ROLLED TUBULAR CENTRAUZER

Cross-Reference to Related Application

[0001] This application is a continuation of to U.S. Patent Application Serial No. 13/957.016, filed on August 1 , 2013, which is a continuation-in-part of U.S. Patent Application Serial No, 13/1 1 ,074, fded on July 26, 201 1. The entirety of both of these applications is incorporated herein by reference.

Field Of Invention

{0002} Embodiments of the present invention generally relate to methods and apparatuses a downboie operation. More particularly, the invention relates to methods and apparatuses for centralization in we!lbores or tubulars.

Background

[0603] n the course of drilling and producing oil and gas wells, it has been found be beneficial to keep the tubular, which may be drill pipe, casing, production pipe, or screens, generally centered in the well. In certain instances it may be desirable to center one tubular within another. By keeping the tubular generally centered in the well a substantially uniform annular area between the wellbore wall and the tubular is maintained. In certain instances, such as cementing the tubular into the well, centralization to provide a substantially uniform annular area is imperative. By having a substantially uniform annular area the cement is better able to fill ail voids between the tubular and the well thereby forming a better bond with both the wellbore wall and the tubular.

[0004} A common type of centraiizer is a bow spring centraiizer. A bow spring centraiizer typically includes a number of bows attached to a collar on the upper end of the bow and on the lower end of the bow. The bow typically curves radially outward between the two collars, in its simplest form the bow spring centraiizer slides over a tubular joint and is restricted only by the tubular couplings at either end of the tubular joint In some situations, when the bow spring centraiizer is pushed into a wellbore on a tubular string the leading collar may be stopped by a restriction that will cause the bows to longitudinally compress thereby radially expanding the bows radially outwards ultimately causing the bow to .fail as the tubular string continues to move down into the well. The problem is compounded due to the thickness of the bow spring centralizer's collars and ribs. Usually the collars and the ribs had the same thickness however the thickness of the centraiizer as a whole centraiizer was effectively PATENT Attorney Docket No, 0186.0028-PCT doubled because the ribs were welded on top of the collar. In the event that a rib was welded edge to edge to the collar a generally weaker collar to rib interface is created and stress points are created by both the welding process and the remaining corners or other sharp points,

[0005] One solution has been to attach at least one of the collars of the bow spring centralizer so that the centralizer will be pulled into the welibore rather than pushed into the wel!bore.

Summary

{0006] In order to minimize any potential stress points created by either welding or by having any sharp points or corners, it was envisioned that a centralizer is fabricated wherein a planar material having an upper end, a lower end, a first side, and a second side is formed into a tubular such that the planar material first side contacts the planar material second side. The planar material first side may be linked with the planar material second side. An elongated opening is then created in the tubular. The tubular has a long axis and the opening has a long axis having a first end and a second end such that the opening first end is adjacent the planar material upper end and the opening second end is adjacent the planar material lower end. Typically the opening does not have any corners and may be an oval, or a rectangle. Preferably the rectangle has rounded corners. In most instances the opening long axis is parallel to the long axis of the tubular although in some cases the opening long axis is not parallel to the long axis of the tubular. Typically the planar material first side is linked to the planar material second side by welding.

[0007] in another embodiment of fabricating a centralizer, a plana material having an upper end, a lower end, a first side, and a second side may be formed into a tubular such that the planar material first side contacts the planar material second side. The planar material first side is linked with the planar material second side. A number of elongated openings are then created in the tubular. The tubular has a long axis and each of the plurality of openings has a long axis having a first end and a second end such that the opening first end is adjacent the planar material upper end and the opening second end is adjacent the planar materia! lower end. While usually the planar material is rolled into a cylinder where the rolling is parallel to one side in some instances the planar material may be rolled into a cylinder by spiral winding process where the rolling is not parallel to either side. In such instances a long tubular may be formed without stopping. Typically the plurality of openings do not have comers. While usually the plurality of openings are ovals the openings may be rectangles although in most instances the rectangles have rounded corners. Typically the plurality of openings long axis are parallel to the long axis of the tubular although in some cases the plurality of openings PATENT Attorney Docket No. 0186.002.8-PCT long axis are not parallel to the long axis of the tubular. Usually the planar materia! first side is linked to the planar material second side by welding. In most instances the openings are created within the tubular structure that was' fonned from the planar material. The material in the tubular structure both above and below the openings define circumferential collars. The material in the tubular structure between, the openings define ribs that are disposed between the upper collar and lower collar. Typically the ribs are expanded radially outward where the expansion process typically, but not always, plastically deforms the ribs. Typically the ribs and in many instances the entire centralizer may be heat-treated, hardened, cured, or any other process known to one skilled in. the art to allow the ribs to elasticaOy deflect after the ribs are expanded. However, in certain instances the ribs or the entire centralizer may be heat-treated, hardened, cured, or any other process known to one skilled in the art,

£0008) In another embodiment of fabricating a centralizer a first planar material having an upper end and a lower end, a first side, and a second side and at least a second planar material having an upper end, a lower end, a first side,, and a second side may be formed into a tubular such that the first planar material first side contacts second planar material second side and the first planar material second side contacts the at least second planar material first side. The first planar material first side may be linked with the at least second planar material second side and the first planar material second side may he linked with the second planar material first side. A number of elongated openings are then created in the tubular. The tubular has a long axis and each of the plurality of openings has a long axis having a first end and a second end such that the opening first end is adjacent the planar material upper end and the opening second end is adjacent the planar material lower end. While usually the planar material is rolled into a cylinder where the roiling is parailei to one side in some instances the planar material may be rolled into a cylinder by spiral winding process where the rolling is not parallel to either side. In such instances a long tubular may be formed without stopping. Typically the plurality of openings do not have corners. While usually the plurality of openings are ovals the openings may be rectangles although in most instances the rectangles have rounded comers. Typically the plurality of openings long axis are parallel to the long axis of the tubular although in some cases the plurality of openings long axis are not parallel to the long axis of the tubular. Usually the planar material first side is linked to the planar material second side by welding. In most instances the openings are created within the tubular structure that was formed from the planar material. The material in the tubular structure both above and below the openings define circumferential collars. The material in the tubular structure between the openings define ribs that are disposed between the upper PATENT Attorney Docket No. 01 86.0028-PCT collar and lower collar. Typically the ribs are expanded radially outward where the expansion process typically, but not always, plastically defomis the ribs. The ribs may be heai-ireaied, .hardened, cured, or any other process known to one skilled in the art before or after the expansion or forming of the ribs.

Brief Description of The Drawings

[0009] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are tlierefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

[0010] Figure ί depicts a generally fiat materia] .

[0011] Figure 2 depicts the generally flat material roiled into a tubular,

[0012] Figure 3 depicts a first and a second generally flat material each formed into a portion of the tubular.

10013} Figure 4 depicts the first and the second generally flat piece of material each formed into a portion of the tube of figure 3 linked together.

[0014] Figure 5 depicts a generally flat piece of materia! having a length substantially greater than its width.

[00.15] Figure 6 depicts the generally flat piece of material of figure 5 formed into a tubular by spiral winding.

[0016] Figure 7 depicts a generally flat piece of material having a nonlinear first side and a mirrored nonlinear second side.

[0017] Figure 8 depicts the generally Oat piece of material of figure 7 roiled into a tubular so that the nonlinear first side and mirrored nonlinear second side mate together.

(0018] Figure 9 depicts a roiled tubular with openings created therein thai are parallel to the long axis of the tubular.

[0019] Figure 10 depicts a rolled tubular with openings created therein that are not parallel to the long axis of the tubular.

[0620] Figure 11 depicts a roiled tubular where the first side and second side are partially linked.

[0021] Figure 12 depicts the rolled tubular of figure 11 where at least one opening is created across the unlinked, portions between the first side and second side. PATENT Attorney Docket No. 0186.0028-PCT

[O022J Figure I 3 depicts a rolled tubular having ribs that have been radially expanded. .Detailed Description

(0023] The description that follows includes exemplary apparatus, methods, techniques, and instruction sequences that embod techniques of the inventive subject matter,

fO©24J Figure 1 depicts a generally flat material 10 having an upper end 12. a lower end 14, a first side 18 and a second side 16. Typically the process of forming a tubular begins with the generally flat material 10 where the generally flat material 10 does not have any openings or notches in the .materia!. When forming the generally flat material 10 into the tubular, the generally flat material 10 may be rolled by a plate roll, may be hydraulic-ally formed, hydro- dynamically formed, stamped, or any other process known for forming flat material into a roll. Whi!e it is anticipated that the generally flat material 10 will typically be a steel or other ferrous material, any materia! may be used including most metals, plastics, or fiber reinforced materials such as carbon fiber polymers and. epoxies,

[0025] Figure 2 depicts the generally flat material .10 from Figure .1 after the generally flat material 10 has been rolled into a tubular 20 so that the first side 18 and the second side 16 are in contact with one another along their length. With the first side 18 in the second side 16 in contact with one another the sides 16 and 18 may be linked, in some instance the sides 16 and 18 may be linked one to the other by welding, crimping, pinning, gluing, epoxy or any other linking process known in the industry.

[0026] in some instances multiple generally flat materials may each be partially formed into a tubular such that when their sides come into contact with one another and are linked to multiple generally flat materials will form the tubular. Figure 3 depicts a first curved piece of material 30 and a second curved piece of material 40 that were formed from two pieces of generally flat material. In this instance, the first curved piece of materia! 30 has an upper end 32, a lower end 34, a first side 36, and a second side 38. The second curved piece of material 40 has an upper end 42, a !ower end 44, a first side 46, and the second side 48.

[00271 Figure depicts the curved pieces of material 30 and 40 respectively that have been aligned such that the first side 36 of the first curved piece of material 30 and the second side 48 of the second curved piece of material 40 are in contact with one another along their length while the second side 38 of the first curved piece of material 30 and the first side 46 of the second curved piece of material 40 are also In contact with one another along their length. With the first curved piece of material 30 and the second curved piece of materia! 40 in PATENT Attorney Docket No. 0186.0028-PCT contact with one another, the curved pieces of material may be linked together to form a tubular 50.

[0028] in other instances a generally flat material may be spiral wound such that its first side and the second side come into contact with one another. Figure 5 depicts an elongated piece of generally flat material 60 where a length 63 is substantially greater than a width 61. The generally flat material 60 has an upper end 62, a lower end 68, a first side 64, and the second side 66. As depicted in figure 6, the generally fiat material 60 has been formed into a tubular 70. The generally flat material 60 was rolled or otherwise formed into the tubular- 70 at an angle that was not parallel to the upper end 62, the lower end 68, the first side 64, or the second side 66. The tubular 70 may be curved by a spiral winding process such that the first side 64 and the second side 66 may be linked to one another.

[0029] In certain instances, as depicted in figure 7, a generally flat material 80 has an upper end 82, a Sower end 84, a first side 88, and a second side 86 where the first side 88 and the second side 86 are nonlinear reflections of one another. Figure 8 depicts the generally flat material 80 from figure 7 after the generally flat material 80 has been formed into a tubular 90 so that the first side 88 and the second side 86 are in contact with one another along their length. With the first side 88 in the second side 86 in contact with one another the two sides 86 and 88 may be linked to form a nonlinear seam between the sides 86 and 88. in those instances where the sides 86 and 88 are nonlinear reflections of one another the two sides may take any form such as a smooth curve, a jagged curve, zig-zags, or any other form.

[0030] Figure 9 depicts the tubular 20 of figure 2 where the first and the second sides 16 and 18 are linked together and with openings 102 created through the tubular 20. Generally the long axis of the tubular 20 is parallel to the seam created by linking first and second sides 16 and 18 although in some cases such as when the tubular is formed by spiral winding the seam will not be parallel to the long axis of the tubular. Each opening 102 has an upper end 104, a lower end 106, and a long axis 108 where the long axis 108 is generally parallel to the long axis of the tubular 20. Ribs 112 are created by the material of the tubular 20 that remains between the openings 102 after the openings 102 are created in the tubular 20. A first collar 114 and a second collar 1 16 are created by the material of the tubular 20 that remains above the upper end 104 of the openings 102 and below the l ower end 106 of the openings 102 after the openings 102 are created in the tubular 20. To prevent failure in the ribs 1 12 as the ribs 1 12 are being moved downhole, the ribs 1 12 are created from the tubular 20 thereby eliminating the potential stress point such as when the ribs in the prior art are welded onto their collars. Additionally the openings 102 are created preferably as ovals to minimize stress PATENT Attorney Docket No. 0186.0028-PCT points in the ribs 112 that may remain after the openings 102 are created in the tubular 20 although any shape that avoids sharp corners or points may be used. The openings 122 may be formed through the tubular 50, 70, and 90 in a similar manner,

[003i] in certain instances such as when the material used to form the tubular is thick enough or is not hardened, heat treated, or cured to obtain spring-like properties, each rib 1 12 will have the ability to plastically deform when subjected to sufficient side load. In such cases, the centraiizer will act like a rigid type central izer that lias the ability to give when inserted through a tight restriction. When the material is not as thick as in the case of a rigid centraiizer described above and when the materia! is heat treated, hardened, or cured to provide spring-like properties, each rib 112 will have spring-like properties and the centraiizer will act as a bow type centraiizer,

[0032] Figure 10 depicts a tubular 120 having an upper end 121, a lower end 123, and openings 122 created through the tubular 120. Each opening 122 has an upper end 124, a lower end 126, and a long axis 128 where the long axis 128 is generally not parallel to the long axis of the tubular 120. Ribs 132 are created by the material of the tubular 120 that remains between the openings 122 after the openings 122 are created in the tubular 120. A first collar 134 and the second collar 136 are created by the material of the tubular 120 that remains above the upper end 124 of the openings 122 and below the lower end 126 of the openings 122 after the openings 122 are created in the tubular 120. The openings 122 may be formed through the tubular 20, 70, and 90 in a similar manner,

[0033] Figure 1 1 depicts the generally flat material 10 from Figure 1 after the generally flat material .10 has been roiled into the tubular 20 so that the first side 1 8 and the second side 16 are in contact with one another along their length. With the first side 8 and the second side 16 in contact with one another a portion of the two sides 16 and 1 8 may be linked. For instance the two sides may be linked along the contact portion of the two sides 18 and 16 from the upper end 12 to any desired point such as point 19 and from the lower end 14 to any desired point such as point 17 leaving the contact portion of the two sides between point 19 and point 17 unlinked.

[0034] Figure 12 depicts the tubular 20 from figure 1 1 having the upper end 12, the lower end 14, and at least one opening 150 created through the tubular 20.

[0035] When creating the opening 150 the material between the upper end 152 and the lower end 154 of the tubular where the first side 18 and second side 16 are adjacent, whether linked o not, is removed. The upper end 152 of the opening 150 may be located a point 19, between point 19 and the upper end 12 of the tubular 20, or between points 19 and 17, The PATENT Attorney Docket No. 0186.0028-PCT lower end 154 of the opening 150 may be located at point 17, between point 17 and the lower end 14 of the tubular 20, or between points 17 and 19. Ribs 160 are created by the material of the tubular 20 that, remains between the openings 150 after the openings 150 are created in the tubular 20. A first collar .162 and the second collar 164 are created by the material of the tubular 20 that remains above the upper end 152. of the openings 150 and below the lower end 154 of the openings 150 after the openings 150 are created in the tubular 20. While only the tubular with linear sides is depicted any created tubular may be used. The opening 150 may be formed through tubular 50 in a similar manner,

[0036] Figure 13 depicts a tubular 140 having an upper end 142, a lower end 144, openings 146, ribs 148, opening upper end 152, opening lower end 154, and upper coilar 156, and a lower collar 158. The ribs 148 have been expanded radially outward so that each of the ribs 148 will have at least one portion, an apex 161 of each of the ribs 148 that extends further radially outward than other portions of each the ribs 148 or of the tubular 140. So that a portion of each of the ribs 348, typically the apex 161 of each rib 148, will contact the wellbore o other tubular wall (not shown). In many instances at least a portion of each of the ribs 148 will be treated to enhance the ability of each of the ribs 148 to elastically deform. Any treatment process such as heat, treating, cold treating, curing, or any other process known in the industry may be used to enhance the ability each of the ribs 148 to elastically deform. f0037] in practice it is generally understood that the tubular 140 (i.e. a centralizer) as depicted in figure 13 is placed on a separate tubular so that the collar 158, collar 156, and ribs 148 are generally coaxial with the separate tubular and that each collar 158 and 156 has a reasonably tight fit on the separate tubular. The centralizer may be allowed to slide up or down the separate tubular within the limits of couplings that are typically attached at either end of the separate tubular although more preferably at least one of the collars 158 or 156 are attached to the separate tubular. Collars 158 or 1.56 may be attached to the separate tubular by any attachment system known in the industry. For instance the collars 158 or 156 may be attached to the separate tubular as disclosed by US patent applications 1 1/749544, 12/042989, 12/756173, 13/019084, 13/476807, and .12/913495 which are each incorporated by reference herein. The tubular 20, 50, 70, 80. or 90 placed on a separate tubular so that the collars and the ribs may be generall coaxial with the separate tubular. The tubular 20, 50, 70, 80, or 90 ma be a centralizer in a similar manner as described in relation to Figure 1 .

[0038] Bottom, lower, or downward denotes the end of the well or device away from the surface, including movement away from the surface. Top. upwards, raised, or higher denotes the end of the well or the device toward the surface, including movement towards the PATENT Attorney Docket No. 01 86.0028-PCT surface. While the embodiments are described with reference to various implementations and exploitations, it will be understood thai these embodiments are illustrative and that the scope of the inventive subject matter is not limited to them. Many variations, modifications, additions and improvements are possible.

0039J Plural instances may be provided for components, operations or structures described herein as a single instance, in general, structures and functionality presented as separate components in the exemplary configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the inventive subject matter.

{0040] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims tha follow.