Collapsible Tubing Expander Tool for Borehole Operations
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Solution Overview
Problem
Existing methods for expanding tubing in boreholes face challenges such as ease of makeup at the drill rig floor, torque transmission, and recovery of stuck expander tools, particularly when dealing with restrictions smaller than the expansion diameter.
Innovation Solution
A system with an expander tool on a work string, featuring a collapsible swage, hydraulic jack, and tubing holding devices, allowing for expansion by transitioning between a collapsed and extended configuration, facilitated by fluid pressure and designed for efficient torque transmission and tool recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the expander tool is carried in with unexpanded tubing, then the tubing can be expanded in the borehole, but it creates additional challenges for ease of operation and tool recovery
Solution Approach 1:
The expander tool is segmented into collapsible components that can be compressed to a smaller diameter for easy transport through the tubing, then expanded downhole to perform the expansion function. This allows the tool to be easily made up at the drill rig floor while maintaining full expansion capability in the borehole.
Solution Approach 2:
The expander tool components are nested within each other in a collapsed configuration, allowing the entire assembly to fit within the unexpanded tubing for transport. Once deployed, the components unfold and expand to their functional size for tubing expansion operations.
2Reliability
If the expander tool is carried in with unexpanded tubing, then the tubing can be expanded in the borehole, but it creates additional challenges for tool recovery
Solution Approach 1:
The expander tool employs dynamic, movable components that can transition between collapsed and expanded states. This dynamic design allows the tool to be easily collapsed for recovery and retrieval through the tubing, while maintaining full expansion capability during the expansion operation.
Solution Approach 2:
The expander tool is designed to be recovered and reused rather than discarded. The collapsible design enables the tool to be retrieved through the tubing after expansion by collapsing to a smaller diameter, allowing for repeated use in multiple expansion operations.
3Reliability
If the expander tool is carried in with unexpanded tubing, then the tubing can be expanded in the borehole, but it creates additional challenges when dealing with restrictions smaller than expansion diameter
Solution Approach 1:
The expander tool uses dynamically collapsible components that can be compressed to a diameter smaller than any tubing restriction, allowing the tool to be run through restricted sections. Once past the restriction, the tool expands to its full diameter for the expansion operation.
Solution Approach 2:
The tool's outer diameter parameter is changed dynamically - collapsed to a small diameter for navigation through restrictions and expanded to a large diameter for the expansion function. This parameter change allows the tool to adapt to different well conditions including restrictions.
4Reliability
If prior expansion techniques are used, then tubing can be expanded, but ease of operation and torque transmission are problematic
Solution Approach 1:
The expander tool is divided into segmented, collapsible components that can be individually adjusted and positioned. This segmentation allows for better torque distribution and transmission through the tool components while maintaining ease of operation during both deployment and recovery.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient expansion of tubing with improved ease of operation and tool recovery, addressing the limitations of prior methods by allowing for effective expansion and handling within boreholes.
Implementation Method 1
a hydraulic operated jack couples to the expander to move the expander relative to the tubing holding devices
Implementation Method 2
Supplying fluid pressure to the jack coupled to the expander thereby moves the expander through the tubing
Data Source
AI summary
Methods and apparatus enable expanding tubing in a borehole of a hydrocarbon well. According to some embodiments, an expander device includes a collapsible swage formed of collets, at least one slip arrangement and a hydraulic jack to stroke the swage through tubing to be expanded. In operation, expanding tubing may include securing an expansion tool to the tubing, lowering the tool and tubing into a borehole, actuating a collapsible expander of the expansion tool to an extended configuration, and supplying fluid pressure to a jack coupled to the expander thereby moving the expander through the tubing which is held by at least one of first and second tubing holding devices disposed respectively ahead of the expander and behind the expander.