Patent Grant
10493515
In hydrocarbon drilling operations, centralizers may be secured at spaced intervals along a tubular string. The centralizers provide a radial stand-off between the tubular and the wall of a drilled borehole in which the tubular is installed. Bow spring centralizers generally include collars defining a bore therethrough to receive the tubular, and a plurality of angularly-spaced bow springs biased to provide stand-off. Bow spring centralizers may collapse to pass, e.g., along with the tubular, through restrictions, and deploy to provide a generally uniform annulus between the exterior of the tubular and the wall of the borehole. Thus, for example in cementing operations, a bow spring centralizer promotes uniform and continuous distribution of cement slurry around the tubular string for cementing the tubular within a targeted interval of the borehole. The resulting cement liner may reinforce the tubular string, isolate the tubular from corrosive formation fluids and prevent fluid flow between penetrated geologic formations.
Currently, when forming a one-piece centralizer, an odd number of bow springs are usually required to be formed. This is because forming tool is positioned between opposing bow springs and expanded, thereby expanding the bow springs outward. With this process and tool, issues arise in forming a one-piece centralizer. For example, the forming process may not have the required stroke/length to appropriately form the opposite bow and therefore would not achieve desired dimensions of the centralizer, e.g., geometry, length, and height. Therefore, there is a need for devices and processes for forming bow springs in one-piece centralizers.
Embodiments of the disclosure may provide a method that includes positioning a centralizer including a plurality of bow springs on a forming device. The forming device may include a press, a movable arm, and a form coupled to movable arm. The form is configured to shape the plurality of bow springs, and a first bow spring of the plurality of bow springs is positioned on the form. The method may also include actuating the press to apply pressure to the first bow spring between the form and the press. Additionally, the method may include repositioning the centralizer to position a second bow spring of the plurality of bow springs on the form, and actuating a press to apply pressure to the second bow spring.
Embodiments of the disclosure may also provide a device that includes a stand for receiving a centralizer having a plurality of bow springs. The stand may include a leg and an arm configured to receive the centralizer. The arm is movably coupled to leg to allow the arm to rotate about an axis of the leg. The stand may also include a form coupled to the arm, wherein the form is configured to shape the plurality of bow springs. The device may also include a press configured to apply pressure to at least one of the plurality of bow springs to shape the at least one of the plurality of bow springs on the form, and a control coupled to the press. The control is configured to actuate to the press to apply pressure to the at least one of the plurality of bow springs
Embodiments of the disclosure may further provide a method including forming a one-piece centralizer comprising a first collar, a second collar, and a plurality of bow springs, and cutting the first collar and the second collar of the one-piece centralizer along a central axis to form two separate halves of the one-piece centralizer. The method may also include forming a plurality of hinges on each of the two halves of the one-piece centralizer, and reforming the one-piece centralizer by attaching the two halves at the plurality of hinges.
Various features of the embodiments may be more fully appreciated, as the same become better understood with reference to the following detailed description of the embodiments when considered in connection with the accompanying figures, in which:
For simplicity and illustrative purposes, the principles of the present teachings are described by referring mainly to examples of various embodiments thereof. However, one of ordinary skill in the art would readily recognize that the same principles are equally applicable to, and may be implemented in, all types of information and systems, and that any such variations do not depart from the true spirit and scope of the present teachings. Moreover, in the following detailed description, references are made to the accompanying figures, which illustrate specific examples of various embodiments. Electrical, mechanical, logical and structural changes may be made to the examples of the various embodiments without departing from the spirit and scope of the present teachings. The following detailed description is, therefore, not to be taken in a limiting sense and the scope of the present teachings is defined by the appended claims and their equivalents.
Aspects of the present disclosure are directed to devices and process for forming bow springs in one-piece centralizers. The device includes a swing arm that is configured to receive the one-piece centralizer. The device and process using the device include mechanically applying, with a press, an external load onto an un-formed bow spring positioned on a form of the swing arm. When the load is applied with the device, the un-formed centralizer is forced downward to allow the bow spring to take the desired form/shape/geometry, length, and height of a formed bow spring. The forming process allows a centralizer with either an even or odd number of bows to be formed.
One example of a one-piece centralizer is a centralizer that is formed from a single tubular, e.g., by cutting, as described in U.S. Pat. No. 7,845,061. Another example of a one-piece centralizer is a centralizer formed from a flat plate that is rolled and then cut to form the end collars and ribs thereof, as disclosed in U.S. Patent Publication No. 2014/0096888. Still another example of a one-piece centralizer is formed as a flat plate, which is then cut and then rolled. The above-listed patent and publication are incorporated herein by reference to the extent not inconsistent with the present disclosure.
As illustrated in
The centralizer forming machine 100 may include a platform 104. The platform 104 may be coupled to the parallel legs 103 to form a level platform to hold a stand 106. In some embodiments, the platform 104 may be moveably coupled to the parallel legs 103 by bolts 107. The bolts 107 may be removed to allow the platform 104 to be moved vertically upwards or downwards on the parallel legs 103.
The stand 106 may be formed of parallel and vertical legs 108 and 109. The legs 108 and 109 may support a swing arm 110. The swing arm 110 may be coupled to the leg 108 by a hinge 112. The hinge 112 may allow the swing arm 110 to swing about the axis of the leg 108. In some embodiments, the hinge 112 may include a bolt or pin coupled to the leg 108 and a circular hole in the swing arm 110 to receive the bolt or pin. The hinge 112 may allow the swing arm 110 to open perpendicular to a plane of the centralizer forming machine 100. The movement of the swing arm 110 may allow a one-piece centralizer to be positioned on the swing arm 110. The swing arm 110 may be coupled to the leg 109 by a locking pin 114. The locking pin 114 allows the swing arm 110 to be secured to the leg 109 to form a solid stand during the formation of bow springs of the one-piece centralizer.
The hinge 112 may allow the swing arm 110 to a swing across a range of angles, allowing the one-piece centralizer to be placed on the swing arm 110. In some embodiments, for example, the hinge 112 may allow the swing arm 110 to rotate to a point that is approximately 90 degrees perpendicular to a plane of the centralizer forming machine 100. But in other embodiments, the hinge 112 may allow the swing arm 110 to rotate to other angles.
The centralizer forming machine 100 may also include a press 116 and a form 118. The press 116 and the form 118 are configured to shape the bow spring of the one-piece centralizer when placed on the form 118. The press 116 may be coupled to the top cross bar 105. The form 118 may be coupled to the swing arm 110. In some embodiments, to form a bow spring, the swing arm 110 may be opened (e.g., swung away from the plane of the centralizer forming machine 100 by some degree) to allow positioning of a bow spring of a one-piece centralizer on the form 118, without disassembling or otherwise breaking-down the one-piece centralizer. Thus, the one-piece centralizer may be positioned around the swing arm 110, such that the swing arm 110 extends, e.g., at least partially between the end collars of the one-piece centralizer. Once placed, the swing arm 110 may be closed and secured in place by the locking pin 114. When locked by the locking pin 114, the form 118, with the positioned bow spring, may be positioned directly below the press 116.
The press 116 may be shaped as a concave curve to form the shape of a bow spring of the one-piece centralizer. The form 118 may be configured in a convex curve that mirrors the concave curve of the press 116. Thus, the form 118 may be disposed radially within the one-piece centralizer, while the press 116 may be formed radially outside of the one-piece centralizer. The press 116, when activated, moves onto the form 118, e.g., vertically, as shown. The press 116 and the form 118 may be positioned on the centralizer forming machine 100 so that convex and concave curves mate when the press 116 moves e.g., descends) onto the form 118. When a bow spring of the one-piece centralizer is positioned on the form 118, the press 116 compresses the bow spring against the form 118. The press 116 may apply a load on the bow spring to form the bow spring in the shape of the form 118. Once formed, the bow spring of the one-piece centralizer may have an outward bow in the shape of the form 118. The form 118 may be removed from the swing arm 110 and replaced with another form of a different size. In one embodiment, the one-piece centralizer may have different shaped bow springs by using different sized forms.
As such, the centralizer forming machine 100 may deform each bow spring in turn, without pushing against an opposing bow spring or, in this case, any adjacent bow springs. In some embodiments, however, the press 116 and/or form 118 may optionally be configured to receive two or more bow springs at a time, e.g., adjacent bow springs, so as to simultaneously expand two or three bow springs. In such case, however, the deformation of the two or more bow springs may occur without employing an opposing part of the centralizer to take up any reaction forces.
Although illustrated as pivoting or swinging through a horizontal plane, it will be appreciated that the swing arm 110 may swing through a vertical plane, or a plane disposed at any orientation between horizontal and vertical. Moreover, the press 116 may move perpendicular to the plane in which the swing arm 110 swings, whether vertical, horizontal, or therebetween. In other embodiments, the press 116 may move in a direction that is not perpendicular to the plane in which the swing arm 110 swings. In another embodiment, the form 118 may be moved toward the press 116.
The centralizer forming machine 100 may also include a control 120. The control 120 may be configured to activate the press 116. For example, the control 120 may be configured to cause the press vertically upwards and downwards (or otherwise toward and away from the press 116) in the centralizer forming machine 100. As illustrated, for example, the control 120 may be configured as one or more foot pedals. The foot pedals may be configured to actuate the press 116 upwards and downwards, respectively, by applying pressure with the ball or heal of a foot to the foot pedals. The foot pedal is one example of a control 120. The control 120 may be any type of electronic and/or mechanical and/or hydraulic and/or pneumatic control that actuates the press 116, for example, an electrical switch, electrical button, mechanical switch, mechanical button, etc.
Once the process begins, in 202, the locking pin may be removed and the swing arm of the stand may be opened. For example, as illustrated in
In 204, the centralizer may be secured to the swing arm and a bow spring of the centralizer may be position on the form. For example, as illustrated in
In 206, the swing arm may be closed and the locking pin may be secured. For example, as illustrated in
In 208, the press may be activated to form the bow spring of the one-piece centralizer. For example, as illustrated in
In 210, it may be determined whether additional bow springs are to be formed. If additional bow springs are to be formed, in 212, the centralizer may be rotated to position the next bow spring to be formed on the form. For example, as illustrated in
Stages 208-212 may be repeated until some or all of the bow springs 304 have been formed. If all the bow springs have been formed, in 214, the locking pin may be removed, the swing arm may be opened, and the centralizer may be removed.
In embodiments described above, any type of one-piece centralizer may be utilized with the centralizer forming machine 100 and process 200. As used herein, a one-piece centralizer may include any centralizer formed in a cylindrical shape in which bow springs are to be formed. The centralizer forming machine 100 may be reconfigured to accommodate one-piece centralizers of different shapes and sizes. For example, in some embodiments, the centralizer forming machine 100 may be reconfigured with different shape and sized versions of the press 116 and the form 118 to accommodate one-piece centralizers of different shapes and sizes. In some embodiments, the platform 104 may be moved upwards and downwards to accommodate one-piece centralizers of different shapes and sizes.
As described above, the centralizer forming machine 100 may be configured so that the swing arm 110 rotates about a vertical axis of the leg 108. In this example, the press 116 and the form may be positioned such that the press 116 moves vertically to engage the form 118. This configuration is one example of the configuration of the components of the centralizer forming machine 100. The components may be configured in any orientation and position in the centralizer forming machine 100 that allow the swing arm 110 to move to review a one-piece centralizer and position the bow springs such that the press 116 can engage the form 118. In some embodiments, for example, the components of the centralizer forming machine may be configured so that the swing arm 110 rotates about a horizontal axis of the leg 108. For example, the stand 106 and/or platform may be coupled vertically to one of the legs 103 of the housing 102. In this example, the press 116 and the form may be positioned such that the press 116 moves horizontally to engage the form 118.
In some embodiments, the one-piece centralizer may be formed of one or more hinged centralizer arms.
As illustrated in
Once the method 500 begins, in 502, centralizer arm patterns may be formed on a sheet of material. The centralizer arm patterns may be formed on the sheet of material in order to maximize the usage of the sheet for material. That is, the patterns may be placed on the sheet of material so that, once the centralizers arms are cut from the sheet of material, the scrap material produced is minimized.
For example, as illustrated in
As illustrated, to maximize the usage of the sheet of material 602, the “I” shape patterns may be interlocked and arranged in different alignments so that the usage of the sheet of material 602 is maximized. The placement of the “I” shape patterns may be selected so that the amount of scrap produced is minimized. In some embodiments, a different sized centralizer arm pattern 606 may be formed in the sheet of material 602. By using different sized centralizer arm pattern 606, the usage of the sheet of material 602 may be maximized. In some embodiments, the centralizer arm patterns 604 may also include hinge finger patterns 607.
While
In some embodiments, for example, the sheet of material 602 may be a metal or metal alloy, for example, steel, aluminum, heat treatable steel, etc. The sheet of material 602 may formed to a thickness of the desired thickness of the centralizer arm. In some embodiments, the sheet of material 602 may be of a thickness that allows hinges to be formed in the collars of the centralizer arms and allows the bow springs to be formed. For example, the sheet of material 602 may have a thickness of between about 1/32 inch, about 1/16 inch, or about 1/10 inch and about ⅙ inch, about ⅕ inch, or about ¼ inch thick (e.g., approximately ⅛ inch thick).
In 504, the centralizer arms may be cut from the sheet of material. In 506, hinge fingers may be cut into the centralizer arms. For example, in some embodiments, the centralizer arms may be cut from the centralizer arm patterns 604 and 606 using a laser. Likewise, for example, the centralizer arms may be cut from the centralizer arm patterns 604 and 606 using a punch press or a water-jet cutter. In some embodiments, the centralizer arm patterns 604 and 606 may include the finger patterns 607 and the hinge fingers may be cut as the centralizer arms are cut. In some embodiments, the hinge fingers may be cut after the centralizer arms are cut from the sheet of material 602.
For example,
In 508, a hinge may be formed in the centralizer arm from the hinge fingers. In some embodiments, for example, the hinges may be formed by rolling the hinge fingers 612 of the collars 610 to form hinges.
In 510, a centralizer may be formed from the centralizer arms. For example, two or more the centralizer arms 608 may be joined to form a one-piece centralizer. The two or more centralizer arms 608 may be joined by welding, bolts, pins, and combinations thereof.
In 512, bow springs may be formed in the centralizer arms of the constructed centralizer. In some embodiments, the bow springs may be formed utilizing the centralizer forming device 100 and process 200 described above. Once the centralizer is formed, the centralizer may be heat treated.
In some embodiments, in an alternative to stages 510 and 512, the centralizer and bow springs may be formed by another heating and forming process. For example, the centralizer arm 608 may be placed in a heating furnace. Once heated, the centralizer arm 608 may be placed in a press with dies conforming to the desired shape. After formation, the heated centralizer arm may be quenched and tempered. In some embodiments, the centralizer arm 608 may include two or more bow springs 614.
In some embodiments, hinged centralizer arms may be formed from a solid, one-piece centralizer.
Once the method 700 begins, in 702, a one-piece centralizer may be formed. The one-piece centralizer may be formed of a solid body that includes two collars coupled by a number of bow springs. The one-piece centralizer may be formed using any processes and devices to form a one-piece centralizer.
For example, as illustrated in
In 704, the one-piece centralizer may be cut into two or more parts, for example, as shown, two halves. The one-piece centralizer may be cut into approximately equal halves by cutting the one-piece centralizer at the upper and lower collars along a central axis of the one-piece centralizer. The one-piece centralizer may be cut using any type of processes or devices, for example, a laser, a saw, water-jet, a cutting torch, etc.
For example, as illustrated in
In 706, hinges may be formed on each of the two halves of the centralizer. The hinges may include eight hinges formed on each half of centralizer. The hinges may be formed on the collars of each half at the locations the collars were cut. The hinges may be formed using any conventional processes or devices. In some embodiments, the hinges may be formed separately and connected to the collars, e.g., welded, either on the exterior of the centralizer, on the interior of the centralizer, in the space created by cutting the centralizer in half, or any combination thereof. In some embodiments, the hinges may be formed from the material of the centralizer. For example, the hinges may be cut from the material of the centralizer.
For example, as illustrated
In 708, the centralizer may be constructed from the two halves. The hinges of each half of the centralizer may be joined to reform the centralizer into one piece. The hinges may be joined using any process or device. For example, the hinges may be joined by a pin or other connector. The hinges allow the centralizer half 810 to rotate (or move) relative to the centralizer half 812. The movement of the centralizer halves 810, 812 allows the centralizer 800 to be placed around a tubular without sliding the centralizer onto the tubular from the end of the tubular. In some embodiments, the hinges may be welded together after being positioned on a tubular.
In the method 700 described above, the bow springs, for example, bow springs 806, may be shaped utilizing the processes and devices described above in
While the teachings have been described with reference to examples of the embodiments thereof, those skilled in the art will be able to make various modifications to the described embodiments without departing from the true spirit and scope. The terms and descriptions used herein are set forth by way of illustration only and are not meant as limitations. In particular, although the method has been described by examples, the steps of the method may be performed in a different order than illustrated or simultaneously. Furthermore, to the extent that the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof are used in either the detailed description and the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.” As used herein, the terms “one or more of” and “at least one of” with respect to a listing of items such as, for example, A and B, means A alone, B alone, or A and B. Further, unless specified otherwise, the term “set” should be interpreted as “one or more.”
Also, the term ‘couple’ or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices, components, and connections. In addition, as used herein, the terms “axial” and “axially” generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms “radial” and “radially” generally mean perpendicular to the central axis. For instance, an axial distance refers to a distance measured along or parallel to the central axis, and a radial distance means a distance measured perpendicular to the central axis. Those skilled in the art will recognize that these and other variations are possible within the spirit and scope as defined in the following claims and their equivalents.
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