Bore liner

• US 20030127225A1
• Filed: 12/20/2002
• Published: 07/10/2003
• Est. Priority Date: 12/22/2001
• Status: Active Grant

• Current Assignee: Weatherford Technology Holdings, LLC (Weatherford International PLC)
• Original Assignee: Weatherford/Lamb Incorporated (Weatherford International PLC)
• Inventors: Harrall, Simon John, Metcalfe, Paul David, Rennison, Paul Antony
• Granted Patent: US 7,152,684 B2
• Time in Patent Office: Days
• US Class Current: 166/285
• CPC Class Codes: B21D 39/10 with rollers for expanding only
• CPC Class Codes: E21B 43/103 of expandable casings, screens, liners, or the like
• CPC Class Codes: E21B 43/105 Expanding tools specially adapted therefor

Abstract

A method of lining a drilled bore comprises running an expandable first tubular into a bore and locating part portion of the first tubular in an unlined section of the bore and another portion of the first tubular overlapping a portion of an existing second tubular. The first tubular is secured relative to the second tubular while retaining the provision of fluid outlets to permit displacement of fluid from an annulus between the first tubular and the bore wall. An expansion device is then run through the first tubular to expand the first tubular to a larger diameter. Cement is then circulated into the annulus between the expanded first tubular and the bore wall. The fluid outlets are then closed.

Claims

1. A method of lining a drilled bore, the method comprising:

running an expandable first tubular into a bore;

locating a first portion of the first tubular in an unlined section of the bore and a second portion of the first tubular overlapping a portion of an existing second tubular;

securing the first tubular relative to the second tubular while retaining fluid outlets to permit displacement of fluid from an annulus between the first tubular and the bore wall;

running an expansion device through the first tubular to expand the first tubular to a larger diameter;

circulating cement into the annulus between the expanded first tubular and the bore wall; and

closing the fluid outlets.

2. The method of claim 1, comprising:

providing flow ports at a location in the first tubular to provide for fluid passage from the annulus into the tubular.

3. The method of claim 2, further comprising expanding the tubular at said location to close the flow ports.

4. The method of claim 3, comprising expanding the tubular at said location into contact with the surrounding second tubular.

5. The method of claim 1, comprising running the expansion device down through the first tubular.

6. The method of claim 1, comprising locating a lower portion of the first tubular in an unlined section of the bore and an upper portion of the first tubular overlapping a lower portion of the second tubular.

7. The method of claim 1, comprising expanding the first tubular by rotary expansion.

8. The method of claim 1, comprising expanding the first tubular using an axial expander.

9. The method of claim 1, comprising expanding the first tubular utilising a compliant expander.

10. The method of claim 1, comprising expanding the first tubular utilising a fixed diameter expander.

11. The method of claim 1, comprising:

expanding the second portion of the first tubular using a variable diameter expansion device; and

expanding the first portion of the first tubular using a fixed diameter expansion device.

12. The method of claim 1, wherein the second portion of the first tubular is expanded to an internal diameter corresponding to an internal diameter of the second tubular.

13. The method of claim 1, wherein a lower end of the second tubular describes a larger diameter than an upper portion of the second tubular, and the first tubular is expanded into said lower end of the second portion.

14. The method of claim 1, wherein the second portion of the first tubular is expanded within the lower end of the second tubular to induce expansion and deformation of the second tubular.

15. The method of claim 1, wherein the second portion of the first tubular is at least partially expanded to secure the first tubular relative to the second tubular.

16. The method of claim 15, wherein the second portion of the first tubular is further expanded to seal the first tubular to the second tubular.

17. The method of claim 1, wherein the lower end of the first tubular is expanded to a still larger internal diameter, to accommodate the upper end of a subsequent tubular.

18. The method of claim 1, wherein the first tubular is liner.

19. The method of claim 1, wherein the second tubular is casing.

20. The method of claim 1, wherein expansion of the first tubular is assisted by application of elevated fluid pressure.

21. The method of claim 1, further comprising positively locating the first tubular relative to the second portion before securing the first tubular relative to the second tubular.

22. The method of claim 1, further comprising expanding the first tubular in sections.

23. The method of claim 1, further comprising cementing the first tubular in sections.

24. The method of claim 1, further comprising:

running an expansion device through a first section of the first tubular to expand said first section to a larger diameter;

circulating cement into a first section of the annulus between the expanded first section and the bore wall.

25. The method of claim 24, further comprising:

running an expansion device through a second section of the first tubular to expand said second section to a larger diameter;

circulating cement into a second section of the annulus between the expanded second section and the bore wall.

39. The method of claim 1, wherein expansion of the first tubular is assisted by application of elevated fluid pressure.

26. A method of lining a drilled bore, the method comprising:

running an expandable first tubular into a bore;

running an expansion device through a first section of the first tubular to expand the first section to a larger diameter;

circulating cement into the annulus between the first section and the bore wall; and

subsequently expanding and cementing further sections of the first tubular.

27. The method of claim 26, comprising expanding the first section prior to circulating cement into the annulus between the first section and the bore wall.

28. A method of lining a bore comprising:

running an expandable first tubular into a bore;

overlapping a portion of the first tubular with a second tubular located in the bore, the second tubular having a larger diameter portion for receiving said portion of the first tubular; and

expanding the first tubular by a combination of compliant and fixed diameter rotary expansion.

29. A method of lining a bore in a single trip, the method comprising:

running an expandable first tubular into a bore;

overlapping a portion of the first tubular with a second tubular located in the bore, the second tubular having a larger diameter portion for receiving said portion of the first tubular and the overlap permitting fluid bypass;

expanding the first tubular to a larger diameter;

cementing the first tubular in the bore; and

closing said fluid bypass.

30. A method of lining a bore in a single trip, the method comprising:

running an expandable first tubular into a bore;

overlapping a portion of the first tubular with a second tubular located in the bore, the second tubular having a larger diameter portion for receiving said portion of the first tubular and the overlap permitting fluid bypass;

expanding the first tubular to a larger diameter;

creating a still larger diameter portion at a lower end of the first tubular;

cementing the first tubular in the bore; and

closing said fluid bypass.

31. A method of lining a bore in a single trip, the method comprising:

running an expandable first tubular into a bore;

overlapping a portion of the first tubular with a second tubular located in the bore, the second tubular having a larger diameter portion for receiving said portion of the first tubular and the overlap permitting fluid bypass;

expanding the at least the first tubular to a larger diameter such that the first tubular and the second tubular define a substantially constant internal diameter;

cementing the first tubular in the bore; and

closing said fluid bypass.

32. A method of lining a bore in a single trip, the method comprising:

running an expandable first tubular into a bore;

overlapping a portion of the first tubular with a second tubular located in the bore, the second tubular having a larger diameter portion for receiving said portion of the first tubular and the overlap permitting fluid bypass;

expanding the first tubular to a larger diameter such that the first tubular and the second tubular define a substantially constant internal diameter;

creating a still larger diameter portion at a lower end of the first tubular;

cementing the first tubular in the bore; and

closing said fluid bypass.

33. A method of lining a drilled bore, the method comprising:

running an expandable first tubular of an external first diameter into a bore;

locating the first tubular in an unlined section of the bore with an upper end of the first tubular overlapping a lower end of an existing second tubular of an internal second diameter larger than said first diameter;

securing the upper end of the first tubular relative to the lower end of the second tubular while retaining fluid outlets to permit displacement of fluid from an annulus between the first tubular and the bore wall;

running an expansion device down through the first tubular to expand the first tubular to a larger diameter; and

sealing the upper end of the first tubular to the lower end of the second tubular.

34. The method of claim 33, wherein the first tubular is expanded into close contact with the surrounding bore wall.

35. The method of claim 33, wherein the first tubular is provided in combination with a sleeve of deformable material for contacting the surrounding bore wall.

36. The method of claim 33, wherein the first tubular is provided in combination with a sleeve of expanding material for contacting the surrounding bore wall.

37. The method of claim 36, wherein the sleeve of material comprises a swelling elastomer.

38. The method of claim 37, further comprising circulating fluid between the first tubular and the bore wall, the fluid being selected to interact with the elastomer and to induce swelling of the elastomer into sealing contact with the bore wall.

40. Apparatus for use in lining a drilled bore, the apparatus comprising:

a body;

a support for a bore-lining tubular; and

a rotary expander for expanding bore-lining tubular, the expander being rotatably mounted relative to the support.

41. The apparatus of claim 40, in combination with an expandable first tubular.

42. The apparatus of claim 41, in combination with an anchor on the tubular for engaging a surrounding second tubular.

43. The apparatus of claim 42, wherein the anchor comprises a C-ring.

44. The apparatus of claim 42, wherein the anchor is initially located axially adjacent the expander.

45. The apparatus of claim 40, comprising a location device for locating the body relative to an existing tubular.

46. The apparatus of claim 45, wherein the location device comprises a radially extending profile adapted for engaging a cooperating profile in the existing tubular.

47. The apparatus of claim 45, wherein the location device comprises a sprung latch.

48. The apparatus of claim 40, comprising a fixed diameter rotary expander.

49. The apparatus of claim 48, wherein the fixed diameter rotary expander comprises at least one inclined axis roller.

50. The apparatus of claim 40, further comprising at least one torque anchor rotatably coupled to the support.

51. The apparatus of claim 50, wherein the torque anchor has at least one anchor member movable between a retracted configuration and an extended configuration.

52. The apparatus of claim 51, wherein the anchor member is pressure actuated.

53. The apparatus of claim 51, wherein the anchor member comprises a roller.

54. The apparatus of claim 53, wherein the roller is piston-mounted.

55. The apparatus of claim 50, wherein the torque anchor is adapted to permit axial movement between the anchor and a surrounding tubular.

56. The apparatus of claim 40, wherein the support comprises at least one member adapted for engaging a bore-lining tubular.

57. The apparatus of claim 56, in combination with a tubular body defining a profile for cooperating with the member.

58. The apparatus of claim 57, wherein the profile is in the form of a window.

59. The apparatus of claim 56, wherein the member is selectively movable between a tubular-engaging position and a tubular-release position.

60. The apparatus of claim 56, wherein the member is selectively movable between an extended position and a retracted position.

61. The apparatus of claim 56, wherein the member is releasably lockable in a tubular-engaging position.

62. The apparatus of claim 56, wherein the member is releasable from a tubular-engaging position by application of fluid pressure.

63. The apparatus of claim 40, comprising a compliant expander.

64. The apparatus of claim 40, comprising a pressure actuated expander.

65. The apparatus of claim 40, further comprising a pressure-actuated torque anchor.

66. The apparatus of claim 40, comprising an expander having at least one expansion member movable between a retracted position and an extended position.

67. The apparatus of claim 40, further comprising a cement stinger.

68. The apparatus of claim 67, wherein the cement stinger is mounted to the body via a swivel.

69. A tubular hanger comprising an expandable body having a tubular wall, the body including an anchor portion adapted for engaging a surrounding tubular on expansion of the body, and at least one port in the body wall for providing a fluid flow path through the body.

70. The hanger of claim 69, wherein the body includes a seal portion adapted for forming a seal with a surrounding tubular on expansion of the body.

71. A tubing hanger assembly comprising:

an expandable first tubular;

a second tubular for receiving the first tubular;

an expandable body for coupling to the first tubular in a drilled bore, the body having a tubular wall and including an anchor portion adapted for engaging the second tubular on expansion of the body, and at least one port in the body wall for providing a fluid flow path through the body.

72. A expandable tubular having a wall defining a plurality of flow ports at axially spaced locations, the flow ports being adapted to close on expansion of the tubular at the port location.

73. The tubular of claim 72, further comprising a sleeve at each of said locations.

74. A tubing hanger assembly comprising:

an expandable tubular body;

a first expansion device initially located within the body for expanding at least a portion of the body to a larger diameter; and

a second expansion device initially located externally of the body and for translation through the body to expand at least a portion of the body to a larger diameter.

75. The assembly of claim 74, wherein the first expansion device is a compliant expansion device.

76. The assembly of claim 74, wherein the first expansion device is a rotary expander.

77. The assembly of claim 74, wherein the second expansion device is a fixed diameter device.

78. The assembly of claim 74, wherein the second expansion device is a rotary expander.

79. A tubular deployment tool for mounting to an elongate support member and for deploying an expandable tubular in a drilled bore, the system comprising:

a tool body;

a releasable tubular support for supporting a tubular from the body;

a tubular expander adapted for translation through a tubular to be expanded; and

a coupling for permitting passage of sealing material from the tool body into an annulus surrounding an expanded tubular.

80. The tool of claim 79, wherein the expander is a rotary expander.

81. The tool of claim 79, comprising a variable diameter expander.

82. The tool of claim 79, comprising a fixed diameter expander.

83. The tool of claim 79, comprising a variable diameter expander and a fixed diameter expander.

84. An expandable tubular system comprising:

an expandable tubular;

an expandable hanger coupled to an upper end of the tubular;

a coupling at a lower end of the tubular for cooperating with a sealing material supply member; and

a shoe.

85. The system of claim 84, wherein the coupling is drillable.

86. The system of claim 84, wherein the shoe is drillable.