Wellbore casing repair

• US 7,048,067 B1
• Filed: 10/31/2000
• Issued: 05/23/2006
• Est. Priority Date: 11/01/1999
• Status: Expired due to Term

• Current Assignee: Enventure Global Technology, LLC (Halliburton Company)
• Original Assignee: Shell Oil Company (Shell Plc)
• Inventors: Ring, Lev, Duell, Alan B., Stewart, R. Bruce, Cook, Robert Lance, Cowan, Kenneth Michael, Filippov, Andrei Gregory, Brisco, David P., Dean, William Joseph, Haut, Richard, Woo Nahm, James Jang, Wyant, Reece E., Mack, Robert D.
• Primary Examiner(s): NEUDER, WILLIAM P
• Application Number:
  US10/111,982
• Time in Patent Office: 2,030 Days
• Field of Search: 166/380, 166/384, 166/207, 166/277, 166/217
• US Class Current: 166/380
• CPC Class Codes: E21B 29/10 Reconditioning of well casings, e.g. straightening
• CPC Class Codes: E21B 43/105 Expanding tools specially adapted therefor

Abstract

An apparatus and method for repairing a wellbore casing (100). An opening (115) in a wellbore casing (100) is located using a logging tool (310). An expandable tubular member (370) is then positioned in opposition to the opening (115) in the wellbore casing (100). The expandable tubular member (370) is then radially expanded into intimate contact with the wellbore casing (100).

Claims

1. A method of repairing an opening in a tubular member, comprising:

positioning an expandable tubular, an expansion cone, and a pump within the tubular member;

positioning the expandable tubular in opposition to the opening in the tubular member;

pressurizing an interior portion of the expandable tubular by operating the pump within the tubular member; and

radially expanding the expandable tubular into intimate contact with the tubular member using the expansion cone.

2. The method of claim 1, further comprising:

locating the opening in the tubular member using an opening locator.

3. The method of claim 1, wherein the tubular member comprises a wellbore casing.

4. The method of claim 1, wherein the tubular member comprises a pipeline.

5. The method of claim 1, wherein the tubular member comprises a structural support.

6. The method of claim 1, further comprising:

sealing off a portion of the expandable tubular member.

7. The method of claim 1, further comprising:

lubricating the interface between the expandable tubular member and the expansion cone.

8. The method of claim 7, wherein lubricating comprises:

coating the expandable tubular member with a lubricant.

9. The method of claim 7, wherein lubricating comprises:

injecting a lubricating fluid into the trailing edge of the interface between the expandable tubular member and the expansion cone.

10. The method of claim 7, wherein lubricating comprises:

coating the expandable tubular member with a first component of a lubricant; and

circulating a second component of the lubricant into contact with the coating on the expandable tubular member.

11. An apparatus for repairing a tubular member, comprising:

a support member;

an expandable tubular member removably coupled to the support member;

an expansion cone movably coupled to the support member; and

a pump coupled to the support member positioned within the expandable tubular member adapted to pressurize a portion of the interior of the expandable tubular member;

wherein the expandable tubular member includes;

a first end having a first outer diameter;

an intermediate portion coupled to the first end having an intermediate outer diameter; and

a second end having a second outer diameter coupled to the intermediate portion having a second outer diameter;

wherein the first and second outer diameters are greater than the intermediate outer diameter.

12. The apparatus of claim 11, wherein the expandable tubular member comprises:

a coating of a lubricant.

13. The apparatus of claim 11, wherein the expandable tubular member comprises:

a coating of a first component of a lubricant.

14. The apparatus of claim 11, wherein the expandable tubular member comprises:

a sealing member coupled to the outer surface of the expandable tubular member.

15. The apparatus of claim 11, wherein the first end, second end, and intermediate portion of the expandable tubular member have wall thicknesses t₁, t₂, and t_INT and inside diameters D₁, D₂ and D_INT;

and wherein the relationship between the wall thicknesses t₁, t₂, and t_INT, the inside diameters D₁, D₂ and D_INT, the inside diameter D_TUBE of the tubular member that the expandable tubular member will be inserted into, and the outside diameter D_cone of the expansion cone is given by the following expression;

16. The apparatus of claim 11, wherein the expandable tubular member comprises:

a sealing member coupled to the outside surface of the intermediate portion.

17. The apparatus of claim 11, wherein the expandable tubular member comprises:

a first transition portion coupled to the first end and the intermediate portion inclined at a first angle; and

a second transition portion coupled to the second end and the intermediate portion inclined at a second angle;

wherein the first and second angles range from about 5 to 45 degrees.

18. The apparatus of claim 11, wherein the expansion cone comprises:

an expansion cone surface having an angle of attack ranging from about 10 to 40 degrees.

19. The apparatus of claim 11, wherein the expansion cone comprises:

a first expansion cone surface having a first angle of attack; and

a second expansion cone surface having a second angle of attack;

wherein the first angle of attack is greater than the second angle of attack.

20. The apparatus of claim 11, wherein the expansion cone comprises:

an expansion cone surface having a substantially parabolic profile.

21. The apparatus of claim 11, wherein the expansion cone comprises:

an inclined surface including one or more lubricating grooves.

22. The apparatus of claim 21, wherein the expansion cone comprises:

one or more internal lubricating passages coupled to each of the lubricating grooves.

23. A method of coupling a first tubular member to a second tubular member, wherein the outside diameter of the first tubular member is less than the inside diameter of the second tubular member, comprising:

positioning at least a portion of the first tubular member within the second tubular member;

positioning a pump within the first tubular member;

pressurizing a portion of the interior of the first tubular member by pumping fluidic materials proximate the first tubular member into the portion of the interior of the first tubular member using the pump; and

displacing an expansion cone within the interior of the first tubular member.

24. The method of claim 23, wherein the second tubular member is selected from the group consisting of a wellbore casing, a pipeline, and a structural support.

25. The method of claim 23, further comprising:

sealing off a portion of the first tubular member.

26. The method of claim 23, further comprising:

lubricating the interface between the first tubular member and the expansion cone.

27. The method of claim 26, wherein lubricating comprises:

coating the first tubular member with a lubricant.

28. The method of claim 26, wherein lubricating comprises:

injecting a lubricating fluid into the trailing edge of the interface between the first tubular member and the expansion cone.

29. The method of claim 26, wherein lubricating comprises:

coating the first tubular member with a first component of a lubricant; and

circulating a second component of the lubricant into contact with the coating on the first tubular member.

30. An apparatus for repairing an opening in a tubular member, comprising:

means for positioning an expandable tubular, and an expansion cone within the tubular member;

means for positioning the expandable tubular in opposition to the opening in the tubular member;

means for pressurizing an interior portion of the expandable tubular; and

means for radially expanding the expandable tubular into intimate contact with the tubular member using the expansion cone.

31. The apparatus of claim 30, further comprising:

means for locating the opening in the tubular member.

32. The apparatus of claim 30, wherein the tubular member comprises a wellbore casing.

33. The apparatus of claim 30, wherein the tubular member comprises a structural support.

34. The apparatus of claim 30, further comprising:

means for coating the expandable tubular member with a lubricant.

35. The apparatus of claim 30, further comprising:

means for injecting a lubricating fluid into the trailing edge of the interface between the expandable tubular member and the expansion cone.

36. The apparatus of claim 30, further comprising:

means for coating the expandable tubular member with a first component of a lubricant; and

means for circulating a second component of the lubricant into contact with the coating on the expandable tubular member.

37. The apparatus of claim 30, further comprising:

means for sealing off a portion of the expandable tubular member.

38. The apparatus of claim 30, wherein the tubular member comprises a pipeline.

39. An apparatus for coupling a first tubular member to a second tubular member, wherein the outside diameter of the first tubular member is less than the inside diameter of the second tubular member, comprising:

means for positioning at least a portion of the first tubular member within the second tubular member;

means for pressurizing a portion of the interior of the first tubular member by pumping fluidic materials proximate the first tubular member into the portion of the interior of the first tubular member;

means for displacing an expansion cone within the interior of the first tubular member.

40. The apparatus of claim 39, wherein the second tubular member is selected from the group consisting of a wellbore casing, a pipeline, and a structural support.

41. The apparatus of claim 39, further comprising:

means for coating the first tubular member with a lubricant.

42. The apparatus of claim 39, further comprising:

means for injecting a lubricating fluid into the trailing edge of the interface between the first tubular member and the expansion cone.

43. The apparatus of claim 39, further comprising:

means for coating the first tubular member with a first component of a lubricant; and

means for circulating a second component of the lubricant into contact with the coating on the first tubular member.

44. The apparatus of claim 39, further comprising:

means for sealing off a portion of the first tubular member.

45. An apparatus for repairing a tubular member, comprising:

a support member;

an expandable tubular member removably coupled to the support member;

an expansion cone movably coupled to the support member; and

a pump positioned within the expandable tubular member coupled to the support member adapted to pressurize a portion of the interior of the expandable tubular member;

wherein the expansion cone includes an inclined surface including one or more lubricating grooves.

46. An apparatus for repairing a tubular member, comprising:

a support member;

an expandable tubular member removably coupled to the support member;

an expansion cone movably coupled to the support member; and

a pump positioned within the expandable tubular member coupled to the support member adapted to pressurize a portion of the interior of the expandable tubular member;

wherein the expansion cone includes an inclined surface including one or more lubricating grooves; and

wherein the expansion cone includes one or more internal lubricating passages coupled to each of the lubricating grooves.

47. A method of repairing an opening in a tubular member, comprising:

positioning an expandable tubular, an expansion cone, and a pump within the tubular member;

positioning the expandable tubular in opposition to the opening in the tubular member;

injecting fluidic materials into an interior portion of the expandable tubular using the pump to pressurize the interior portion of the expandable tubular; and

displacing the expansion cone relative to the expandable tubular member to radial expand the expandable tubular into intimate contact with the tubular member.

48. The method of claim 47, further comprising:

locating the opening in the tubular member using an opening locator.

49. The method of claim 47, wherein the tubular member comprises a wellbore casing.

50. The method of claim 47, wherein the tubular member comprises a pipeline.

51. The method of claim 47, wherein the tubular member comprises a structural support.

52. The method of claim 47, further comprising:

lubricating the interface between the expandable tubular member and the expansion cone.

53. The method of claim 52, wherein lubricating comprising:

coating the expandable tubular member with a lubricant.

54. The method of claim 52, wherein lubricating comprises:

injecting a lubricating fluid into the trailing edge of the interface between the expandable tubular member and the expansion cone.

55. The method of claim 52, wherein lubricating comprises:

coating the expandable tubular member with a first component of a lubricant; and

circulating a second component of the lubricant into contact with the coating on the expandable tubular member.

56. The method of claim 47, further comprising:

sealing off a portion of the expandable tubular member.

57. An apparatus for repairing a tubular member, comprising:

a support member;

an expandable tubular member removably coupled to the support member;

a tubular expansion cone movably coupled to the support member; and

a pump positioned within the expandable tubular member coupled to the support member adapted to pressurize a portion of the interior of the expandable tubular member.

58. The apparatus of claim 57, wherein the expandable tubular member comprises:

a coating of a lubricant.

59. The apparatus of claim 57, wherein the expandable tubular member comprises:

a coating of a first component of a lubricant.

60. The apparatus of claim 57, wherein the expandable tubular member comprises:

a sealing member coupled to the outer surface of the expandable tubular member.

61. The apparatus of claim 57, wherein the expandable tubular member comprises:

a first end having a first outer diameter;

an intermediate portion coupled to the first end having an intermediate outer diameter; and

a second end having a second outer diameter coupled to the intermediate portion having a second outer diameter;

wherein the first and second outer diameters are greater than the intermediate outer diameter.

62. The apparatus of claim 61, wherein the first end, second end, and intermediate portion of the expandable tubular member have wall thicknesses t₁, t₂, and t_INT and inside diameters D₁, D₂ and D_INT;

and wherein the relationship between the wall thicknesses t₁, t₂, and t_INT, the inside diameters D₁, D₂ and D_INT, the inside diameter D_TUBE of the tubular member that the expandable tubular member will be inserted into, and the outside diameter D_cone of the expansion cone is given by the following expression;

63. The apparatus of claim 61, wherein the expandable tubular member comprises:

a sealing member coupled to the outside surface of the intermediate portion.

64. The apparatus of claim 61, wherein the expandable tubular member comprises:

a first transition portion coupled to the first end and the intermediate portion inclined at a first angle; and

a second transition portion coupled to the second end and the intermediate portion inclined at a second angle;

wherein the first and second angles range from about 5 to 45 degrees.

65. The apparatus of claim 57, wherein the tubular expansion cone comprises:

an expansion cone surface having an angle of attack ranging from about 10 to 40 degrees.

66. The apparatus of claim 57, wherein the tubular expansion cone comprises:

a first expansion cone surface having a first angle of attack; and

a second expansion cone surface having a second angle of attack;

wherein the first angle of attack is greater than the second angle of attack.

67. The apparatus of claim 57, wherein the tubular expansion cone comprises:

an expansion cone surface having a substantially parabolic profile.

68. The apparatus of claim 57, wherein the tubular expansion cone comprises:

an inclined surface including one or more lubricating grooves.

69. The apparatus of claim 68, wherein the tubular expansion cone comprises:

one or more internal lubricating passages coupled to each of the lubricating grooves.

70. A method of coupling a first tubular member to a second tubular member, wherein the outside diameter of the first tubular member is less than the inside diameter of the second tubular member, comprising:

positioning at least a portion of the first tubular member within the second tubular member;

positioning a pump within the first tubular member;

pressurizing a portion of the interior of the first tubular member by pumping fluidic materials into the portion of the interior of the first tubular member by operating the pump; and

displacing a tubular expansion cone within the interior of the first tubular member.

71. The method of claim 70, wherein the second tubular member is selected from the group consisting of a wellbore casing, a pipeline, and a structural support.

72. The method of claim 70, further comprising:

lubricating the interface between the first tubular member and the expansion cone.

73. The method of claim 72, wherein lubricating comprises:

coating the first tubular member with a lubricant.

74. The method of claim 73, wherein lubricating comprises:

coating the first tubular member with a first component of a lubricant; and

circulating a second component of the lubricant into contact with the coating on the first tubular member.

75. The method of claim 72, wherein lubricating comprises:

injecting a lubricating fluid into the trailing edge of the interface between the first tubular member and the tubular expansion cone.

76. The method of claim 70, further comprising:

sealing off a portion of the first tubular member.

77. An apparatus for repairing an opening in a tubular member, comprising:

means for positioning an expandable tubular, an expansion cone, and a pump within the tubular member;

means for positioning the expandable tubular in opposition to the opening in the tubular member;

means for injecting fluidic materials into an interior portion of the expandable tubular using the pump to pressurize the interior portion of the expandable tubular; and

means for displacing the expansion cone relative to the expandable tubular member to radial expand the expandable tubular into intimate contact with the tubular member.

78. The apparatus of claim 77, further comprising:

means for locating the opening in the tubular member.

79. The apparatus of claim 77, wherein the tubular member comprises a wellbore casing.

80. The apparatus of claim 77, wherein the tubular member comprises a pipeline.

81. The apparatus of claim 77, wherein the tubular member comprises a structural support.

82. The apparatus of claim 77, further comprising:

means for lubricating the interface between the expandable tubular member and the expansion cone.

83. The apparatus of claim 82, further comprising:

means for coating the expandable tubular member with a lubricant.

84. The apparatus of claim 82, further comprising:

means for injecting a lubricating fluid into the trailing edge of the interface between the expandable tubular member and the expansion cone.

85. The apparatus of claim 82, further comprising:

means for coating the expandable tubular member with a first component of a lubricant; and

means for circulating a second component of the lubricant into contact with the coating on the expandable tubular member.

86. The apparatus of claim 77, further comprising:

means for sealing off a portion of the expandable tubular member.

87. An apparatus for coupling a first tubular member to a second tubular member, wherein the outside diameter of the first tubular member is less than the inside diameter of the second tubular member, comprising:

means for positioning at least a portion of the first tubular member within the second tubular member;

means for pressurizing a portion of the interior of the first tubular member by pumping fluidic materials into the portion of the interior of the first tubular member; and

means for displacing a tubular expansion cone within the interior of the first tubular member.

88. The apparatus of claim 87, wherein the second tubular member is selected from the group consisting of a wellbore casing, a pipeline, and a structural support.

89. The apparatus of claim 87, further comprising:

means for lubricating the interface between the first tubular member and the tubular expansion cone.

90. The apparatus of claim 89, further comprising:

means for coating the first tubular member with a lubricant.

91. The apparatus of claim 89, further comprising:

means for injecting a lubricating fluid into the trailing edge of the interface between the first tubular member and the tubular expansion cone.

92. The apparatus of claim 89, further comprising:

means for coating the first tubular member with a first component of a lubricant; and

means for circulating a second component of the lubricant into contact with the coating on the first tubular member.

93. The apparatus of claim 87, further comprising:

means for sealing off a portion of the first tubular member.

94. An apparatus for repairing a tubular member, comprising:

a support member;

an expandable tubular member removably coupled to the support member;

an expansion cone movably coupled to the support member; and

a pump coupled to the support member adapted to pressurize a portion of the interior of the expandable tubular member;

wherein the expandable tubular member comprises;

a first end having a first outer diameter;

an intermediate portion coupled to the first end having an intermediate outer diameter; and

a second end having a second outer diameter coupled to the intermediate portion having a second outer diameter;

wherein the first and second outer diameters are greater than the intermediate outer diameter;

wherein the first end, second end, and intermediate portion of the expandable tubular member have wall thicknesses t₁, t₂, and t_INT and inside diameters D₁, D₂ and D_INT; and

wherein the relationship between the wall thicknesses t₁, t₂, and t_INT, the inside diameters D₁, D₂ and D_INT, the inside diameter D_TUBE of the tubular member that the expandable tubular member will be inserted into, and the outside diameter D_cone of the expansion cone is given by the following expression;

95. An apparatus for radially expanding and plastically deforming a tubular member into engagement with a preexisting tubular member, comprising:

a support member;

an expandable tubular member operably coupled to the support member; and

an expansion device coupled to the support member;

wherein the expandable tubular member comprises;

a first end having a first outer diameter;

an intermediate portion coupled to the first end having an intermediate outer diameter; and

a second end having a second outer diameter coupled to the intermediate portion having a second outer diameter;

wherein the first and second outer diameters are greater than the intermediate outer diameter;

wherein the first end, second end, and intermediate portion of the expandable tubular member have wall thicknesses t₁, t₂, and t_INT and inside diameters D₁, D₂ and D_INT; and

wherein the relationship between the wall thicknesses t₁, t₂, and t_INT, the inside diameters D₁, D₂ and D_INT, the inside diameter D_TUBE of the preexisting tubular member that the expandable tubular member will be inserted into, and the outside diameter D_{EXPANSION DEVICE} of the expansion device is given by the following expression;

96. A method of repairing a tubular member, comprising:

positioning an expandable tubular member, an expansion device, and a pump within the tubular member; and

pressurizing and interior portion of the expandable tubular member using the pump; and

displacing the expansion device relative to the expandable tubular member to radially expand and plastically deform the expandable tubular member into engagement with the tubular member;

wherein the expandable tubular member comprises;

a first end having a first outer diameter;

an intermediate portion coupled to the first end having an intermediate outer diameter; and

a second end having a second outer diameter coupled to the intermediate portion having a second outer diameter;

wherein the first and second outer diameters are greater than the intermediate outer diameter;

wherein the first end, second end, and intermediate portion of the expandable tubular member have wall thicknesses t₁, t₂, and t_INT and inside diameters D₁, D₂ and D_INT; and

wherein the relationship between the wall thicknesses t₁, t₂, and t_INT, the inside diameters D₁, D₂ and D_INT, the inside diameter D_TUBE of the tubular member that the expandable tubular member will be inserted into, and the outside diameter D_{EXPANSION DEVICE} of the expansion device is given by the following expression;

97. An apparatus for repairing a tubular member using an expandable tubular member, comprising:

a support member;

an expandable tubular member removably coupled to the support member;

an expansion device movably coupled to the support member and positioned within the expandable tubular member; and

a pump coupled to the support member positioned proximate the expansion device adapted to pressurize a portion of the interior of the expandable tubular member.

98. An apparatus for coupling an expandable tubular member to a preexisting tubular member, comprising:

means for positioning an expandable tubular member, and an expansion device within the preexisting tubular member;

means for positioning the expandable tubular member in opposition to the preexisting tubular member;

means for pressurizing an interior portion of the expandable tubular member; and

means for radially expanding the expandable tubular member into engagement with the preexisting tubular member using the expansion device;

wherein during the radial expansion of the expandable tubular member, the interior portion of the preexisting tubular member is not pressurized.