Expansion Cone Sleeve System for Wellbore Tubular Diameter Control
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Solution Overview
Problem
Existing expansion systems in the oil and gas industry are often too large to pass through previously expanded tubular sections, limiting the ability to install multiple expanded tubular sections with the same inside diameter.
Innovation Solution
An expansion system comprising an expansion cone, an expansion sleeve with weakening features, and a housing, allowing the expansion cone to radially expand the tubular member to a diameter equal to the cone's expansion diameter plus twice the sleeve's thickness, enabling the system to pass through and expand within existing casing sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large diameter expansion system is used to expand tubular members, then the expansion capability and structural strength are improved, but the system cannot pass through previously expanded tubular sections
Solution Approach 1:
The expansion system is divided into separate functional components: an expandable tubular member that can be collapsed to a small diameter for running, and an expansion cone that provides the expansion force. The tubular member is segmented into segments that can collapse radially inward, allowing the system to pass through previously expanded sections while maintaining structural integrity during expansion operations
Solution Approach 2:
The expandable tubular member is designed to collapse radially inward to a small diameter, allowing it to be nested within or pass through previously expanded tubular sections. The expansion cone is positioned within the tubular member, and both components work together in a nested configuration during running, then expand to perform the expansion function
2Length of moving object
If a small diameter expansion system is used to pass through previously expanded sections, then the ability to install multiple sections is improved, but the expansion capability and structural strength are reduced
Solution Approach 1:
The expandable tubular member transitions dynamically between two states: a collapsed small-diameter state for running and passing through existing sections, and an expanded large-diameter state for providing structural strength during expansion operations. The expansion cone similarly transitions from a compact running configuration to an expanded working configuration, providing the necessary structural support and expansion force only when needed
3Strength
If the expansion system is designed to expand to a large diameter, then the expansion force and structural support are improved, but the system cannot be removed from the wellbore after expansion
Solution Approach 1:
The expandable tubular member and expansion cone are designed with dynamic dimensional changes. After performing the expansion function and providing structural support, the tubular member can be collapsed radially inward to a small diameter, allowing it to be easily pulled out of the wellbore. The expansion cone can also be retracted or collapsed to facilitate system removal, transforming from a large-diameter structural support element to a compact removable configuration
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 tubular members to a consistent diameter, allowing multiple sections to be installed with the same inside diameter, overcoming the size limitations of prior systems and facilitating efficient wellbore expansion.
Implementation Method 1
As the expansion cone is displaced axially within the tubular member, the expansion cone imparts radial force to the inner surface of the tubular member. In response to the radial force, the tubular member plastically deforms, thereby permanently increasing both its inner and outer diameters.
Data Source
Figure 1
Figure 2~3
Figure 4~7
AI summary
A method of expanding a tubular member by assembling an expansion system having an expansion cone and an expansion sleeve and coupling a tubular member to the expansion system so that the expansion sleeve is at least partially disposed within the tubular member. The expansion system and tubular member are then disposed in a wellbore and the expansion cone is translated relative to the expansion sleeve and tubular member so as to radially expand the tubular member into engagement with the wellbore and the expansion system is removed from the wellbore. The tubular member is expanded to an inside diameter equal to an expansion diameter of the expansion cone plus twice a thickness of the expansion sleeve.