Expandable tubular installation systems, methods, and apparatus

Abstract

Systems, apparatus and well intervention methods are described. Tubular member radial expansion apparatus includes a support member having forward and rearward ends; a drive unit and an expansion member disposed on the support member providing force for propelling the expansion member through an expandable tubular and expanding it, the drive unit disposed rearward of the expansion member; front and rear anchors disposed on the support member for engaging the expandable tubular's ID to provide reaction forces to propagate the expansion member through the expandable tubular, the rear anchor positioned behind the drive unit and providing its reaction force after the front anchor has exited the expandable tubular; a casing lock disposed on the support member and positioned between the expansion member and the front anchor, securing the expandable tubular to the support member during running-in-hole (RIH); and a valve attached to the forward end of the expandable tubular.

1 . A tubular member radial expansion apparatus comprising:
 a) a support member having a forward end and a rearward end;   b) a drive unit and an expansion member disposed on the support member providing force for propelling the expansion member through and radially expanding an expandable tubular, the drive unit disposed rearward of the expansion member;   c) front and rear anchors disposed on the support member for engaging the expandable tubular's ID to provide reaction forces to propagate the expansion member through the expandable tubular, the rear anchor positioned behind the drive unit and providing its reaction force after the front anchor has exited the expandable tubular;   d) a casing lock disposed on the support member and positioned between the expansion member and the front anchor, releasably securing the expandable tubular to the support member during running-in-hole; and   e) a valve attached to a forward end of the expandable tubular.   
   
   
       2 . The apparatus of  claim 1  wherein the support member defines one or more internal fluid passages. 
   
   
       3 . The apparatus of  claim 2  comprising a flow valve fluidly connected to the forward end of the support member and at least one of the internal fluid passages. 
   
   
       4 . The apparatus of  claim 1  comprising a fluid filter fluidly connected to the support member and at least one of the internal fluid passages and positioned at the rearward end of the support member preventing large mud particles from reaching the tool seals and inner mechanisms. 
   
   
       5 . The apparatus of  claim 1  wherein the support member is tubular. 
   
   
       6 . The apparatus of  claim 1  wherein the expansion member is conical, having an outer surface engaging an inner surface of the expandable tubular, the outer surface having a diameter which decreases from a forward end to a rearward end of the expansion member. 
   
   
       7 . The apparatus of  claim 1  comprising an end cap attached to the forward end of the support member. 
   
   
       8 . The apparatus of  claim 1  wherein the expandable tubular is metallic and has an expansion ratio ranging from about 20 to about 40 percent. 
   
   
       9 . The apparatus of  claim 8  able to achieve a bend radius ranging from 20-50°/100 ft (20-50°/30.5 m). 
   
   
       10 . A tubular member radial expansion system comprising:
 a) a deployment component; and   b) a tubular member radial expansion apparatus comprising:
 i) a support member having a forward end and a rearward end; 
 ii) a drive unit and an expansion member disposed on the support member providing force for propelling the expansion member through and radially expanding an expandable tubular, the drive unit disposed rearward of the expansion member; 
 iii) front and rear anchors disposed on the support member for engaging the expandable tubular's ID to provide reaction forces to propagate the expansion member through the expandable tubular, the rear anchor positioned behind the drive unit and providing its reaction force after the front anchor has exited the expandable tubular; 
 iv) a casing lock disposed on the support member and positioned between the expansion member and the front anchor, releasably securing the expandable tubular to the support member during running-in-hole; and 
 v) a valve attached to a forward end of the expandable tubular. 
   
   
   
       11 . The system of  claim 10  wherein the deployment component is selected from coiled tubing and drill pipe. 
   
   
       12 . The system of  claim 10  wherein the support member defines one or more internal fluid passages. 
   
   
       13 . The system of  claim 10  wherein the expansion member is conical, having an outer surface engaging an inner surface of the expandable tubular, the outer surface having a diameter which decreases from a forward end to a rearward end of the expansion member. 
   
   
       14 . The system of  claim 10  wherein the expandable tubular is metallic and has an expansion ratio ranging from about 20 to about 40 percent. 
   
   
       15 . The system of  claim 14  able to achieve a bend radius ranging from about 20 to about 50°/100 ft (20-50°/30.5 m). 
   
   
       16 . A method of expanding a tubular member, comprising:
 a) deploying an expandable tubular and an expansion tool into a wellbore, the expandable tubular secured to a support member of the expansion tool, the support member having a forward end and a rearward end, the rearward end attached to a deployment component communicating with the surface; and   b) performing an intervention operation on the wellbore comprising using the expansion tool to expand the expandable tubular and so complete the wellbore,
 wherein the expansion tool further comprises a drive unit and an expansion member disposed on the support member providing force for propelling the expansion member through the expandable tubular axially from rear to forward and radially expanding the expandable tubular, the drive unit disposed rearward of the expansion member; front and rear anchors disposed on the support member for engaging the expandable tubular's ID to provide reaction forces to propagate the expansion member through the expandable tubular, the rear anchor positioned behind the drive unit and providing its reaction force after the front anchor has exited the expandable tubular. 
   
   
   
       17 . The method of  claim 16  wherein the deploying proceeds by using deployment components selected from coiled tubing and drill pipe. 
   
   
       18 . The method of  claim 16  wherein the well intervention operation is selected from open-hole clads, sidetracking, and cased-hole patches. 
   
   
       19 . The method of  claim 16  comprising radially expanding the expandable tubular to an expansion ratio ranging from about 20 to about 40 percent. 
   
   
       20 . The method of  claim 19  comprising deploying the expansion tool and expandable tubular into a non-horizontal wellbore having a bend radius ranging from about 20 to about 50°/100 ft (20-50°/30.5 m).