Source: http://www.google.com/patents/US7108072?dq=6514640
Timestamp: 2015-09-03 13:58:11
Document Index: 465596015

Matched Legal Cases: ['application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60']

Patent US7108072 - Lubrication and self-cleaning system for expansion mandrel - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsAn expansion mandrel includes a lubrication system for lubricating the trailing edge portion of the interface between the expansion mandrel and a tubular member during the radial expansion of the tubular member....http://www.google.com/patents/US7108072?utm_source=gb-gplus-sharePatent US7108072 - Lubrication and self-cleaning system for expansion mandrelAdvanced Patent SearchPublication numberUS7108072 B2Publication typeGrantApplication numberUS 10/382,325Publication dateSep 19, 2006Filing dateMar 5, 2003Priority dateNov 16, 1998Fee statusLapsedAlso published asUS6557640, US7044218, US7048062, US7086475, US20030094279, US20030098154, US20030098162, US20030173090Publication number10382325, 382325, US 7108072 B2, US 7108072B2, US-B2-7108072, US7108072 B2, US7108072B2InventorsRobert Lance Cook, David Paul Brisco, R. Bruce Stewart, Reece E. Wyant, Lev Ring, James Jang Woo Nahm, Richard Carl Haut, Robert Donald Mack, Alan B. Duell, Andrei Gregory FilippovOriginal AssigneeShell Oil CompanyExport CitationBiBTeX, EndNote, RefManPatent Citations (99), Non-Patent Citations (99), Referenced by (14), Classifications (62), Legal Events (4) External Links: USPTO, USPTO Assignment, EspacenetLubrication and self-cleaning system for expansion mandrel
US 7108072 B2Abstract
An expansion mandrel includes a lubrication system for lubricating the trailing edge portion of the interface between the expansion mandrel and a tubular member during the radial expansion of the tubular member.
1. A method of lubricating the interface between a tubular member and an expansion device comprising an expansion surface during the radial expansion of the tubular member by the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, comprising:
injecting a lubricating fluid through at least a portion of the expansion device into the trailing edge portion.
2. The method of claim 1, wherein the lubricating fluid has a viscosity ranging from about 1 to 10,000 centipoise.
3. The method of claim 1, wherein the injecting comprises:
injecting the lubricating fluid through the expansion surface of the expansion device.
4. The method of claim 3, wherein the injecting comprises:
injecting the lubricating fluid into the area around the axial midpoint of the expansion surface of the expansion device.
5. The method of claim 1, wherein the expansion device further comprises another portion coupled to the expansion surface; and wherein the injecting comprises:
injecting the lubricating fluid into the other portion of the expansion device.
6. The method of claim 1, wherein the expansion device further comprises a another portion coupled to the expansion surface; and wherein the injecting comprises:
injecting the lubricating fluid through the expansion surface and the other portion of the expansion device.
7. The method of claim 1, wherein the injecting comprises:
injecting the lubricating fluid into the interior of the expansion device.
8. The method of claim 1, wherein the injecting comprises:
injecting the lubricating fluid into a plurality of discrete locations along the trailing edge portion.
10. The method of claim 1, wherein the lubricating fluid comprises:
11. The method of claim 1, wherein the tubular member comprises a wellbore casing.
12. The method of claim 1, wherein the tubular member comprises a pipeline.
13. The method of claim 1, wherein the tubular member comprises a structural support.
14. A system for lubricating the interface between a tubular member and an expansion device comprising an expansion surface during the radial expansion of the tubular member by the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, comprising:
means for injecting a lubricating fluid through at least a portion of the expansion device into the trailing edge portion.
15. The system of claim 14, wherein the lubricating fluid has a viscosity ranging from about 1 to 10,000 centipoise.
16. The system of claim 14, wherein the means for injecting comprises:
means for injecting the lubricating fluid through the expansion surface of the expansion device.
17. The system of claim 14, wherein the means for injecting comprises:
means for injecting the lubricating fluid into the area around the axial midpoint of the expansion surface of the expansion device.
18. The system of claim 14, wherein the expansion device further comprises another portion coupled to the expansion surface; and wherein the means for injecting comprises:
means for injecting the lubricating fluid into the other portion of the expansion device.
19. The system of claim 14, wherein the expansion device further comprises another portion coupled to the expansion surface; and wherein the means for injecting comprises:
means for injecting the lubricating fluid through the expansion surface and the other portion of the expansion device.
20. The system of claim 14, wherein the means for injecting comprises:
means for injecting the lubricating fluid into the interior of the expansion device.
21. The system of claim 14, wherein the means for injecting comprises:
22. The system of claim 14, wherein the means for injecting comprises:
means for injecting the lubricating fluid into a plurality of discrete locations along the trailing edge portion.
23. The system of claim 14, wherein the lubricating fluid comprises:
24. The system of claim 14, wherein the tubular member comprises a wellbore casing.
25. The system of claim 14, wherein the tubular member comprises a pipeline.
26. The system of claim 14, wherein the tubular member comprises a structural support.
27. A method of lubricating the interface between a tubular member and an expansion device comprising an expansion surface during the radial expansion of the tubular member by the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, comprising:
injecting a lubricating fluid into the expansion device through a plurality of passages; and
exhausting the lubricating fluid from the passages through the expansion surface of the expansion device into a plurality of discrete locations along the trailing edge portion.
28. A method of lubricating the interface between a tubular member and an expansion device comprising an expansion surface during the radial expansion of the tubular member by the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, comprising:
injecting a lubricating fluid through the expansion device through a plurality of grooves formed in the expansion surface in the expansion device; and
exhausting the lubricating fluid from the grooves into a plurality of discrete locations along the trailing edge portion.
29. A method of lubricating the interface between a tubular member and an expansion device comprising an expansion surface during the radial expansion of the tubular member by the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, comprising:
exhausting the lubricating fluid from the passages through the expansion surface into a plurality of discrete locations along the trailing edge portion.
30. A method of lubricating the interface between a tubular member and an expansion device comprising an expansion surface during the radial expansion of the tubular member by the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, comprising:
injecting a lubricating fluid through the expansion device through a plurality of supply grooves; and
exhausting the lubricating fluid from the supply grooves through a plurality of lubricating grooves into a plurality of discrete locations along the trailing edge portion.
31. A method of lubricating the interface between a tubular member and an expansion device comprising an expansion surface during the radial expansion of the tubular member by the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, comprising:
injecting a lubricating fluid into the interior of the expansion device; and
injecting the lubricating fluid into the trailing edge portion.
32. A method of lubricating the interface between a tubular member and an expansion device comprising an expansion surface during the radial expansion of the tubular member by the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, comprising:
injecting a lubricating fluid through the expansion surface of the expansion device; and
33. A method of lubricating the interface between a tubular member and an expansion device comprising an expansion surface during the radial expansion of the tubular member by the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, comprising:
injecting a lubricating fluid into a plurality of discrete locations along the trailing edge portion; and
34. A system for lubricating the interface between a tubular member and an expansion device comprising an expansion surface during the radial expansion of the tubular member by the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, comprising:
means for injecting a lubricating fluid into the interior of the expansion cone; and
means for injecting the lubricating fluid into the trailing edge portion.
35. A system for lubricating the interface between a tubular member and an expansion device comprising an expansion surface during the radial expansion of the tubular member by the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, comprising:
means for injecting a lubricating fluid through the expansion surface of the expansion device; and
36. A system for lubricating the interface between a tubular member and an expansion device comprising an expansion surface during the radial expansion of the tubular member by the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, comprising:
means for injecting a lubricating fluid into a plurality of discrete locations along the trailing edge portion; and
37. A method of radially expanding a tubular member, comprising:
positioning an expansion device comprising an expansion surface for engaging the tubular member;
pressurizing a region within the tubular member proximate the expansion device; and
lubricating the interface between the tubular member and the expansion device, wherein the interface between the tubular member and the expansion surface of the expansion device includes a leading edge portion and a trailing edge portion, by a process comprising:
38. A method of radially expanding a tubular member, comprising:
positioning an expansion device comprising an expansion surface at least partially within the tubular member;
39. A method of radially expanding a tubular member, comprising:
40. A system for lubricating the interface between a tubular member and an expansion cone comprising a tapered portion during the radial expansion of the tubular member by the expansion cone, wherein the interface between the tubular member and the tapered portion of the expansion cone includes a leading edge portion and a trailing edge portion, comprising:
means for injecting a lubricating fluid through at least a portion of the expansion cone into the trailing edge portion and means for injecting the lubricating fluid into the tapered portion of the expansion cone.
This application is a continuation of U.S. patent application Ser. No. 09/588,946, which claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, filed on Jun. 7, 1999, which is a continuation-in-part of U.S. patent application Ser. No. 09/559,122, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/131,106, filed on Apr. 26, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/523,460, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/124,042, filed on Mar. 11, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/510,913, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/121,702, filed on Feb. 25, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/119,611, filed on Feb. 11, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/111,293, filed on Dec. 7, 1998.
This application is related to the following co-pending applications: provisional patent application No. 60/108,558, filed Nov. 16, 1998, provisional patent application No. 60/111,293, filed Dec. 7, 1998, provisional patent application No. 60/119,611, filed Feb. 11, 1999, provisional patent application No. 60/121,702, filed Feb. 25, 1999, provisional patent application No. 60/121,907, filed Feb. 26, 1999, provisional patent application No. 60/124,042, filed Mar. 11, 1999, and provisional patent application No. 60/131,106, filed Apr. 26, 1999, the disclosures of which are incorporated by reference.
According to one aspect of the present invention, an expansion cone for expanding a tubular member is provided that includes a housing including a tapered first end and a second end, one or more grooves formed in the outer surface of the tapered first end, and one or more axial flow passages fluidicly coupled to the circumferential grooves.
According to another aspect of the present invention, a method of lubricating the interface between a tubular member and an expansion cone having a first tapered end and a second end during the radial expansion of the tubular member by the expansion cone, wherein the interface between the tubular member and the first tapered end of the expansion cone includes a leading edge portion and a trailing edge portion, is provided that includes injecting a lubricating fluid into the trailing edge portion.
According to another aspect of the present invention, a method of removing debris formed during the radial expansion of a tubular member by an expansion cone from the interface between the tubular member and the expansion cone, the expansion cone including a first tapered end and a second end, the interface between the tubular member and the first tapered end of the expansion cone includes a leading edge portion and a trailing edge portion, is provided that includes injecting a lubricating fluid into the interface between the tubular member and the expansion cone.
According to another aspect of the present invention, a tubular member is provided that includes an annular member having a wall thickness that varies less than about 8%, a hoop yield strength that varies less than about 10%, imperfections of less than about 8% of the wall thickness, no failure for radial expansions of up to about 30%, and no necking of the walls of the annular member for radial expansions of up to about 25%.
According to another aspect of the present invention, a wellbore casing is provided that includes one or more tubular members. Each tubular member includes an annular member having a wall thickness that varies less than about 8%, a hoop yield strength that varies less than about 10%, imperfections of less than about 8% of the wall thickness, no failure for radial expansions of up to about 30%, and no necking of the walls of the annular member for radial expansions of up to about 25%.
According to another aspect of the present invention, a method of forming a wellbore casing is provided that includes placing a tubular member and an expansion cone in a wellbore and displacing the expansion cone relative to the tubular member. The tubular member includes an annular member having a wall thickness that varies less than about 8%, a hoop yield strength that varies less than about 10%, imperfections of less than about 8% of the wall thickness, no failure for radial expansions of up to about 30%, and no necking of the walls of the annular member for radial expansions of up to about 25%.
According to another aspect of the present invention, a method of selecting a group of tubular members for subsequent radial expansion is provided that includes radially expanding the ends of a representative sample of the group of tubular members, measuring the amount of necking of the walls of the radially expanded ends of the tubular members, and if the radially expanded ends of the tubular members do not exhibit necking for radial expansions of up to about 25%, then accepting the group of tubular members.
According to another aspect of the present invention, a method of selecting a group of tubular members is provided that includes radially expanding the ends of a representative sample of the group of tubular members until each of the tubular members fail, and if the radially expanded ends of the tubular members do not fail for radial expansions of up to about 30%, then accepting the group of tubular members.
According to another aspect of the present invention, a method of inserting a tubular member into a wellbore is provided that includes injecting a lubricating fluid into the wellbore and inserting the tubular member into the wellbore.
FIG. 3 is a fragmentary cross-sectional view illustrating the injection of a first quantity of a fluidic material into the new section of the well borehole.
FIG. 3 a is another fragmentary cross-sectional view illustrating the injection of a first quantity of a hardenable fluidic sealing material into the new section of the well borehole.
FIG. 4 is a fragmentary cross-sectional view illustrating the injection of a second quantity of a fluidic material into the new section of the well borehole.
FIG. 9 a is another cross-sectional illustration of the apparatus of FIG. 9.
FIG. 9 b is another cross-sectional illustration of the apparatus of FIG. 9.
FIG. 9 c is another cross-sectional illustration of the apparatus of FIG. 9.
FIG. 10 a is a cross-sectional illustration of a wellbore including a pair of adjacent overlapping casings.
FIG. 10 b is a cross-sectional illustration of an apparatus and method for creating a tie-back liner using an expandable tubular member.
FIG. 10 c is a cross-sectional illustration of the pumping of a fluidic sealing material into the annular region between the tubular member and the existing casing.
FIG. 10 d is a cross-sectional illustration of the pressurizing of the interior of the tubular member below the mandrel.
FIG. 10 e is a cross-sectional illustration of the extrusion of the tubular member off of the mandrel.
FIG. 10 f is a cross-sectional illustration of the tie-back liner before drilling out the shoe and packer.
FIG. 10 g is a cross-sectional illustration of the completed tie-back liner created using an expandable tubular member.
FIG. 11 a is a fragmentary cross-sectional view illustrating the drilling of a new section of a well borehole.
FIG. 11 b is a fragmentary cross-sectional view illustrating the placement of an embodiment of an apparatus for hanging a tubular liner within the new section of the well borehole.
FIG. 11 c is a fragmentary cross-sectional view illustrating the injection of a first quantity of a hardenable fluidic sealing material into the new section of the well borehole.
FIG. 11 d is a fragmentary cross-sectional view illustrating the introduction of a wiper dart into the new section of the well borehole.
FIG. 11 e is a fragmentary cross-sectional view illustrating the injection of a second quantity of a hardenable fluidic sealing material into the new section of the well borehole.
FIG. 11 f is a fragmentary cross-sectional view illustrating the completion of the tubular liner.
FIG. 12 is a cross-sectional illustration of a preferred embodiment of a wellhead system utilizing expandable tubular members.
FIG. 13 is a partial cross-sectional illustration of a preferred embodiment of the wellhead system of FIG. 12.
FIG. 14 a is an illustration of the formation of an embodiment of a mono-diameter wellbore casing.
FIG. 14 b is another illustration of the formation of the mono-diameter wellbore casing.
FIG. 14 c is another illustration of the formation of the mono-diameter wellbore casing.
FIG. 14 d is another illustration of the formation of the mono-diameter wellbore casing.
FIG. 14 e is another illustration of the formation of the mono-diameter wellbore casing.
FIG. 14 f is another illustration of the formation of the mono-diameter welbore casing.
FIG. 15 is an illustration of an embodiment of an apparatus for expanding a tubular member.
FIG. 15 a is another illustration of the apparatus of FIG. 15.
FIG. 15 b is another illustration of the apparatus of FIG. 15.
FIG. 16 is an illustration of an embodiment of an apparatus for forming a mono-diameter wellbore casing.
FIG. 17 is an illustration of an embodiment of an apparatus for expanding a tubular member.
FIG. 17 a is another illustration of the apparatus of FIG. 16.
FIG. 17 b is another illustration of the apparatus of FIG. 16.
FIG. 18 is an illustration of an embodiment of an apparatus for forming a mono-diameter wellbore casing.
FIG. 19 is an illustration of another embodiment of an apparatus for expanding a tubular member.
FIG. 19 a is another illustration of the apparatus of FIG. 17.
FIG. 19 b is another illustration of the apparatus of FIG. 17.
FIG. 20 is an illustration of an embodiment of an apparatus for forming a mono-diameter wellbore casing.
FIG. 21 is an illustration of the isolation of subterranean zones using expandable tubulars.
FIG. 22 a is a fragmentary cross-sectional illustration of an embodiment of an apparatus for forming a wellbore casing while drilling a wellbore.
FIG. 22 b is another fragmentary cross-sectional illustration of the apparatus of FIG. 22 a. FIG. 22 c is another fragmentary cross-sectional illustration of the apparatus of FIG. 22 a. FIG. 22 d is another fragmentary cross-sectional illustration of the apparatus of FIG. 22 a. FIG. 23 a is a fragmentary cross-section illustration of an embodiment of an apparatus and method for expanding tubular members.
FIG. 23 b is another fragmentary cross-sectional illustration of the apparatus of FIG. 23 a. FIG. 23 c is another fragmentary cross-sectional illustration of the apparatus of FIG. 23 a. FIG. 24 a is a fragmentary cross-section illustration of an embodiment of an apparatus and method for expanding tubular members.
FIG. 24 b is another fragmentary cross-sectional illustration of the apparatus of FIG. 24 a. FIG. 24 c is another fragmentary cross-sectional illustration of the apparatus of FIG. 24 a. FIG. 24 d is another fragmentary cross-sectional illustration of the apparatus of FIG. 24 a. FIG. 24 e is another fragmentary cross-sectional illustration of the apparatus of FIG. 24 a. FIG. 25 is a partial cross-sectional illustration of an expansion mandrel expanding a tubular member.
FIG. 26 is a graphical illustration of the relationship between propagation pressure and the angle of attack of the expansion mandrel.
FIG. 27 is a cross-sectional illustration of an embodiment of an expandable connector.
FIG. 28 is a cross-sectional illustration of another embodiment of an expandable connector.
FIG. 29 is a cross-sectional illustration of another embodiment of an expandable connector.
FIG. 30 is a cross-sectional illustration of another embodiment of an expandable connector.
FIG. 31 is a fragmentary cross-sectional illustration of the lubrication of the interface between an expansion mandrel and a tubular member during the radial expansion process.
FIG. 32 is an illustration of an embodiment of an expansion mandrel including a system for lubricating the interface between the expansion mandrel and a tubular member during the radial expansion of the tubular member.
FIG. 33 is an illustration of an embodiment of an expansion mandrel including a system for lubricating the interface between the expansion mandrel and a tubular member during the radial expansion of the tubular member.
FIG. 34 is an illustration of an embodiment of an expansion mandrel including a system for lubricating the interface between the expansion mandrel and a tubular member during the radial expansion of the tubular member.
FIG. 35 is an illustration of an embodiment of an expansion mandrel including a system for lubricating the interface between the expansion mandrel and a tubular member during the radial expansion of the tubular member.
FIG. 36 is an illustration of an embodiment of an expansion mandrel including a system for lubricating the interface between the expansion mandrel and a tubular member during the radial expansion of the tubular member.
FIG. 37 is an illustration of an embodiment of an expansion mandrel including a system for lubricating the interface between the expansion mandrel and a tubular member during the radial expansion of the tubular member.
FIG. 38 is an illustration of an embodiment of an expansion mandrel including a system for lubricating the interface between the expansion mandrel and a tubular member during the radial expansion of the tubular member.
FIG. 39 is an illustration of a preferred embodiment of an expansion mandrel including a system for lubricating the interface between the expansion mandrel and a tubular member during the radial expansion of the tubular member.
FIG. 40 is a cross-sectional illustration of the first axial groove of the expansion mandrel of FIG. 39.
FIG. 41 is a cross-sectional illustration of the circumferential groove of the expansion mandrel of FIG. 39.
FIG. 42 is a cross-sectional illustration of one of the second axial grooves of the expansion mandrel of FIG. 39.