Expandable Tubular Connection with Sequential Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for connecting tubular members in a wellbore face challenges such as hydraulic lock formation and high manufacturing costs due to complex profiles and limited adaptability, which affect the reliability and cost-effectiveness of the seal and axial load transfer.
Innovation Solution
An expandable tubular connection system featuring a host tubular member with reinforcing annular members that provide varying resistance to radial load, allowing for sequential expansion and preventing hydraulic lock by expelling fluid, while maintaining a uniform wall thickness and allowing for easy configuration adaptation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If circumferential recesses or grooves are preformed on the inner surface of the outer tubular member, then a seal can be formed between tubular members, but well fluid may become trapped in the recesses leading to hydraulic lock formation
Solution Approach 1:
The expandable tubular member is designed with expansion capability before actual installation. The sequential expansion mechanism is pre-configured with varying resistance regions that will automatically expel fluid during the expansion process, preventing hydraulic lock before it can form and compromise the seal.
Solution Approach 2:
The tubular member's dimensional parameters are changed during installation through controlled radial expansion. By designing regions with different resistance to radial expansion, the system creates a progressive expansion sequence that maintains fluid expulsion pathways open, preventing hydraulic lock while achieving the seal.
2Reliability
If the inner tubular member has varying sidewall thickness to enable sequential expansion, then fluid can be expelled from the interface, but the manufacturing cost increases due to complicated profile
Solution Approach 1:
Instead of varying the overall tubular wall thickness, localized quality changes are introduced through circumferential reinforcement elements positioned at specific axial locations. These reinforcements create regions of different radial expansion resistance without requiring complex varying wall thickness throughout the entire tubular structure, simplifying manufacturing.
Solution Approach 2:
The tubular member is segmented into regions with different expansion characteristics through discrete circumferential reinforcements rather than continuous varying wall thickness. This segmentation approach allows each region to be manufactured separately with uniform properties, then assembled or formed in sequence, reducing manufacturing complexity while achieving the desired sequential expansion and fluid expulsion.
3Ease of manufacture
If a single piece assembly with uniform wall thickness is used, then manufacturing cost is reduced, but the ability to modify the assembly for different applications is limited
Solution Approach 1:
The system transitions from a static uniform structure to a dynamic configuration through the addition of circumferential reinforcements that can be positioned at different locations and with different properties. This allows the same basic uniform tubular component to be adapted for different applications by modifying the reinforcement pattern, achieving versatility without requiring completely different base components.
Solution Approach 2:
The uniform wall thickness tubular member serves as a universal base component that can be adapted for multiple applications through the strategic placement of circumferential reinforcements. The same fundamental tubular design can be configured for different sealing requirements, expansion characteristics, and application-specific needs by simply adjusting the reinforcement configuration, enhancing versatility while maintaining manufacturing simplicity.
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
The solution provides a reliable, cost-effective hermetic seal and secure axial load transfer, preventing hydraulic lock and enabling adaptation to different applications with reduced manufacturing complexity.
Implementation Method 1
The expandable portion is expandable radially outwardly against the second tubular member until one or more hermetic seals are formed between the expandable portion and the second tubular member
Implementation Method 2
The expandable portion comprises one or more reinforcing annular members mounted around the expandable portion; the or each annular member providing resistance to radial load and defining on the expandable portion annular regions having differing resistance to the radial load
Implementation Method 3
the or each annular member providing resistance to radial load and defining on the expandable portion annular regions having differing resistance to the radial load whereby the or each region having lower resistance expands prior to the or each region having greater resistance
Implementation Method 4
The outward expansion may be achieved, for example, by application of radial outward pressure or force to side walls of the expandable portion within an inner bore of the expandable portion
Data Source
AI summary
Apparatus and method for connecting tubular members in a wellbore. A host tubular member (101) has reinforcing annular members (106) mounted thereon to provide regions of differing resistance to the radial load. When the host tubular member (101) is expanded radially outwardly, within a second tubular member, each weaker region starts expanding first and seals the host tubular member against the second tubular member prior to the stronger region. Embodiments of host tubular members are described including members of progressive resistance, split rings, gripper elements (116) and sealing elements (118).