The length of tubular element that may be run into the wellbore with the starter joint  42  may be up to 3500 ft (1067 m). 
     The load carrying capacity of the starter joint  42  may be increased in the following ways:
         increase the wall thickness t u  at the internal upset  48 ;   increase the wall thickness of the outwardly flaring lower section  52  from t 0  to t 1 ;   increase the yield grade of the material of the outwardly flaring lower section  52  from e.g. steel grade 50 to an expandable steel grade 80, which may be combined with an increased wall thickness of lower section  52 . The latter may be butt welded to the remaining portion of the starter joint  42 .       

     A combination of the above measures may result in an increase of the load carrying capacity of the starter joint  42  of about 100% or more. The invention may thus enable for instance about 7000 ft (2134 m) of expandable tubular element to be run into the borehole in a controlled way in a single trip. 
     The above design modifications may result in a significantly increased peak expansion force of the starter joint relative to the load carrying capacity, which may put a high demand on the pulling capacity of the drilling rig. To mitigate this effect the wall thickness of a section of the starter joint just above the outwardly flaring lower section  52  may be reduced. 
     Referring to  FIG. 4 , the starter joint  42  also may be used for cladding of a host casing in a wellbore. The host casing may for example be a conventional casing or an already expanded casing. Cladding the existing casing may increase the collapse rating of the host casing. In such application, a constant wall thickness of the starter joint may be required in order to provide a constant support to the host casing and to control the peak expansion force. 
     The starter joint  42  may also function to anchor the expanded tubular element to the host casing. Thus, the expanded starter joint will form a cased hole anchor, i.e. an anchor for anchoring the expanded tubular element to the casing of the cased borehole. This can be achieved by providing cylindrical section  56  of the starter joint  42  with a high friction layer  58 . For this purpose carbide particles may be used that may be brazed or laser-coated to the outer surface of cylindrical section  56 . Alternatively small ceramic ball may be partly pressed into the wall of cylindrical section  56 . Such cased hole anchor provides a very effective means of anchoring the expanded tubular element to the host casing and allows the remainder of the tubular element to be expanded by rig overpull. 
     With the assembly described herein it may be achieved that the expansion string is locked to the starter joint during transport to the rig and during make-up of the tubular element on the rig floor. Further, the starter joint transfers the weight of the tubular element to the expansion string without the tubular element being prematurely expanded, and transfers rotary torque from the expansion string to the tubular element required for making-up and breaking-out of the on-off sub connection and for reaming with the expansion assembly while running into the borehole. Also, the starter joint transfers a downward force from the expansion string to the tubular element to enable the tubular element to be pushed into the borehole in case obstructions are encountered on the way down. 
     The present invention is not limited to the embodiments thereof described above, wherein many modifications are conceivable within the scope of the appended claims. Features of respective embodiments may for instance be combined.