Method for assembly of a gravel packing apparatus having expandable channels

Abstract

A gravel packing apparatus ( 210 ) having expandable channels ( 244 ) comprises first and second tubulars ( 212, 214 ) forming an annulus therebetween. First and second base plates ( 230, 232 ) are positioned within the annulus, each base plate ( 230, 232 ) having at least one receiving notch ( 234, 236 ). An expandable channel ( 244 ) having first and second configurations extends between the respective receiving notches ( 234, 236 ) of the first and second base plates ( 230, 232 ) within the annulus. Each expandable channel ( 244 ) initially has a flexible hose ( 252 ) disposed therein such that when the flexible hose ( 252 ) is pressurizing, the expandable channels ( 244 ) are expanded from the first configuration to a second configuration, thereby forming slurry passageways in the gravel packing apparatus ( 210 ).

What is claimed is:  
     
         1 . A method for assembling a gravel packing apparatus comprising the steps of: 
 providing a first tubular;    installing first and second base plates proximate each end of the first tubular, each base plate having a receiving notch;    extending an expandable channel in a first configuration between the receiving notches of the first and second base plates;    disposing a flexible hose within the expandable channel;    positioning a second tubular substantially around the first and second base plates and the expandable channel;    pressurizing the flexible hose;    expanding the expandable channel from the first configuration to a second configuration; and    removing the flexible hose.    
     
     
         2 . The method as recited in  claim 1  further comprising after the step of extending an expandable channel in a first configuration between the receiving notches of the first and second base plates, the step of spot welding the expandable channel to the first tubular.  
     
     
         3 . The method as recited in  claim 1  wherein the step of expanding the expandable channel from the first configuration to the second configuration further comprises expanding side sections of the expandable channel from a first angle relative to a web section of the expandable channel to a second angle that is larger than the first angle.  
     
     
         4 . The method as recited in  claim 1  wherein the step of expanding the expandable channel from the first configuration to the second configuration further comprises expanding side sections of the expandable channel from an acute angle relative to a web section of the expandable channel to an obtuse angle.  
     
     
         5 . The method as recited in  claim 1  wherein the step of expanding the expandable channel from the first configuration to the second configuration further comprises expanding side sections of the expandable channel relative to a web section of the expandable channel such that the end portion of the side sections contacts the second tubular.  
     
     
         6 . The method as recited in  claim 1  wherein the step of expanding the expandable channel from the first configuration to the second configuration further comprises plastically deforming the expandable channel.  
     
     
         7 . The method as recited in  claim 1  further comprising the steps of: 
 welding the first and second base plates to the first tubular;  
 welding the second tubular to the first and second base plates; and  
 welding the expandable channel to the receiving notches of the first and second base plates after the expandable channel has been expanded.  
 
     
     
         8 . The method as recited in  claim 1  further comprising placing centralizers on the first tubular such that when the second tubular is positioned substantially around the first and second base plates and the expandable channel, the second tubular is substantially concentric with the first tubular.  
     
     
         9 . A method for assembling a gravel packing apparatus comprising the steps of: 
 providing a first tubular;    installing first and second base plates proximate each end of the first tubular, each base plate having a plurality of receiving notches;    extending a plurality of expandable channels each in a first configuration between respective pairs of the receiving notches of the first and second base plates;    disposing a flexible hose within each of the expandable channels;    positioning a second tubular substantially around the first and second base plates and the expandable channels;    simultaneously pressurizing each of the flexible hoses;    expanding each of the expandable channels from the first configuration to a second configuration; and    removing the flexible hoses.    
     
     
         10 . The method as recited in  claim 9  further comprising after the step of extending a plurality of expandable channels each in a first configuration between respective pairs of the receiving notches of the first and second base plates, the step of spot welding each of the expandable channels to the first tubular.  
     
     
         11 . The method as recited in  claim 9  wherein the step of expanding each of the expandable channels from the first configuration to the second configuration further comprises expanding respective side sections of the expandable channels from a first angle relative to web sections of the expandable channels to a second angle that is larger than the first angle.  
     
     
         12 . The method as recited in  claim 9  wherein the step of expanding each of the expandable channels from the first configuration to the second configuration further comprises expanding respective side sections of the expandable channels from an acute angle relative to web sections of the expandable channels to an obtuse angle.  
     
     
         13 . The method as recited in  claim 9  wherein the step of expanding each of the expandable channels from the first configuration to the second configuration further comprises expanding respective side sections of the expandable channels relative to web sections of the expandable channels such that the end portion of the side sections contacts the second tubular.  
     
     
         14 . The method as recited in  claim 9  wherein the step of expanding each of the expandable channels from the first configuration to the second configuration further comprises plastically deforming the expandable channels.  
     
     
         15 . The method as recited in  claim 9  further comprising the steps of: 
 welding the first and second base plates to the first tubular;  
 welding the second tubular to the first and second base plates; and  
 welding the expandable channels to the receiving notches of the first and second base plates after the expandable channels have been expanded.  
 
     
     
         16 . The method as recited in  claim 9  further comprising placing centralizers on the first tubular such that when the second tubular is positioned substantially around the first and second base plates and the expandable channels, the second tubular is substantially concentric with the first tubular.  
     
     
         17 . A method for expanding an expandable channel in an annulus between two tubulars comprising the steps of: 
 supporting the expandable channel in a first configuration having a flexible hose disposed within the expandable channel in the annulus between two tubulars;    pressurizing the flexible hose;    expanding the expandable channel from the first configuration to a second configuration; and    removing the flexible hose.    
     
     
         18 . The method as recited in  claim 17  wherein the step of expanding the expandable channel from the first configuration to the second configuration further comprises expanding side sections of the expandable channel from a first angle relative to a web section of the expandable channel to a second angle that is larger than the first angle.  
     
     
         19 . The method as recited in  claim 17  wherein the step of expanding the expandable channel from the first configuration to the second configuration further comprises expanding side sections of the expandable channel from an acute angle relative to a web section of the expandable channel to an obtuse angle.  
     
     
         20 . The method as recited in  claim 17  wherein the step of expanding the expandable channel from the first configuration to the second configuration further comprises expanding side sections of the expandable channel relative to a web section of the expandable channel such that the end portion of the side sections contacts the second tubular.  
     
     
         21 . The method as recited in  claim 17  wherein the step of expanding the expandable channel from the first configuration to the second configuration further comprises plastically deforming the expandable channel.  
     
     
         22 . The method as recited in  claim 17  further comprising placing centralizers between the two tubulars to assure substantial concentricity.  
     
     
         23 . A method for assembling a gravel packing apparatus comprising the steps of: 
 providing first and second inner tubulars;    installing first and second base plates proximate both ends of the first and second inner tubulars, each base plate having a receiving notch;    extending an expandable channel in a first configuration between the receiving notches of the first and second base plates on each of the first and second inner tubulars;    disposing a flexible hose within each of the expandable channels;    positioning first and second outer tubulars substantially around the first and second base plates and the expandable channel of the respective first and second inner tubulars;    pressurizing each of the flexible hoses;    expanding each of the expandable channels from the first configuration to a second configuration;    removing the flexible hoses; and    coupling the first inner tubular to the second inner tubular and the first outer tubular to the second outer tubular.    
     
     
         24 . The method as recited in  claim 23  wherein the step of expanding each of the expandable channels from the first configuration to the second configuration further comprises expanding side sections of the expandable channels from a first angle relative to web sections of the expandable channels to a second angle that is larger than the first angle.  
     
     
         25 . The method as recited in  claim 23  wherein the step of expanding each of the expandable channels from the first configuration to the second configuration further comprises expanding side sections of the expandable channels from an acute angle relative to web sections of the expandable channels to an obtuse angle.  
     
     
         26 . The method as recited in  claim 23  wherein the step of expanding each of the expandable channels from the first configuration to the second configuration further comprises expanding side sections of the expandable channels relative to web sections of the expandable channels such that the end portion of the side sections contacts the respective outer tubular.  
     
     
         27 . The method as recited in  claim 23  wherein the step of expanding each of the expandable channels from the first configuration to the second configuration further comprises plastically deforming each of the expandable channels.  
     
     
         28 . A method for assembling a gravel packing apparatus comprising the steps of: 
 providing a first tubular;    installing first and second base plates proximate each end of the first tubular, each base plate having a receiving notch;    extending an expandable channel in a first configuration between the receiving notches of the first and second base plates;    disposing a flexible hose within the expandable channel;    positioning a second tubular substantially around the first and second base plates and the expandable channel;    pressurizing the flexible hose;    expanding the expandable channel from the first configuration to a second configuration such that side sections of the expandable channel expand relative to a web section of the expandable channel causing end portions of the side sections to contact the second tubular; and    removing the flexible hose.    
     
     
         29 . The method as recited in  claim 28  further comprising after the step of extending an expandable channel in a first configuration between the receiving notches of the first and second base plates, the step of spot welding the expandable channel to the first tubular.  
     
     
         30 . The method as recited in  claim 28  wherein the step of expanding the expandable channel from the first configuration to the second configuration further comprises expanding the side sections of the expandable channel from a first angle relative to the web section of the expandable channel to a second angle that is larger than the first angle.  
     
     
         31 . The method as recited in  claim 28  wherein the step of expanding the expandable channel from the first configuration to the second configuration further comprises expanding the side sections of the expandable channel from an acute angle relative to the web section of the expandable channel to an obtuse angle.  
     
     
         32 . The method as recited in  claim 28  wherein the step of expanding the expandable channel from the first configuration to the second configuration further comprises plastically deforming the expandable channel.  
     
     
         33 . The method as recited in  claim 28  further comprising the steps of: 
 welding the first and second base plates to the first tubular;  
 welding the second tubular to the first and second base plates; and  
 welding the expandable channel to the receiving notches of the first and second base plates after the expandable channel has been expanded.  
 
     
     
         34 . The method as recited in  claim 28  further comprising placing centralizers on the first tubular such that when the second tubular is positioned substantially around the first and second base plates and the expandable channel, the second tubular is substantially concentric with the first tubular.  
     
     
         35 . An apparatus for gravel packing an interval of a wellbore comprising: 
 first and second tubulars forming an annulus therebetween;    first and second base plates positioned within the annulus, each base plate having a receiving notch; and    an expandable channel having first and second configurations extending between the receiving notches of the first and second base plates within the annulus, the expandable channel initially having a flexible hose disposed therein such that when the flexible hose is pressurized, the expandable channel is expanded from the first configuration to a second configuration.    
     
     
         36 . The apparatus as recited in  claim 35  wherein the expandable channel is spot welded to the first tubular.  
     
     
         37 . The apparatus as recited in  claim 35  wherein the expandable channel has a pair of oppositely disposed sides and a web therebetween and wherein angle between the sides and the web is smaller in the first configuration as compared to the second configuration.  
     
     
         38 . The apparatus as recited in  claim 35  wherein the expandable channel has a pair of oppositely disposed sides and a web therebetween and wherein angle between the sides and the web is acute in the first configuration and obtuse in the second configuration.  
     
     
         39 . The apparatus as recited in  claim 35  wherein the expandable channel has a pair of oppositely disposed sides and a web therebetween and wherein end portions of the side sections contact the second tubular when the expandable channel is in the second configuration.  
     
     
         40 . The apparatus as recited in  claim 35  wherein the expandable channel is plastically deformed from the first configuration to the second configuration.  
     
     
         41 . The apparatus as recited in  claim 35  wherein the first and second base plates are welded to the first tubular, wherein the second tubular is welded to the first and second base plates and wherein the expandable channel is welded to the receiving notches of the first and second base plates when the expandable channel is in the second configuration.  
     
     
         42 . The apparatus as recited in  claim 35  further comprising centralizers positioned in the annulus such that the second tubular is substantially concentric with the first tubular.  
     
     
         43 . A gravel packing apparatus assembled by the method as recited in  claim 1 .  
     
     
         44 . A gravel packing apparatus assembled by the method as recited in  claim 9 .  
     
     
         45 . A gravel packing apparatus assembled by the method as recited in  claim 17 .  
     
     
         46 . A gravel packing apparatus assembled by the method as recited in  claim 23 .  
     
     
         47 . A gravel packing apparatus assembled by the method as recited in  claim 28.