Apparatus and process for expanding a tubular using a cone assembly

Abstract

A cone assembly for use in expanding the diameter of a pipe has a rigid cone adapted to be positioned adjacent to an end of the pipe, a flexible cone positioned adjacent an end of the rigid cone and being movable between an expanded diameter at a reduced diameter, and an actuator having an end in contact with the flexible cone. The actuator is movable between an extended position and a retracted position. The extended position is adapted to cause the rigid cone to expand the outer diameter of the pipe and causes the flexible cone to expand in diameter. The retracted position of the actuator removes the force applied to the flexible cone so as to cause the flexible cone to have the reduced diameter. The flexible cone is a ring having a continuous wall with a single slot therethrough.

I claim: 
     
         1 . A cone assembly for use in expanding the diameter of a pipe, the cone assembly comprising:
 a rigid cone adapted to be positioned adjacent to an end of the pipe;   a flexible cone positioned adjacent an end of said rigid cone, said flexible cone movable between an expanded diameter and a reduced diameter, said flexible cone having an internal taper, the flexible cone comprising a ring with a continuous wall having a single slot therethrough; and   an actuator having an end in contact with said flexible cone, said actuator movable between an extended position and a retracted position, the extended position adapted to cause said rigid cone to expand a diameter of the pipe and to cause said flexible cone to have the expanded diameter, the retracted position of said actuator removing or releasing a force applied to said flexible cone so as to cause said flexible cone to have the reduced diameter.   
     
     
         2 . The cone assembly of  claim 1 , the slot of the flexible cone extending longitudinally through the wall of said flexible cone, the slot widening in the expanded diameter of said flexible cone, the slot narrowing in the reduced diameter of said flexible cone. 
     
     
         3 . The cone assembly of  claim 1 , said actuator comprising a piston having an end bearing adjacent the opposite end of said flexible cone when said flexible cone has the expanded diameter. 
     
     
         4 . The cone assembly of  claim 1 , said slot positioned at an angle with respect to a center axis of the flexible cone. 
     
     
         5 . The cone assembly of  claim 1 , the end of said actuator having a tapered outer diameter that corresponds to the internal taper of said flexible cone. 
     
     
         6 . The cone assembly of  claim 5 , wherein the tapered outer diameter of said actuator is slidable along the internal taper of said flexible cone. 
     
     
         7 . The cone assembly of  claim 1 , wherein the internal taper of said flexible cone is slidable along an external taper of said rigid cone. 
     
     
         8 . An assembly comprising:
 a pipe having an end and an inner diameter;   a rigid cone positioned adjacent the end of the pipe, said rigid cone having a tapered outer diameter that reduces from one end of the rigid cone toward an opposite end of said rigid cone, the opposite end of said rigid cone having an outer diameter less than an inner diameter of the end of said pipe, the end of said rigid cone having an outer diameter greater than the inner diameter of the end of said pipe;   a flexible cone comprising a ring with a continuous wall having a single slot therethrough, the flexible cone having an end at the end of said rigid cone and an opposite end, said flexible cone having a tapered inner diameter, said flexible cone having an expanded diameter upon an application of force and a reduced diameter when no force or a minimal force is applied to said flexible cone; and   an actuator having an end facing the opposite end of said flexible cone, the end of said actuator being in contact with the flexible cone, said actuator movable between an extended position and a retracted position, the extended position causing the flexible cone to have the expanded diameter and to urge said flexible cone and said rigid cone to expand the diameter of said pipe, the retracted position allowing said flexible cone and said rigid cone to be removed from the inner diameter at the end of said pipe.   
     
     
         9 . The assembly of  claim 8 , wherein the flexible cone has a slot extending axially through the wall of said flexible cone from the end of said flexible cone to the opposite end of said flexible cone. 
     
     
         10 . The assembly of  claim 8 , wherein the reduced diameter of said flexible cone is less than the inner diameter of said pipe when the actuator is in the retracted position. 
     
     
         11 . The assembly of  claim 8 , wherein the actuator has a tapered outer diameter at an end thereof, the tapered outer diameter of said actuator generally matching the tapered inner diameter of said flexible cone. 
     
     
         12 . The assembly of  claim 11 , wherein the tapered outer diameter of said actuator is slidable with respect to the tapered inner diameter of said flexible cone as said actuator moves between the extended position and the retracted position. 
     
     
         13 . The assembly of  claim 8 , said slot positioned at an angle with respect to a center axis of the flexible cone. 
     
     
         14 . The assembly of  claim 8 , wherein the internal taper of said flexible cone is slidable along an external taper of said rigid cone. 
     
     
         15 . A method for expanding the diameter of a pipe, the method comprising:
 positioning a rigid cone and a flexible cone adjacent the end of the pipe such that the rigid cone has a narrow diameter end adjacent the end of the pipe, the flexible cone being positioned adjacent a wide diameter end of said rigid cone, the flexible cone comprising a ring with a continuous wall having a single slot therethrough;   applying a force to the flexible cone so as to translate the flexible cone and the rigid cone into the end of the pipe;   expanding the diameter of the pipe by sliding an outer diameter of said rigid cone along an inner diameter of said pipe;   expanding a diameter of said flexible cone during the application of force to the flexible cone;   releasing or reducing the force on the flexible cone after the end of the pipe has a desired expanded diameter so as to cause the flexible cone to reduce the outer diameter of the flexible cone; and   removing the flexible cone and the rigid cone from the end of the pipe after the force is reduced or released.   
     
     
         16 . The method of  claim 15 , wherein the rigid cone has a tapered outer diameter, the tapered outer diameter having a large diameter greater than an inner diameter of the end of the pipe prior to the step of expanding the outer diameter of the pipe and a small diameter less than the inner diameter of the end of the pipe prior to the step of expanding the outer diameter of the pipe. 
     
     
         17 . the method of  claim 16 , wherein the large diameter of the rigid cone is less than an inner diameter of the end of the pipe following the steps of expanding the outer diameter of the pipe. 
     
     
         18 . The method of  claim 15 , wherein the step of applying the force comprises:
 actuating an actuator so as to move from a retracted position to an extended position, the extended position bearing against an end of the flexible cone.   
     
     
         19 . The method of  claim 18 , the step of expanding the outer diameter of the flexible cone comprising:
 sliding a tapered surface of the actuator or a tapered outer surface of the rigid cone along the tapered inner diameter of the flexible cone such that the slot formed in the outer wall of the flexible cone widens.   
     
     
         20 . The method of  claim 18 , wherein the step of removing comprises:
 retracting the actuator so as to pull the rigid cone and the flexible cone from the end of the pipe; and   retrieving the flexible cone and the rigid cone to a remote location.