Patent Publication Number: US-7591059-B2

Title: Expansion activated anti-rotation device

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   Embodiments of the invention generally relate to tubular connections. 
   2. Description of the Related Art 
   In order to access hydrocarbons in subsurface formations, it is typically necessary to drill a bore into the earth. The process of drilling a borehole and of subsequently completing the borehole in order to form a wellbore requires the use of various tubular strings. These tubular members are typically run downhole where the mechanical and seal integrity of the jointed connections are critically important in the original make-up of the tubular members, during expansion of the tubular members, and after expansion of the tubular members. 
   Typically, simple male to female threaded connections connect multiple tubular members end-to-end. The male end is generally referred to as a pin, and the female end as a box. The tubular members are connected, or “made-up,” by transmitting torque against one of the tubular members while the other tubular member is typically held stationary. Transmitting torque in a single direction corresponding with connection make-up tightens the threaded joint in order to establish the seal integrity and lock in the applied torque. 
   When running tubular members, there is sometimes a requirement to run jointed tubular members that will later be expanded by various types of expansion mechanisms. The most basic type of expander tool employs a simple cone-shaped body, which is typically run into a wellbore to the tubular member that is to be expanded. The expander tool is then forced through the tubular members to be expanded by pushing or pulling on the working string from the surface and/or applying fluid pressure on one side of the cone. Alternatively, rotary expander tools can employ one or more rows of compliant rollers that are urged outwardly from a body of the expander tool in order to engage and to expand the surrounding tubular member. The rotary expander tool is rotated downhole so that the actuated rollers can act against the inner surface of the tubular member to be expanded in order to expand the tubular body circumferentially. Radial expander tools are described in U.S. Pat. No. 6,457,532, issued to Simpson et al., and that patent is incorporated herein by reference in its entirety. 
   Expanding tubular members that use the same threaded connections as employed with conventional oil-field tubular members proves to be problematic. First, changes in geometry of the connection once expanded can reduce the locked in torque and the tensile capacity of the connection due to loss of intimate contact between the threads when the locked in torque is reduced. Additionally, a threaded connection potentially turns and loosens during expansion due to rotation and frictional contact of a rotary expansion tool. For example, left hand threaded box by pin connections rotate in the clockwise direction when expanded with the rotary expansion tool in the clockwise direction. This transferred rotation potentially slackens off the threaded connections within a multiple joint tubular string being expanded that is differentially stuck at the bottom when expansion takes place top down. On the other hand, transferred clockwise rotation from the rotary expansion tool potentially loosens the threaded connection regardless of differential sticking when expansion occurs in a bottom to top direction. Addition of right hand threaded connections for use in the tubular string to help remedy these problems related to undoing of the connection during expansion only present further issues such as inventory concerns and specialized equipment requirements. 
   Therefore, a need exists for an improved tubular connection that is capable of being made-up and broken-out numerous times prior to expansion while torsionally locking itself upon being expanded. 
   SUMMARY OF THE INVENTION 
   Embodiments of the invention generally relate to threaded tubular ends having a slot cut across a thread at a location along the circumference of the thread. A connection according to embodiments of the invention includes those formed between two tubular members that have the slot disposed in either or both of a pin or box end of the tubular members. The slots represent no impediment to the make-up or break-out of a box by pin connection prior to expansion. During expansion of the connection, the threads of either the box or pin end are forced via plastic flow into the slot in the corresponding thread. This results in locking the connection and preventing relative rotation between the two tubular members, which could otherwise loosen the connection. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments. 
       FIG. 1  is a side view of a portion of a tubular member having a pin end with an axial slot extending across threads formed on the pin end. 
       FIG. 2  is a cross sectional view of a portion of a tubular member having a box end with an axial slot extending across threads formed inside the box end. 
       FIG. 3  is a partial cross sectional view of a connection between two tubular members with a box end cut away to illustrate a random pattern of slots in threads circumscribing a pin end. 
       FIG. 4  is an elevation view schematically showing tubular members within a borehole and a representative expander tool at a connection according to aspects of the invention between two of the tubular members. 
   

   DETAILED DESCRIPTION 
     FIG. 1  shows a portion of a tubular member  102  having a pin end  104  with an axial slot  106  extending across a helical thread  108  formed on the pin end  104 . The slot  106  interrupts the thread  108  at the same circumferential point along the entire axial length of the pin end  104 . For some embodiments, the slot  106  extends across only a portion of the pin end  104  such that at least some individual turns of the thread  108  are continuous through the 360° of one turn. The slot  106  preferably extends from the crest of the thread  108  to a depth no greater than the root of the thread  108 . In general, any standard pin end can be modified by cutting the slot  106  axially across the thread  108 . 
   As with other embodiments described herein, multiple slots may be spaced around the circumference of the thread  108 . For example, both the slot  106  and an additional slot  103  interrupt the thread  108  within a single 360° turn of the thread  108 . The slots  103 ,  106  may be parallel or non-parallel to one another. The additional slot  103  can extend across only a portion of the pin end  104  as shown or can extend across the entire axial length of the pin end  104 . Additionally, the size and shape of the slot(s) can vary. For example, the slot(s) can be at an angle or curved. Furthermore, the slots described herein represent no impediment to the make-up or break-out of a box by pin connection prior to expansion. Specifically, the thread continues as a normal thread on each side of the slot even though the thread is not continuous due to the slot. 
     FIG. 2  illustrates a portion of a tubular member  202  having a box end  204  with an axial slot  206  extending across threads  208  formed inside the box end  204 . The slot  206  in the box end  204  serves a similar function and may be modified in a similar manner as the slot  106  in the pin end  104 . Connections according to embodiments of the invention include those formed between tubular members that have the slot disposed in either or both of the pin or box ends. 
     FIG. 3  shows a connection  360  between a first tubular member  301  and a second tubular member  302  with a box end  304  of the second tubular member  302  cut away to illustrate a random pattern of a slot  306  disposed along a thread  308  circumscribing a pin end  303  of the first tubular member  301 . The thread  308  of the pin end  303  mates with a corresponding thread  309  of the box end  304 . The slot  306  cuts through individual turns of the thread  308  at various locations around the circumference of the pin end  303 . In contrast to the embodiment shown in  FIG. 1  where the slot  106  is straight, the slot  306  interrupts the thread  308  at different circumferential points along the axial length of the pin end  303 . Again, the random pattern can be applied to a slot (not shown) in the corresponding thread  309  of the box end  304  as an alternative to or in combination with the slot  306  in the pin end  303  without departing from the scope of the invention. 
     FIG. 4  illustrates embodiments of the invention in use within a wellbore  10 . Accordingly,  FIG. 4  shows a representative rig  2 , a ground surface  6 , a formation  4 , a drill string or running string  8 , a first tubular member  101 , a second tubular member  201 , a representative expander tool  40  comprising a body  42  and an extendable member  45  or roller, a bore  400  running through the tubular members, and a connection  60  or joint between the first tubular member  101  and the second tubular member  201 . In operation, the first tubular member  101  and the second tubular member  201  are mated together at the surface  6  according to normal stab-in and threading procedures. The stab-in procedures can be preformed with tubular members arranged in a pin up and a box down configuration or a configuration with the pin down and the box up. 
   After run-in, the tubular members can be expanded from within by any method known to those skilled in the art. The expansion process can be run in any axial and/or rotational direction within the tubular members  101 ,  201  without risk of the connection rotating and loosening since the connection  60  becomes torsionally locked after being expanded as described below. The running string  8  with an expander tool  40  attached thereto runs through the bore  400  of the tubular members. At a desired location, an operator expands the tubular members using the expander tool  40 . 
   When the expander tool  40  reaches the connection  60  between the first tubular member  101  and the second tubular member  201 , an internal wall of a pin end expands into an internal wall of a box end. The connection  60  between the tubular members  101 ,  201  is capable of being expanded without losing its mechanical integrity. The threads of either the box or pin end are forced via plastic flow into a slot (e.g., the slots  106 ,  206  and/or  306  illustrated in  FIGS. 1-3 ) on the corresponding thread of the other end. This results in locking the first and second tubular member  101 ,  201  together, thereby preventing rotation across the connection or relative rotation between the tubular members  101 ,  201 . Thus, any rotation translated to the tubular members  101 ,  201  from rotation of the expander tool  40  cannot operate to break-out the connection  60  once the connection is expanded. 
   The plastic flow of material into the slots which are disclosed herein upon expansion of the connection can be caused to occur based at least on differential movement between the pin and box ends due to the expansion. For example, the pin end tends to elongate while the box end tends to contract when expanding the connection using rotary expansion methods. For some expansion methods such as those utilizing a cone or expansion mandrel, both the pin and box end can shrink with the relative amount of shrinkage of each end being sufficiently different to create the differential movement that at least enhances flow of material into the slots to lock the connection. 
   The expandable tubular members  101 ,  201  with the connection  60  according to aspects of the invention can be part of a liner, an open hole or cased hole patch that is run-in to a predetermined location or any other type of expandable tubular string for use in a well. A method in accordance with embodiments of the invention includes providing a first end of a first expandable tubular member and a second end of a second expandable tubular member, wherein a slot is disposed to intersect a circumference of a thread profile of the first end, the thread profile continuing on both sides of the slot, threading the first and second ends of the expandable tubular members to form a connection therebetween, and expanding the connection with a radial force. The method can further include running the expandable tubular members into a wellbore. The expanding of the connection can include extending extendable members of an expander tool and then rotating and axially translating the expander tool across the connection. 
   While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.