Apparatus and method for radially expanding a wellbore casing using and adaptive expansion system

Abstract

An apparatus and method for radially expanding a wellbore using an adaptive expansion system.

Description

CROSS REFERENCE TO RELATED APPLICATIONS [0001] The present application claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60 / 455,124, attorney docket no. 25791.241, filed on Mar. 17, 2003, the disclosure of which is incorporated herein by reference. [0002] The present application is related to the following: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09 / 454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60 / 111,293, filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09 / 510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claims priority from provisional application 60 / 121,702, filed on Feb. 25, 1999, (3) U.S. patent application Ser. No. 09 / 502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claims priority from provisional application 60 / 119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, whic...

AI Technical Summary

Benefits of technology

[0018] According to another aspect of the present invention, an apparatus for radially expanding and plastically deforming a tubular member within a wellbore that traverses a subterranean formation is provided that includes a support member; and an adaptive expansion device coupled to the support member for radially expanding and plastically deforming the tubular member and elastically deforming the subterranean formation that includes a support structure coupled to the support member; one or more expansion device segments for engaging the threaded connection to thereby radially expand and plastically deform the tubular member and elastically deform the subterranean formation; and one or more sensors for sensing operating conditions during the radial expansion and plastic deformation of the tubular member and the elastic deformation of the subterranean formation; and a controller operably coupled to the expansion device segments and the sensors; wherein the controller is programmed to controllably adjust one or more operational characteristics of one or more of the expansion device segments as a function of a sensing of the subterranean formation by one or more of the sensors.

[0019] According to another aspect of the present invention, a method of adaptively radially expanding a tubular member within a wellbore that traverses a subterranean formation is provided that includes inserting an adaptive expansion device comprising one or more expansion device segments for engaging and radially expanding and plastically deforming the tubular member and elastically deforming the subterranean formation within the wellbore; radially expanding and plastically deforming the tubular member and elastically deforming the subterranean formation using the adaptive expansion device; sensing the subterranean formation during the radial expansion and plastic deformation of the tubular member and the elastic deformation of the subterranean formation; and as a function of the sensing of the subterranean formation, controllably adjusting an operational characteristic of one or more of the expansion device segments during the radial expansion and plastic deformation of the tubular member and the elastic deformation of the subterranean formation.

[0020] According to another aspect of the present invention, a system for adaptively radially expanding a tubular member within a wellbore that traverses a subterranean formation is provided that includes means for inserting an adaptive expansion device comprising one or more expansion device segments for engaging and radially expanding and plastically deforming the tubular member and elastically deforming the subterranean formation within the wellbore; means for radially expanding and plastically deforming the tubular member and elastically deforming the subterranean formation using the adaptive expansion device; means for sensing the subterranean formation during the radial expansion and plastic deformation of the tubular member and the elastic deformation of the subterranean formation; and means for, as a function of the sensing of the subterranean formation, controllably adjusting an operational characteristic of one or more of the expansion device segments during the radial expansion and plastic deformation of the tubular member and the elastic deformation of the subterranean formation.

[0021] According to another aspect of the present invention, an apparatus for radially expanding and plastically deforming a tubular member is provided that includes a support member, and an adaptive expansion device coupled to the support member for radially expanding and plastically deforming the tubular member that includes a support structure coupled to the support member; and one or more expansion device segments coupled to the support structure for engaging the tubular member to thereby radially expand and plastically deform the tubular member; one or more sensors for sensing one or more operating conditions during the radial expansion and plastic deformation of the tubular member; and a controller operably coupled to the expansion device segments and the sensors; and wherein the controller is programmed to controllably adjust one or more of the operational characteristics of one or more the expansion device segments as a function of the operating conditions sensed by the sensors.

[0022] According to another aspect of the present invention, a method of adaptively radially expanding a tubular member within a wellbore is provided that includes inserting an adaptive expansion device into the tubular member; radially expanding and plastically deforming the tubular member using the adaptive expansion device; sensing one or more operating conditions during the radial expansion and plastic deformation of the tubular member; and as a function of the sensed operating conditions, controllably adjusting one or more of the operating characteristics of the adaptive expansion device during the radial expansion and plastic deformation of the tubular member.

[0023] According to another aspect of the present invention, a system for adaptively radially expanding a tubular member within a wellbore is provided that includes means for inserting an adaptive expansion device into the tubular member; means for radially expanding and plastically deforming the tubular member using the adaptive expansion device; means for sensing one or more operating conditions during the radial expansion and plastic deformation of the tubular member; and means for, as a function of the sensed operating conditions, controllably adjusting one or more of the operating characteristics of the adaptive expansion device during the radial expansion and plastic deformation of the tubular member.

Problems solved by technology

Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings.

Moreover, increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.

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