Expandable Wellbore Liner Cone Assembly for Nested Expansion
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Solution Overview
Problem
Existing expansion systems for wellbore tubulars are often too large to pass through previously expanded sections, limiting the ability to install series of expanded tubulars with the same inside diameter.
Innovation Solution
A system comprising a cone assembly, jack assembly, and latch assembly that allows for the radial expansion of expandable liners by moving a cone assembly from a retracted to an extended position within the liner, using fluid pressure to lock and release the assembly, and retaining the expanded position, enabling the passage and expansion of subsequent tubular sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large diameter expansion system is used to expand tubulars to a larger inside diameter, then the expansion capability is improved, but the system cannot pass through previously expanded tubular sections
Solution Approach 1:
The expansion system employs a collapsible/expandable structure where the cone assembly and support tubular can be compressed to a smaller diameter for passage through previously expanded sections, then expanded to the required size for expansion operations. This dynamic size change capability resolves the contradiction between needing large expansion capability and being able to pass through smaller openings.
Solution Approach 2:
The cone assembly is nested within the support tubular, and the entire expansion system can be nested within previously expanded tubular sections during installation. This nesting arrangement allows the system to pass through constrained spaces while maintaining its full expansion capability when deployed.
2Ease of operation
If a small diameter expansion system is used to pass through previously expanded sections, then the passability is improved, but the expansion capability is limited
Solution Approach 1:
The system transitions from a small compressed state during installation to a large expanded state during operation, allowing it to achieve the required inside diameter consistency only when needed, while maintaining passability during installation.
Solution Approach 2:
The expansion system is divided into collapsible segments that can be compressed for passage and then expanded to the required size. This segmentation allows the system to adapt its size - small for passage, large for expansion - resolving the contradiction between passability and expansion capability.
3Manufacturing precision
If the cone assembly is moved axially through the tubular member, then the radial expansion is achieved, but the system requires significant axial space and force
Solution Approach 1:
The cone assembly uses a tapered/curved surface geometry that converts axial movement into radial expansion more efficiently. The conical shape allows the expansion force to be applied gradually and uniformly, reducing the total axial travel distance required compared to a straight cylindrical pusher.
Solution Approach 2:
The system converts the expansion problem from a purely radial action to an axial-radial coupled action. By moving the cone axially, radial expansion is achieved indirectly, allowing the use of axial force (which is easier to apply via hydraulic pressure) to achieve the desired radial expansion.
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 the expansion of wellbore tubulars to a consistent diameter, allowing for the installation of multiple expanded sections with the same inside diameter, overcoming the limitations of prior art expansion systems.
Implementation Method 1
Axial movement of the cone assembly set in the extended position through the expandable liner may radially expand the expandable liner. The jack assembly may be operable to move the cone assembly from the retracted position to the extended position
Implementation Method 2
The upper coupling may comprise a piston sleeve operable to move from a first position urging dogs toward the jack assembly and a second position permitting the dogs to move radially outward, and one or more pins configured to shear upon the fluid applying the predetermined pressure on the piston sleeve
Data Source
AI summary
A tool for expanding a liner in a wellbore includes a cone assembly that is moveable between a retracted position and an extended position. The tool also includes a jack assembly that is operable by fluid pressure to move the cone assembly from the retracted position to the extended position. The fluid pressure is also applied to expansion cup seals to generate axial load that urges the cone assembly to move through the expandable liner and radially expand of the expandable liner. A latch assembly axially fixes the liner while the cone assembly moves to the extended position. Once the cone assembly is fully moved to the extended position, the latch assembly releases the liner, allowing the cone assembly to move through the liner and radially expand the liner.