BACKGROUND

[0001] In the oil and gas industry, expandable tubing is often used for casing, liners and the like. To create a casing, for example, a tubular member is installed in a wellbore and subsequently expanded by displacing an expansion cone through the tubular member. The expansion cone may be pushed or pulled using mechanical means, such as by a support tubular coupled thereto, or driven by hydraulic pressure. 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. In other words, the tubular member expands radially. Expandable tubulars may also be used to repair, seal, or remediate existing casing that has been perforated, parted, corroded, or otherwise damaged since installation.

BRIEF DESCRIPTION OF THE DRAWINGS

[0002] FIGS. IA- IE are schematic illustrations of an expansion apparatus at various steps in an expansion process in accordance with one embodiment.

DETAILED DESCRIPTION

[0003] The present disclosure relates to apparatus and methods for expanding a tubular within a wellbore. In some embodiments, a first expansion cone is used to expand the lower end of a tubular before a second expansion cone expands at least a portion of the tubular.

[0004] Referring to FIG. IA, an embodiment of an expansion apparatus 10 for radially expanding and plastically deforming a tubular member 15 is shown in a running position. The expansion apparatus 10 includes a tubular support member 60 that includes an extendable section 25, which may be, for example, a bumper sub, slack joint, or hydromechanical actuator configured to act downwardly. A releasable anchor 31 is located above the extendable section 25, and may be anchored to the expandable tubular 15 using a profile 30 formed inside the expandable tubular 15. An upper expandable cone 40, an anchor 50, and a lower expansion cone 20 are located below the extendable section 25. The lower expansion cone 20 fits partially within an expansion sleeve 21. The individual components in the expansion apparatus may include an inner bore 70 to allow fluid pumped from the surface to pass through the expansion apparatus 10 and exit through the expansion sleeve 21. The fluids may be hardenable, such as cement, or non-hardenable, such as drilling mud. The lower expansion cone 20 and/or the expansion sleeve 21 may include a check valve 71 [0005] The expansion apparatus 10 in the running position is located at a selected location in a wellbore before beginning the expansion process. Once on depth, cement or other hardenable fluid can be pumped through the expansion apparatus 10, followed by a wiper dart or ball (not shown) to clean the cement and provide a pressure plug within or above the lower expansion cone 20. A seat 72 may be located above the check valve 71 and below a port 26 to provide a pressure plug to initiate expansion using the wiper dart or ball. Although shown with an upset 16 prior to expansion, the expandable tubular 15 may instead have a constant outside diameter before expansion according to various design considerations while designing the wellbore. The first step of expansion is to downwardly displace the lower expansion cone 20 into the expansion sleeve 21. If the extendable section 25 is a bumper sub, fluid may be pumped through the port 26 below the upper expandable cone 40. Port 26 may be initially sealed with a rupture disk that ruptures in response to pressure buildup after seating of the dart or ball in seat 72. A seal 32, such as a cup sub, above the extendable section 25 seals the annulus between the support member 60 and the expandable tubular 15 to provide a fluid chamber 27 above the lower expansion cone 20. Fluid pumped into fluid chamber 27 forces the lower expansion cone 20 downward into the expansion sleeve 21, which radially expands to accommodate the lower expansion cone 20 therein. The expansion sleeve 21 is not substantially compressible and may be made of a polymer material, such as polyurethane. Forcing the expansion sleeve 21 outward expands the lower section of the expandable tubular 15. To stay in place axially relative to the expandable tubular 15, the expansion sleeve 21 may have a higher friction coefficient on its outer diameter than on its inside diameter, which causes the expansion sleeve 21 to grip the inside of the expandable tubular 15 while allowing the lower expansion cone 20 inside the expansion sleeve 21.

[0006] FIG. IB shows the expansion apparatus 10 after expanding the lower end of the expandable tubular 15. After partial expansion of the lower end, the lower expansion cone 20 axially displaces the end of the expansion sleeve 21 to continue expansion until the end of the expandable tubular 15 is radially expanded. In one embodiment, downward expansion may continue until the lower expansion cone 20 and expansion sleeve 21 are partially or fully extruded off the expandable tubular 15. The downward expansion process creates a launcher portion 28 at the lower end of the expandable tubular 15. The upper expandable cone 40 and the anchor 50 move axially with the extendable section 25 and the lower expansion cone 20 during the downward expansion such that they are located within the launcher portion 28 of the expandable tubular 15 after completion of the downward expansion. Anchor 50 may then be actuated to anchor within the launcher portion 28 of the expandable tubular 15. Anchor 50 may be, for example, a hydraulically actuated packer that sets in response to increased pressure from fluid pumped into the expansion apparatus 10.

[0007] Turning to FIG. 1C, the upper expandable cone 40 is expanded to increase its outer diameter to about the inside diameter of the launcher portion 28. As with anchor 50, the upper expandable cone 40 may actuate in response to pressure from fluid pumped into the expansion apparatus 10. Because of the earlier downward expansion, the upper expandable cone 40 is able to freely expand to a greater diameter without the force that would be required to simultaneously expand the expandable tubular 15. Releasable anchor 31 is released to allow axial movement of support member 60 and expansion of the upper portion of the expandable tubular 15. In one embodiment, releasable anchor 31 may be configured to automatically release during downward expansion when extendable section 25 extends to a selected length. Although FIG. 1C shows the anchor 50, upper expandable cone 40, and releasable anchor 31 actuated sequentially, the disclosure is not limited to a particular order of actuation between those components.

[0008] FIG. ID shows the upper expansion process after releasing from anchor 50. The anchor 50 may be releasably axially secured below the upper expandable cone 40 by shear pins or other releasable mechanisms. The upward force to release from anchor 50 may be provided by pulling upward on the support member 60 from the surface or by pressure from fluid pumped into the launcher portion 28 above anchor 50, or a combination thereof. The upper expandable cone 40 is pushed upward beyond launcher portion 28 by pressure from fluid pumped below the upper expandable cone 40 and/or pulled upward by support member 60. Anchor 50 may be used to provide a seal below the upper expandable cone 40 to allow pressure buildup to drive the upward expansion. In one embodiment, the extendable section 25 is a dual acting actuator that pulls upward on the expandable cone 40 during upward expansion.

[0009] Upward expansion continues as shown in FIG. IE until the expandable tubular 15, or a desired portion thereof, is expanded. The anchor 50, lower expansion cone 20, and expansion sleeve 21 are left in the end of the expanded tubular 15 to be drilled out at a later time. The materials for the anchor 50 and lower expansion cone 21 may be selected to be easily drillable. Drillable materials include cast iron, aluminum, plastic, ceramic, aluminum-bronze, or other materials depending on the expansion force required to expand the lower portion of the expandable tubular. For the anchor 50, drillable packers are commercially available from multiple companies, such as TIW Corporation (Houston, Texas). To aid drilling, the lower expansion cone 20 and expansion sleeve 21 may further include anti-rotation features, such as grooves or knurled surfaces, to prevent relative rotation between each component and the expanded tubular 15 while drilled out. For example, in one embodiment, the bottom of the expansion sleeve may include protrusions that engage the bottom of the wellbore and the bottom of the lower expansion cone 20 may include protrusions that engage the expansion sleeve 21. After drilling out the components left in the expanded tubular 15, a single diameter liner is provided in the wellbore.

[0010] Embodiments of the disclosure create a launcher portion in situ, which allows for the outer diameter of the lower portion of the expandable tubular to be the same or only slightly larger than the rest of the expandable tubular. This reduces the risk of the expansion apparatus being stuck within the wellbore before reaching the desired location and allows the expansion apparatus to be run through liners or casing with inside diameters that are equal or only slightly greater than what the outside diameter of the expandable tubular will be after expansion by the upper expandable cone.

[0011] Although this detailed description has shown and described illustrative embodiments of the invention, this description contemplates a wide range of modifications, changes, and substitutions. In some instances, one may employ some features of the present invention without a corresponding use of the other features. Accordingly, it is appropriate that readers should construe the appended claims broadly, and in a manner consistent with the scope of the invention.