Claims
- 1. An apparatus for forming an expanded connection in a wellbore, the apparatus comprising:
a first tubular radially expandable outward into contact with an inner wall of a second tubular upon the application of an outwardly directed force supplied to an inner surface of the first tubular; and a plurality of outwardly extending formations formed on an outer surface of the first tubular, the formations constructed and arranged to provide a frictional relationship between the first tubular and the second tubular while leaving a fluid path when the first tubular is expanded to engage the inner wall of the second tubular.
- 2. The apparatus of claim 1, further including gripping means formed on the plurality of formations for further increasing friction between the first and second tubulars upon expansion of the first tubular.
- 3. The apparatus of claim 2, wherein the gripping means define raised members extending outward from an outer surface of the plurality of formations.
- 4. The apparatus of claim 3, wherein the raised members define inserts that are press-fitted, epoxied, soldered, threaded, or combinations thereof into preformed apertures in the outer surface of the plurality of formations.
- 5. The apparatus of claim 4, wherein the inserts are fabricated from a hardened metal alloy.
- 6. The apparatus of claim 4, wherein the inserts are fabricated from a ceramic material.
- 7. The apparatus of claim 4, wherein the inserts define a plurality of buttons having teeth.
- 8. The apparatus of claim 1, further including at least one tubular seal disposed on the outer surface of the first tubular, wherein the at least one tubular seal is radially expandable to create an annular fluid seal between the first and second tubulars.
- 9. The apparatus of claim 8, wherein the at least one tubular seal is fabricated from an elastomeric material.
- 10. The apparatus of claim 8, wherein the at least one tubular seal is fabricated from a metallic material.
- 11. The apparatus of claim 1, wherein an expander tool supplies the outwardly directed force.
- 12. The apparatus of claim 11, wherein the expander tool includes a plurality of ribs on an outer surface thereof, the ribs define a first outer diameter at a first location smaller than a second outer diameter at a second location.
- 13. The apparatus of claim 12, wherein the expander tool is oriented in the first tubular such that the plurality of ribs are positioned between the plurality of formations on the first tubular.
- 14. The apparatus of claim 12, wherein the expander tool further includes a plurality of selectively extendable elements to substantially fill a space between the plurality of ribs resulting in the expander tool having a substantially uniform outer diameter.
- 15. A method of completing a wellbore, comprising:
positioning a first tubular coaxially within a portion of a second tubular, the first tubular including a plurality of outwardly extending formations on an outer surface thereof to provide a frictional relationship between the first tubular and the second tubular while leaving a fluid path through the expanded connection; positioning an expander tool within the first tubular at a depth proximate the plurality of formations on the first tubular; urging the expander tool axially through the first tubular to expand the first tubular into frictional contact with the second tubular; and forming a fluid path through an overlapped portion between the first and second tubulars.
- 16. The method of claim 15, wherein the expander tool includes a plurality of ribs formed circumferentially around an outer surface thereof.
- 17. The method of claim 16, further including orientating the expander tool such that the plurality of ribs are misaligned with the plurality of formations.
- 18. The method of claim 15, further including circulating cement through the wellbore and subsequently through the fluid path to secure the first tubular in the wellbore.
- 19. The method of claim 15, wherein at least one tubular seal is disposed around the first tubular.
- 20. The method of claim 19, further including expanding the at least one tubular seal to close off the fluid path and create a fluid seal between the first and second tubulars.
- 21. An apparatus for forming an expandable connection in a wellbore, the apparatus comprising:
a first tubular radially expandable outward into contact with an inner wall of a second tubular upon the application of an outwardly directed force supplied to an inner surface of the first tubular; and a complaint slip system formed on an outer surface of the first tubular, the compliant slip system constructed and arranged to permit the first tubular to conform to the inner wall of the second tubular while providing a frictional relationship between the first tubular and the second tubular.
- 22. The method of claim 21, wherein the compliant slip system comprises a plurality of ribs with a plurality of flutes therebetween.
- 23. The method of claim 21, wherein the compliant slip system comprises a plurality of griping members having a reduced portion that is constructed and arranged to fail at a predetermined load.
- 24. The method of claim 21, wherein the compliant slip system comprises a plurality of holes formed in the first tubular that are constructed and arranged to collapse at a predetermined load.
- 25. A method of compliantly expanding a tubular into contact with a casing wall, comprising:
placing the tubular at a predefined location within the casing, the tubular having at least two outwardly extending, substantially longitudinal formations formed on an outer surface thereof; and passing an expander tool through an inside diameter of the tubular to expand its outer diameter, the expander tool having at least two substantially longitudinal ribs formed on an outer surface thereof, the expander tool centered within the tubular in a manner whereby the at least two ribs are misaligned with the at least two formations providing a compliant force between the at least two formations and the casing wall.
- 26. The method of claim 25, further including circulating cement between the expanded tubular and the casing wall, the cement traveling in a fluid path formed between the at least two formations.
- 27. The method of claim 26, further including sealing the fluid path.
- 28. An apparatus for expanding a tubular, comprising:
a body; and a plurality of outwardly extending substantially longitudinal formations formed on the body, the plurality of formations defining a first smaller outer diameter of the body and a second larger outer diameter of the body.
- 29. The apparatus of claim 28, wherein the first smaller outer diameter is defined at a first end of the body.
- 30. The apparatus of claim 29, further including a second smaller diameter of the body defined opposite the first end.
- 31. The apparatus of claim 28, wherein a tapered interface is formed between the first smaller outer diameter and the second larger outer diameter.
- 32. The apparatus of claim 28, wherein a plurality of substantially longitudinal flutes are equally spaced around a circumference of the body between the plurality of formations.
- 33. The apparatus of claim 32, wherein the plurality of substantially longitudinal flutes extend along the entire length of the body.
- 34. The apparatus of claim 32, further including a plurality of selectively extendable elements disposed in the plurality of substantially longitudinal flutes.
- 35. The apparatus of claim 34, wherein the plurality of selectively extendable elements extend radially outward upon activation to substantially fill the plurality of substantially longitudinal flutes resulting in the apparatus having a substantially uniform outer diameter.
- 36. The apparatus of claim 28, wherein the plurality of formations are constructed and arranged to be orientated in an alternating relationship between a plurality of ribs formed on a tubular to expand the tubular into contact with a larger tubular while leaving a fluid path therebetween.
- 37. An expandable apparatus for expanding a tubular, comprising:
an upper member having a tapered portion on an outer surface thereof; a lower member having an oppositely tapered portion on an outer surface thereof, whereby the tapered portions are movable towards each other; and a plurality of pads disposed between the tapered portions, the pads extendable outwards to increase an outer diameter of the apparatus when the tapered portions are moved toward each other.
- 38. The expandable apparatus of claim 37, wherein a thread drive moves the tapered portions toward each other.
- 39. The expandable apparatus of claim 37, wherein a hydraulic cylinder moves the tapered portions toward each other.
- 40. The expandable apparatus of claim 37, wherein the plurality of pads are circumferentially spaced around the expandable apparatus.
- 41. The expandable apparatus of claim 40, wherein a plurality of spaces are formed between the plurality of pads.
- 42. The expandable apparatus of claim 41, further including an extendable component to fill the plurality of spaces.
- 43. The expandable apparatus of claim 42, wherein the extendable component is a dog assembly.
- 44. A method of completing a wellbore, comprising:
positioning a first tubular coaxially within a portion of a second tubular, the first tubular including a plurality of outwardly extending formations on an outer surface thereof to provide a frictional relationship between the first tubular and the second tubular while leaving a fluid path through the expanded connection; positioning an expandable apparatus within the first tubular at a depth proximate the plurality of formations on the first tubular, the expandable apparatus includes a plurality of selectively extendable members; activating the expandable apparatus by extending the plurality of selectively extendable members radially outward; urging the expandable apparatus axially through the first tubular to expand the first tubular into frictional contact with the second tubular; and forming a fluid path through an overlapped portion between the first and second tubulars.
- 45. The method of claim 44, wherein a plurality of flutes are formed between the plurality of formations on the outer surface of the first tubular.
- 46. The method of claim 45, further including orientating the expandable apparatus such that the plurality of selectively extendable members are aligned with the plurality of flutes.
- 47. The method of claim 44, wherein the expandable apparatus further includes a forgiving member disposed behind the plurality of pads, whereby the forgiving member is constructed and arranged to deform at a predetermined load.
- 48. The method of claim 44, wherein at least one tubular seal is disposed around the first tubular.
- 49. The method of claim 48, further including activating an extendable component to fill a plurality of spaces between the plurality of pads.
- 50. The method of claim 49, further including closing the fluid path and creating a fluid seal between the first and second tubulars.
- 51. The method of claim 50, wherein the fluid path is closed by expanding the at least one tubular seal with the expandable apparatus and the extendable component.
- 52. The method of claim 44, wherein the plurality of selectively extendable members are a plurality of pads that are radially extendable upon convergence of at least two cones.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 10/428,163, entitled SOLID EXPANDABLE HANGER WITH COMPLIANT SLIP SYSTEM, filed on May 1, 2003, which patent application is herein incorporated by reference.
Continuation in Parts (1)
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Number |
Date |
Country |
Parent |
10428163 |
May 2003 |
US |
Child |
10458064 |
Jun 2003 |
US |