Method of operating an apparatus for radially expanding a tubular member

Information

  • Patent Grant
  • 6631769
  • Patent Number
    6,631,769
  • Date Filed
    Friday, February 15, 2002
    22 years ago
  • Date Issued
    Tuesday, October 14, 2003
    21 years ago
Abstract
A method of operating an apparatus for radially expanding a tubular member.
Description




BACKGROUND OF THE INVENTION




This invention relates generally to wellbore casings, and in particular to wellbore casings that are formed using expandable tubing.




Conventionally, when a wellbore is created, a number of casings are installed in the borehole to prevent collapse of the borehole wall and to prevent undesired outflow of drilling fluid into the formation or inflow of fluid from the formation into the borehole. The borehole is drilled in intervals whereby a casing which is to be installed in a lower borehole interval is lowered through a previously installed casing of an upper borehole interval. As a consequence of this procedure the casing of the lower interval is of smaller diameter than the casing of the upper interval. Thus, the casings are in a nested arrangement with casing diameters decreasing in downward direction. Cement annuli are provided between the outer surfaces of the casings and the borehole wall to seal the casings from the borehole wall. As a consequence of this nested arrangement a relatively large borehole diameter is required at the upper part of the wellbore. Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings. Moreover, increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.




Conventionally, at the surface end of the wellbore, a wellhead is formed that typically includes a surface casing, a number of production and/or drilling spools, valving, and a Christmas tree. Typically the wellhead further includes a concentric arrangement of casings including a production casing and one or more intermediate casings. The casings are typically supported using load bearing slips positioned above the ground. The conventional design and construction of wellheads is expensive and complex.




The present invention is directed to overcoming one or more of the limitations of the existing procedures for forming wellbores and wellheads.




SUMMARY OF THE INVENTION




According to one aspect of the present invention, a method of operating an apparatus for radially expanding a tubular member including an expansion cone is provided that includes lubricating the interface between the expansion cone and the tubular member, centrally positioning the expansion cone within the tubular member, and applying a substantially constant axial force to the tubular member prior to a beginning of a radial expansion process.




According to another aspect of the present invention, a method of operating an apparatus for radially expanding and plastically deforming a tubular member including an annular expansion cone is provided that includes coupling the tubular member and the annular expansion cone to a support member, applying a substantially constant axial force of between about 500 to 2,000 lbf from the support member to the annular expansion cone to preload the annular expansion cone against the interior surface of the tubular member prior to the radial expansion and plastic deformation of the tubular member to seal the interface between the annular expansion cone and the tubular member, pumping a lubricant into the interface between the annular expansion cone and the tubular member, centrally positioning the annular expansion cone within the tubular member, and during the radial expansion and plastic deformation of the tubular member, displacing the annular expansion cone relative to the support member.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1A

is a cross-sectional view illustrating the placement of an embodiment of an apparatus for creating a casing within a well borehole.





FIG. 1B

is a cross-sectional view illustrating the injection of a fluidic material into the well borehole of FIG.


1


A.





FIG. 1C

is a cross-sectional view illustrating the injection of a wiper plug into the apparatus of FIG.


1


B.





FIG. 1D

is a fragmentary cross-sectional view illustrating the injection of a ball plug and a fluidic material into the apparatus of FIG.


1


C.





FIG. 1E

is a fragmentary cross-sectional view illustrating the continued injection of fluidic material into the apparatus of

FIG. 1D

in order to radially expand a tubular member.





FIG. 1F

is a cross-sectional view of the completed wellbore casing.





FIG. 2A

is a cross-sectional illustration of a portion of an embodiment of an apparatus for forming and/or repairing a wellbore, pipeline or structural support.





FIG. 2B

is an enlarged illustration of a portion of the apparatus of FIG.


2


A.





FIG. 2C

is an enlarged illustration of a portion of the apparatus of FIG.


2


A.





FIG. 2D

is an enlarged illustration of a portion of the apparatus of FIG.


2


A.





FIG. 2E

is a cross-sectional illustration of the apparatus of FIG.


2


A.





FIG. 2F

is a cross-sectional illustration of another portion of the apparatus of FIG.


2


A.





FIG. 2G

is an enlarged illustration of a portion of the apparatus of FIG.


2


F.





FIG. 2H

is an enlarged illustration of a portion of the apparatus of FIG.


2


F.





FIG. 2I

is an enlarged illustration of a portion of the apparatus of FIG.


2


F.





FIG. 2J

is a cross-sectional illustration of another portion of the apparatus of FIG.


2


A.





FIG. 2K

is an enlarged illustration of a portion of the apparatus of FIG.


2


J.





FIG. 2L

is an enlarged illustration of a portion of the apparatus of FIG.


2


J.





FIG. 2M

is an enlarged illustration of a portion of the apparatus of FIG.


2


J.





FIG. 2N

is an enlarged illustration of a portion of the apparatus of FIG.


2


J.





FIG. 2O

is a cross-sectional illustration of the apparatus of FIG.


2


J.





FIGS. 3A

to


3


D are exploded views of a portion of the apparatus of

FIGS. 2A

to


2


O.





FIG. 3E

is a cross-sectional illustration of the outer collet support member and the liner hanger setting sleeve of the apparatus of

FIGS. 2A

to


2


O.





FIG. 3F

is a front view of the locking dog spring of the apparatus of

FIGS. 2A

to


2


O.





FIG. 3G

is a front view of the locking dogs of the apparatus of

FIGS. 2A

to


2


O.





FIG. 3H

is a front view of the collet assembly of the apparatus of

FIGS. 2A

to


2


O.





FIG. 3I

is a front view of the collet retaining sleeve of the apparatus of

FIGS. 2A

to


2


O.





FIG. 3J

is a front view of the collet retaining adaptor of the of apparatus of

FIGS. 2A

to


2


O.





FIGS. 4A

to


4


G are fragmentary cross-sectional illustrations of an embodiment of a method for placing the apparatus of

FIGS. 2A-2O

within a wellbore.





FIGS. 5A

to


5


C are fragmentary cross-sectional illustrations of an embodiment of a method for decoupling the liner hanger, the outer collet support member, and the liner hanger setting sleeve from the apparatus of

FIGS. 4A

to


4


G.





FIGS. 6A

to


6


C are fragmentary cross-sectional illustrations of an embodiment of a method for releasing the lead wiper from the apparatus of

FIGS. 4A

to


4


G.





FIGS. 7A

to


7


G are fragmentary cross-sectional illustration of an embodiment of a method for cementing the region outside of the apparatus of

FIGS. 6A

to


6


C.





FIGS. 8A

to


8


C are fragmentary cross-sectional illustrations of an embodiment of a method for releasing the tail wiper from the apparatus of

FIGS. 7A

to


7


G.





FIGS. 9A

to


9


H are fragmentary cross-sectional illustrations of an embodiment of a method of radially expanding the liner hanger of the apparatus of

FIGS. 8A

to


8


C.





FIGS. 10A

to


10


E are fragmentary cross-sectional illustrations of the completion of the radial expansion of the liner hanger using the apparatus of

FIGS. 9A

to


9


H.





FIGS. 11A

to


11


E are fragmentary cross-sectional illustrations of the decoupling of the radially expanded liner hanger from the apparatus of

FIGS. 10A

to


10


E.





FIGS. 12A

to


12


C are fragmentary cross-sectional illustrations of the completed wellbore casing.





FIG. 13A

is a cross-sectional illustration of a portion of an alternative embodiment of an apparatus for forming and/or repairing a wellbore, pipeline or structural support.





FIG. 13B

is a cross-sectional view of the standoff adaptor of the apparatus of FIG.


13


A.





FIG. 13C

is a front view of the standoff adaptor of FIG.


13


B.





FIG. 13D

is a cross-sectional illustration of another portion of an alternative embodiment of the apparatus of FIG.


13


A.





FIG. 13E

is an enlarged view of the threaded connection between the liner hanger and the outer collet support member of FIG.


13


D.





FIG. 13F

is an enlarged view of the connection between the outer collet support member


645


and the liner hanger setting sleeve


650


of FIG.


13


D.





FIG. 13G

is a cross-sectional view of the liner hanger setting sleeve of FIG.


13


F.











DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS




An apparatus and method for forming a wellbore casing within a subterranean formation is provided. The apparatus and method permits a wellbore casing to be formed in a subterranean formation by placing a tubular member and a mandrel in a new section of a wellbore, and then extruding the tubular member off of the mandrel by pressurizing an interior portion of the tubular member. The apparatus and method further permits adjacent tubular members in the wellbore to be joined using an overlapping joint that prevents fluid and or gas passage. The apparatus and method further permits a new tubular member to be supported by an existing tubular member by expanding the new tubular member into engagement with the existing tubular member. The apparatus and method further minimizes the reduction in the hole size of the wellbore casing necessitated by the addition of new sections of wellbore casing.




A crossover valve apparatus and method for controlling the radial expansion of a tubular member is also provided. The crossover valve assembly permits the initiation of the radial expansion of a tubular member to be precisely initiated and controlled.




A force multiplier apparatus and method for applying an axial force to an expansion cone is also provided. The force multiplier assembly permits the amount of axial driving force applied to the expansion cone to be increased. In this manner, the radial expansion process is improved.




A radial expansion apparatus and method for radially expanding a tubular member is also provided. The radial expansion apparatus preferably includes a mandrel, an expansion cone, a centralizer, and a lubrication assembly for lubricating the interface between the expansion cone and the tubular member. The radial expansion apparatus improves the efficiency of the radial expansion process.




A preload assembly for applying a predetermined axial force to an expansion cone is also provided. The preload assembly preferably includes a compressed spring and a spacer for controlling the amount of compression of the spring. The compressed spring in turn is used to apply an axial force to the expansion cone. The preload assembly improves the radial expansion process by presetting the position of the expansion cone using a predetermined axial force.




A coupling assembly for controllably removably coupling an expandable tubular member to a support member is also provided. The coupling assembly preferably includes an emergency release in order to permit the coupling assembly to be decoupled in an emergency.




In several alternative embodiments, the apparatus and methods are used to form and/or repair wellbore casings, pipelines, and/or structural supports.




Referring initially to

FIGS. 1A-1F

, an embodiment of an apparatus and method for forming a wellbore casing within a subterranean formation will now be described. As illustrated in

FIG. 1A

, a wellbore


100


is positioned in a subterranean formation


105


. The wellbore


100


includes an existing cased section


110


having a tubular casing


115


and an annular outer layer of cement


120


.




As illustrated in

FIG. 1A

, an apparatus


200


for forming a wellbore casing in a subterranean formation is then positioned in the wellbore


100


.




The apparatus


200


preferably includes a first support member


205


, a manifold


210


, a second support member


215


, a tubular member


220


, a shoe


225


, an expansion cone


230


, first sealing members


235


, second sealing members


240


, third sealing members


245


, fourth sealing members


250


, an anchor


255


, a first passage


260


, a second passage


265


, a third passage


270


, a fourth passage


275


, a throat


280


, a fifth passage


285


, a sixth passage


290


, a seventh passage


295


, an annular chamber


300


, a chamber


305


, and a chamber


310


. In a preferred embodiment, the apparatus


200


is used to radially expand the tubular member


220


into intimate contact with the tubular casing


115


. In this manner, the tubular member


220


is coupled to the tubular casing


115


. In this manner, the apparatus


200


is preferably used to form or repair a wellbore casing, a pipeline, or a structural support. In a particularly preferred embodiment, the apparatus is used to repair or form a wellbore casing.




The first support member


205


is coupled to a conventional surface support and the manifold


210


. The first support member


205


may be fabricated from any number of conventional commercially available tubular support members. In a preferred embodiment, the first support member


205


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the first support member


205


further includes the first passage


260


and the second passage


265


.




The manifold


210


is coupled to the first support member


205


, the second support member


215


, the sealing members


235




a


and


235




b


, and the tubular member


200


. The manifold


210


preferably includes the first passage


260


, the third passage


270


, the fourth passage


275


, the throat


280


and the fifth passage


285


. The manifold


210


may be fabricated from any number of conventional tubular members.




The second support member


215


is coupled to the manifold


210


, the sealing members


245




a


,


245




b


, and


245




c


, and the expansion cone


230


. The second support member


215


may be fabricated from any number of conventional commercially available tubular support members. In a preferred embodiment, the second support member


215


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the second support member


215


further includes the fifth passage


285


.




The tubular member


220


is coupled to the sealing members


235




a


and


235




b


and the shoe


225


. The tubular member


220


is further movably coupled to the expansion cone


230


and the sealing members


240




a


and


240




b


. The first support member


205


may comprise any number of conventional tubular members. The tubular member


220


may be fabricated from any number of conventional commercially available tubular members. In a preferred embodiment, the tubular member


220


is further provided substantially as described in one or more of the following: (1) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, which issued as U.S. Pat. No. 6,328,113, which claimed benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/108,558, filed on Nov. 16, 1998, (2) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claimed benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/111,293, filed on Dec. 7, 1998, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/119,611, filed Feb. 11, 1999, (4) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/121,702, filed on Feb. 25, 1999, (5) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application No. 60/121,907, filed Feb. 26, 1999, (6) U.S. Provisional Patent Application Serial No. 60/124,042, filed on Mar. 11, 1999, (7) U.S. Provisional Patent Application Serial No. 60/131,106, filed on Apr. 26, 1999, (8) U.S. Provisional Patent Application Serial No. 60/137,998, filed on Jun. 7, 1999, (9) U.S. Provisional Patent Application Serial No. 60/143,039, filed on Jul. 9, 1999, and (10) U.S. Provisional Patent Application Serial No. 60/146,203, filed on Jul. 29, 1999, the disclosures of which are incorporated by reference.




The shoe


225


is coupled to the tubular member


220


. The shoe


225


preferably includes the sixth passage


290


and the seventh passage


295


. The shoe


225


preferably is fabricated from a tubular member. In a preferred embodiment, the shoe


225


is further provided substantially as described in one or more of the following: (1) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, which claimed benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/108,558, filed on Nov. 16, 1998, (2) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claimed benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/111,293, filed on Dec. 7, 1998, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/119,611, filed Feb. 11, 1999, (4) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/121,702, filed on Feb. 25, 1999, (5) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application No. 60/121,907, filed Feb. 26, 1999, (6) U.S. Provisional Patent Application Serial No. 60/124,042, filed on Mar. 11, 1999, (7) U.S. Provisional Patent Application Serial No. 60/131,106, filed on Apr. 26, 1999, (8) U.S. Provisional Patent Application Serial No. 60/137,998, filed on Jun. 7, 1999, (9) U.S. Provisional Patent Application Serial No. 60/143,039, filed on Jul. 9,1999, and (10) U.S. Provisional Patent Application Serial No. 60/146,203, filed on Jul. 29, 1999, the disclosures of which are incorporated by reference.




The expansion cone


230


is coupled to the sealing members


240




a


and


240




b


and the sealing members


245




a


,


245




b


, and


245




c


. The expansion cone


230


is movably coupled to the second support member


215


and the tubular member


220


. The expansion cone


230


preferably includes an annular member having one or more outer conical surfaces for engaging the inside diameter of the tubular member


220


. In this manner, axial movement of the expansion cone


230


radially expands the tubular member


220


. In a preferred embodiment, the expansion cone


230


is further provided substantially as described in one or more of the following: (1) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, which issued as U.S. Pat. No. 6,328,113, which claimed benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/108,558, filed on Nov. 16, 1998, (2) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claimed benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/111,293, filed on Dec. 7, 1998, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/119,611, filed Feb. 11, 1999, (4) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/121,702, filed on Feb. 25, 1999, (5) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application No. 60/121,907, filed Feb. 26, 1999, (6) U.S. Provisional Patent Application Serial No. 60/124,042, filed on Mar. 11, 1999, (7) U.S. Provisional Patent Application Serial No. 60/131,106, filed on Apr. 26, 1999, (8) U.S. Provisional Patent Application Serial No. 60/137,998, filed on Jun. 7, 1999, (9) U.S. Provisional Patent Application Serial No. 60/143,039, filed on Jul. 9, 1999, and (10) U.S. Provisional Patent Application Serial No. 60/146,203, filed on Jul. 29, 1999, the disclosures of which are incorporated by reference.




The first sealing members


235




a


and


235




b


are coupled to the manifold


210


and the tubular member


220


. The first sealing members


235




a


and


235




b


preferably fluidicly isolate the annular chamber


300


from the chamber


310


. In this manner, annular chamber


300


is optimally pressurized during operation of the apparatus


200


. The first sealing members


235




a


and


235




b


may comprise any number of conventional commercially available sealing members. In a preferred embodiment, the first sealing members


235




a


and


235




b


include O-rings with seal backups available from Parker Seals in order to provide a fluidic seal between the tubular member


200


and the expansion cone


230


during axial movement of the expansion cone


230


.




In a preferred embodiment, the first sealing member


235




a


and


235




b


further include conventional controllable latching members for removably coupling the manifold


210


to the tubular member


200


. In this manner, the tubular member


200


is optimally supported by the manifold


210


. Alternatively, the tubular member


200


is preferably removably supported by the first support member


205


using conventional controllable latching members.




The second sealing members


240




a


and


240




b


are coupled to the expansion cone


230


. The second sealing members


240




a


and


240




b


are movably coupled to the tubular member


220


. The second sealing members


240




a


and


240




b


preferably fludicly isolate the annular chamber


300


from the chamber


305


during axial movement of the expansion cone


230


. In this manner, the annular chamber


300


is optimally pressurized. The second sealing members


240




a


and


240




b


may comprise any number of conventional commercially available sealing members.




In a preferred embodiment, the second sealing members


240




a


and


240




b


further include a conventional centralizer and/or bearings for supporting and positioning the expansion cone


230


within the tubular member


200


during axial movement of the expansion cone


230


. In this manner, the position and orientation of the expansion cone


230


is optimally controlled during axial movement of the expansion cone


230


.




The third sealing members


245




a


,


245




b


, and


245




c


are coupled to the expansion cone


230


. The third sealing members


245




a


,


245




b


, and


245




c


are movably coupled to the second support member


215


. The third sealing members


245




a


,


245




b


, and


245




c


preferably fludicly isolate the annular chamber


300


from the chamber


305


during axial movement of the expansion cone


230


. In this manner, the annular chamber


300


is optimally pressurized. The third sealing members


245




a


,


245




b


and


240




c


may comprise any number of conventional commercially available sealing members. In a preferred embodiment, the third sealing members


245




a


,


245




b


, and


245




c


include O-rings with seal backups available from Parker Seals in order to provide a fluidic seal between the expansion cone


230


and the second support member


215


during axial movement of the expansion cone


230


.




In a preferred embodiment, the third sealing members


245




a


,


245




b


and


240




c


further include a conventional centralizer and/or bearings for supporting and positioning the expansion cone


230


around the second support member


215


during axial movement of the expansion cone


230


. In this manner, the position and orientation of the expansion cone


230


is optimally controlled during axial movement of the expansion cone


230


.




The fourth sealing member


250


is coupled to the tubular member


220


. The fourth sealing member


250


preferably fluidicly isolates the chamber


315


after radial expansion of the tubular member


200


. In this manner, the chamber


315


outside of the radially expanded tubular member


200


is fluidicly isolated. The fourth sealing member


250


may comprise any number of conventional commercially available sealing members. In a preferred embodiment, the fourth sealing member


250


is a RTTS packer ring available from Halliburton Energy Services in order to optimally provide a fluidic seal.




The anchor


255


is coupled to the tubular member


220


. The anchor


255


preferably anchors the tubular member


200


to the casing


115


after radial expansion of the tubular member


200


. In this manner, the radially expanded tubular member


200


is optimally supported within the wellbore


100


. The anchor


255


may comprise any number of conventional commercially available anchoring devices. In a preferred embodiment, the anchor


255


includes RTTS mechanical slips available from Halliburton Energy Services in order to optimally anchor the tubular member


200


to the casing


115


after the radial expansion of the tubular member


200


.




The first passage


260


is fluidicly coupled to a conventional surface pump, the second passage


265


, the third passage


270


, the fourth passage


275


, and the throat


280


. The first passage


260


is preferably adapted to convey fluidic materials including drilling mud, cement and/or lubricants at flow rates and pressures ranging from about 0 to 650 gallons/minute and 0 to 10,000 psi, respectively in order to optimally form an annular cement liner and radially expand the tubular member


200


.




The second passage


265


is fluidicly coupled to the first passage


260


and the chamber


310


. The second passage


265


is preferably adapted to controllably convey fluidic materials from the first passage


260


to the chamber


310


. In this manner, surge pressures during placement of the apparatus


200


within the wellbore


100


are optimally minimized. In a preferred embodiment, the second passage


265


further includes a valve for controlling the flow of fluidic materials through the second passage


265


.




The third passage


270


is fluidicly coupled to the first passage


260


and the annular chamber


300


. The third passage


270


is preferably adapted to convey fluidic materials between the first passage


260


and the annular chamber


300


. In this manner, the annular chamber


300


is optimally pressurized.




The fourth passage


275


is fluidicly coupled to the first passage


260


, the fifth passage


285


, and the chamber


310


. The fourth passage


275


is preferably adapted to convey fluidic materials between the fifth passage


285


and the chamber


310


. In this manner, during the radial expansion of the tubular member


200


, fluidic materials from the chamber


305


are transmitted to the chamber


310


. In a preferred embodiment, the fourth passage


275


further includes a pressure compensated valve and/or a pressure compensated orifice in order to optimally control the flow of fluidic materials through the fourth passage


275


.




The throat


280


is fluidicly coupled to the first passage


260


and the fifth passage


285


. The throat


280


is preferably adapted to receive a conventional fluidic plug or ball. In this manner, the first passage


260


is fluidicly isolated from the fifth passage


285


.




The fifth passage


285


is fluidicly coupled to the throat


280


, the fourth passage


275


, and the chamber


305


. The fifth passage


285


is preferably adapted to convey fluidic materials to and from the first passage


260


, the fourth passage


275


, and the chamber


305


.




The sixth passage


290


is fluidicly coupled to the chamber


305


and the seventh passage


295


. The sixth passage is preferably adapted to convey fluidic materials to and from the chamber


305


. The sixth passage


290


is further preferably adapted to receive a conventional plug or dart. In this manner, the chamber


305


is optimally fluidicly isolated from the chamber


315


.




The seventh passage


295


is fluidicly coupled to the sixth passage


290


and the chamber


315


. The seventh passage


295


is preferably adapted to convey fluidic materials between the sixth passage


290


and the chamber


315


.




The annular chamber


300


is fluidicly coupled to the third passage


270


. Pressurization of the annular chamber


300


preferably causes the expansion cone


230


to be displaced in the axial direction. In this manner, the tubular member


200


is radially expanded by the expansion cone


230


. During operation of the apparatus


200


, the annular chamber


300


is preferably adapted to be pressurized to operating pressures ranging from about 1000 to 10000 psi in order to optimally radially expand the tubular member


200


.




The chamber


305


is fluidicly coupled to the fifth passage


285


and the sixth passage


290


. During operation of the apparatus


200


, the chamber


305


is preferably fluidicly isolated from the annular chamber


300


and the chamber


315


and fluidicly coupled to the chamber


310


.




The chamber


310


is fluidicly coupled to the fourth passage


275


. During operation of the apparatus


200


, the chamber


310


is preferably fluidicly isolated from the annular chamber


300


and fluidicly coupled to the chamber


305


.




During operation, as illustrated in

FIG. 1A

, the apparatus


200


is preferably placed within the wellbore


100


in a predetermined overlapping relationship with the preexisting casing


115


. During placement of the apparatus


200


within the wellbore


100


, fluidic materials within the chamber


315


are preferably conveyed to the chamber


310


using the second, first, fifth, sixth and seventh fluid passages


265


,


260


,


285


,


290


and


295


, respectively. In this manner, surge pressures within the wellbore


100


during placement of the apparatus


200


are minimized. Once the apparatus


200


has been placed at the predetermined location within the wellbore


100


, the second passage


265


is preferably closed using a conventional valve member.




As illustrated in

FIG. 1

B, one or more volumes of a non-hardenable fluidic material are then injected into the chamber


315


using the first, fifth, sixth and seventh passages,


260


,


285


,


290


and


295


in order to ensure that all of the passages are clear. A quantity of a hardenable fluidic sealing material such as, for example, cement, is then preferably injected into the chamber


315


using the first, fifth, sixth and seventh passages


260


,


285


,


290


and


295


. In this manner, an annular outer sealing layer is preferably formed around the radially expanded tubular member


200


.




As illustrated in

FIG. 1C

, a conventional wiper plug


320


is then preferably injected into the first passage


260


using a non-hardenable fluidic material. The wiper plug


320


preferably passes through the first and fifth passages,


260


and


285


, and into the chamber


305


. Inside the chamber


305


, the wiper plug


320


preferably forces substantially all of the hardenable fluidic material out of the chamber


305


through the sixth passage


290


. The wiper plug


320


then preferably lodges in and fluidicly seals off the sixth passage


290


. In this manner, the chamber


305


is optimally fluidicly isolated from the chamber


315


. Furthermore, the amount of hardenable sealing material within the chamber


305


is minimized.




As illustrated in

FIG. 1D

, a conventional sealing ball or plug


325


is then preferably injected into the first passage


260


using a non-hardenable fluidic material. The sealing ball


325


preferably lodges in and fluidicly seals off the throat


280


. In this manner, the first passage


260


is fluidicly isolated from the fifth fluid passage


285


. Consequently, the injected non-hardenable fluidic sealing material passes from the first passage


260


into the third passage


270


and into the annular chamber


300


. In this manner, the annular chamber


300


is pressurized.




As illustrated in

FIG. 1E

, continued injection of a non-hardenable fluidic material into the annular chamber


300


preferably increases the operating pressure within the annular chamber


300


, and thereby causes the expansion cone


230


to move in the axial direction. In a preferred embodiment, the axial movement of the expansion cone


230


radially expands the tubular member


200


. In a preferred embodiment, the annular chamber


300


is pressurized to operating pressures ranging from about 1000 to 10000 psi. during the radial expansion process. In a preferred embodiment, the pressure differential between the first passage


260


and the fifth passage


285


is maintained at least about 1000 to 10000 psi. during the radial expansion process in order to optimally fluidicly seal the throat


280


using the sealing ball


325


.




In a preferred embodiment, during the axial movement of the expansion cone


230


, at least a portion of the interface between the expansion cone


230


and the tubular member


200


is fluidicly sealed by the sealing members


240




a


and


240




b


. In a preferred embodiment, during the axial movement of the expansion cone


230


, at least a portion of the interface between the expansion cone


230


and the second support member


215


is fluidicly sealed by the sealing members


245




a


,


245




b


and


240




c


. In this manner, the annular chamber


300


is optimally fluidicly isolated from the chamber


305


during the radial expansion process.




During the radial expansion process, the volumetric size of the annular chamber


300


preferably increases while the volumetric size of the chamber


305


preferably decreases during the radial expansion process. In a preferred embodiment, during the radial expansion process, fluidic materials within the decreasing chamber


305


are transmitted to the chamber


310


using the fourth and fifth passages,


275


and


285


. In this manner, the rate and amount of axial movement of the expansion cone


230


is optimally controlled by the flow rate of fluidic materials conveyed from the chamber


300


to the chamber


310


. In a preferred embodiment, the fourth passage


275


further includes a conventional pressure compensated valve in order to optimally control the initiation of the radial expansion process. In a preferred embodiment, the fourth passage


275


further includes a conventional pressure compensated orifice in order to optimally control the rate of the radial expansion process.




In a preferred embodiment, continued radial expansion of the tubular member


200


by the expansion cone


230


causes the sealing members


250


to contact the inside surface of the existing casing


115


. In this manner, the interface between the radially expanded tubular member


200


and the preexisting casing


115


is optimally fluidicly sealed. Furthermore, in a preferred embodiment, continued radial expansion of the tubular member


200


by the expansion cone


230


causes the anchor


255


to contact and at least partially penetrate the inside surface of the preexisting casing


115


. In this manner, the radially expanded tubular member


200


is optimally coupled to the preexisting casing


115


.




As illustrated in

FIG. 1F

, upon the completion of the radial expansion process using the apparatus


200


and the curing of the hardenable fluidic sealing material, a new section of wellbore casing is generated that preferably includes the radially expanded tubular member


200


and an outer annular fluidic sealing member


330


. In this manner, a new section of wellbore casing is generated by radially expanding a tubular member into contact with a preexisting section of wellbore casing. In several alternative preferred embodiments, the apparatus


200


is used to form or repair a wellbore casing, a pipeline, or a structural support.




Referring now to

FIGS. 2A-2O

, and


3


A-


3


J, a preferred embodiment of an apparatus


500


for forming or repairing a wellbore casing, pipeline or structural support will be described. The apparatus


500


preferably includes a first support member


505


, a debris shield


510


, a second support member


515


, one or more crossover valve members


520


, a force multiplier outer support member


525


, a force multiplier inner support member


530


, a force multiplier piston


535


, a force multiplier sleeve


540


, a first coupling


545


, a third support member


550


, a spring spacer


555


, a preload spring


560


, a lubrication fitting


565


, a lubrication packer sleeve


570


, a body of lubricant


575


, a mandrel


580


, an expansion cone


585


, a centralizer


590


, a liner hanger


595


, a travel port sealing sleeve


600


, a second coupling


605


, a collet mandrel


610


, a load transfer sleeve


615


, one or more locking dogs


620


, a locking dog retainer


622


, a collet assembly


625


, a collet retaining sleeve


635


, a collet retaining adapter


640


, an outer collet support member


645


, a liner hanger setting sleeve


650


, one or more crossover valve shear pins


655


, one or more set screws


660


, one or more collet retaining sleeve shear pins


665


, a first passage


670


, one or more second passages


675


, a third passage


680


, one or more crossover valve chambers


685


, a primary throat passage


690


, a secondary throat passage


695


, a fourth passage


700


, one or more inner crossover ports


705


, one or more outer crossover ports


710


, a force multiplier piston chamber


715


, a force multiplier exhaust chamber


720


, one or more force multiplier exhaust passages


725


, a second annular chamber


735


, one or more expansion cone travel indicator ports


740


, one or more collet release ports


745


, a third annular chamber


750


, a collet release throat passage


755


, a fifth passage


760


, one or more sixth passages


765


, one or more seventh passages


770


, one or more collet sleeve passages


775


, one or more force multiplier supply passages


790


, a first lubrication supply passage


795


, a second lubrication supply passage


800


, and a collet sleeve release chamber


805


.




The first support member


505


is coupled to the debris shield


510


and the second support member


515


. The first support member


505


includes the first passage


670


and the second passages


675


for conveying fluidic materials. The first support member


505


preferably has a substantially annular cross section. The first support member


505


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the first support member


505


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. The first support member


505


preferably further includes a first end


1005


, a second end


1010


, a first threaded portion


1015


, a sealing member


1020


, a second threaded portion


1025


, and a collar


1035


.




The first end


1005


of the first support member


505


preferably includes the first threaded portion


1015


and the first passage


670


. The first threaded portion


1015


is preferably adapted to be removably coupled to a conventional support member. The first threaded portion


1015


may include any number of conventional commercially available threads. In a preferred embodiment, the first threaded portion


1015


is a 4½″ API IF box threaded portion in order to optimally provide high tensile strength.




The second end


1010


of the first support member


505


is preferably adapted to extend within both the debris shield


510


and the second support member


515


. The second end


1010


of the first support member


505


preferably includes the sealing member


1020


, the second threaded portion


1025


, the first passage


670


, and the second passages


675


. The sealing member


1020


is preferably adapted to fluidicly seal the interface between first support member


505


and the second support member


515


. The sealing member


1020


may comprise any number of conventional commercially available sealing members. In a preferred embodiment, the sealing member


1020


is an O-ring sealing member available from Parker Seals in order to optimally provide a fluidic seal. The second threaded portion


1025


is preferably adapted to be removably coupled to the second support member


515


. The second threaded portion


1025


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the second threaded portion


1025


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength. In a preferred embodiment, the second end


1010


of the first support member


505


includes a plurality of the passages


675


in order to optimally provide a large flow cross sectional area. The collar


1035


preferably extends from the second end


1010


of the first support member


505


in an outward radial direction. In this manner, the collar


1035


provides a mounting support for the debris shield


510


.




The debris shield


510


is coupled to the first support member


505


. The debris shield


510


preferably prevents foreign debris from entering the passage


680


. In this manner, the operation of the apparatus


200


is optimized. The debris shield


510


preferably has a substantially annular cross section. The debris shield


510


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the debris shield


510


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide resistance to erosion. The debris shield


510


further preferably includes a first end


1040


, a second end


1045


, a channel


1050


, and a sealing member


1055


.




The first end


1040


of the debris shield


510


is preferably positioned above both the outer surface of the second end


1010


of the first support member


505


and the second passages


675


and below the inner surface of the second support member


515


. In this manner, fluidic materials from the passages


675


flow from the passages


675


to the passage


680


. Furthermore, the first end


1040


of the debris shield


510


also preferably prevents the entry of foreign materials into the passage


680


.




The second end


1045


of the debris shield


510


preferably includes the channel


1050


and the sealing member


1055


. The channel


1050


of the second end


1045


of the debris shield


510


is preferably adapted to mate with and couple to the collar


1035


of the second end


1010


of the first support member


505


. The sealing member


1055


is preferably adapted to seal the interface between the second end


1010


of the first support member


505


and the second end


1045


of the debris shield


510


. The sealing member


1055


may comprise any number of conventional commercially available sealing members. In a preferred embodiment, the sealing member


1055


is an O-ring sealing member available from Parker Seals in order to optimally provide a fluidic seal.




The second support member


515


is coupled to the first support member


505


, the force multiplier outer support member


525


, the force multiplier inner support member


530


, and the crossover valve shear pins


655


. The second support member


515


is movably coupled to the crossover valve members


520


. The second support member


515


preferably has a substantially annular cross section. The second support member


515


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the second support member


515


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. The second support member


515


preferably further includes a first end


1060


, an intermediate portion


1065


, a second end


1070


, a first threaded portion


1075


, a second threaded portion


1080


, a third threaded portion


1085


, a first sealing member


1090


, a second sealing member


1095


, and a third sealing member


1100


.




The first end


1060


of the second support member


515


is preferably adapted to contain the second end


1010


of the first support member


505


and the debris shield


510


. The first end


1060


of the second support member


515


preferably includes the third passage


680


and the first threaded portion


1075


. The first threaded portion


1075


of the first end


1060


of the second support member


515


is preferably adapted to be removably coupled to the second threaded portion


1025


of the second end


1010


of the first support member


505


. The first threaded portion


1075


may include any number of conventional commercially available threaded portions. In a preferred embodiment, the first threaded portion


1075


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The intermediate portion


1065


of the second support member


515


preferably includes the crossover valve members


520


, the crossover valve shear pins


655


, the crossover valve chambers


685


, the primary throat passage


690


, the secondary throat passage


695


, the fourth passage


700


, the seventh passages


770


, the force multiplier supply passages


790


, the second threaded portion


1080


, the first sealing member


1090


, and the second sealing member


1095


. The second threaded portion


1080


is preferably adapted to be removably coupled to the force multiplier outer support member


525


. The second threaded portion


1080


may include any number of conventional commercially available threaded portions. In a preferred embodiment, the second threaded portion


1080


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength. The first and second sealing members,


1090


and


1095


, are preferably adapted to fluidicly seal the interface between the intermediate portion


1065


of the second support member


515


and the force multiplier outer support member


525


.




The second end


1070


of the second support member


515


preferably includes the fourth passage


700


, the third threaded portion


1085


, and the third sealing member


1100


. The third threaded portion


1085


of the second end


1070


of the second support member


515


is preferably adapted to be removably coupled to the force multiplier inner support member


530


. The third threaded portion


1085


may include any number of conventional commercially available threaded portions. In a preferred embodiment, the third threaded portion


1085


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength. The third sealing member


1100


is preferably adapted to fluidicly seal the interface between the second end


1070


of the second support member


515


and the force multiplier inner support member


530


. The third sealing member


1100


may comprise any number of conventional commercially available sealing members. In a preferred embodiment, the third sealing member


1100


is an o-ring sealing member available from Parker Seals in order to optimally provide a fluidic seal.




Each crossover valve member


520


is coupled to corresponding crossover valve shear pins


655


. Each crossover valve member


520


is also movably coupled to the second support member


515


and contained within a corresponding crossover valve chamber


685


. Each crossover valve member


520


preferably has a substantially circular cross-section. The crossover valve members


520


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the crossover valve members


520


are fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, each crossover valve member


520


includes a first end


1105


, an intermediate portion


1110


, a second end


1115


, a first sealing member


1120


, a second sealing member


1125


, and recesses


1130


.




The first end


1105


of the crossover valve member


520


preferably includes the first sealing member


1120


. The outside diameter of the first end


1105


of the crossover valve member


520


is preferably less than the inside diameter of the corresponding crossover valve chamber


685


in order to provide a sliding fit. In a preferred embodiment, the outside diameter of the first end


1105


of the crossover valve member


520


is preferably about 0.005 to 0.010 inches less than the inside diameter of the corresponding crossover valve chamber


685


in order to provide an optimal sliding fit. The first sealing member


1120


is preferably adapted to fluidicly seal the dynamic interface between the first end


1105


of the crossover valve member


520


and the corresponding crossover valve chamber


685


. The first sealing member


1120


may include any number of conventional commercially available sealing members. In a preferred embodiment, the first sealing member


1120


is an o-ring sealing member available from Parker Seals in order to optimally provide a dynamic fluidic seal.




The intermediate end


1110


of the crossover valve member


520


preferably has an outside diameter that is less than the outside diameters of the first and second ends,


1105


and


1115


, of the crossover valve member


520


. In this manner, fluidic materials are optimally conveyed from the corresponding inner crossover port


705


to the corresponding outer crossover ports


710


during operation of the apparatus


200


.




The second end


1115


of the crossover valve member


520


preferably includes the second sealing member


1125


and the recesses


1130


. The outside diameter of the second end


1115


of the crossover valve member


520


is preferably less than the inside diameter of the corresponding crossover valve chamber


685


in order to provide a sliding fit. In a preferred embodiment, the outside diameter of the second end


1115


of the crossover valve member


520


is preferably about 0.005 to 0.010 inches less than the inside diameter of the corresponding crossover valve chamber


685


in order to provide an optimal sliding fit. The second sealing member


1125


is preferably adapted to fluidicly seal the dynamic interface between the second end


1115


of the crossover valve member


520


and the corresponding crossover valve chamber


685


. The second sealing member


1125


may include any number of conventional commercially available sealing members. In a preferred embodiment, the second sealing member


1125


is an O-ring sealing member available from Parker Seals in order to optimally provide a dynamic fluidic seal. The recesses


1130


are preferably adapted to receive the corresponding crossover valve shear pins


655


. In this manner, the crossover valve member


520


is maintained in a substantially stationary position.




The force multiplier outer support member


525


is coupled to the second support member


515


and the liner hanger


595


. The force multiplier outer support member


525


preferably has a substantially annular cross section. The force multiplier outer support member


525


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the force multiplier outer support member


525


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. The force multiplier outer support member


525


preferably further includes a first end


1135


, a second end


1140


, a first threaded portion


1145


, and a sealing member


1150


.




The first end


1135


of the force multiplier outer support member


525


preferably includes the first threaded portion


1145


and the force multiplier piston chamber


715


. The first threaded portion


1145


is preferably adapted to be removably coupled to the second threaded portion


1080


of the intermediate portion


1065


of the second support member


515


. The first threaded portion


1145


may include any number of conventional commercially available threads. In a preferred embodiment, the first threaded portion


1145


is a stub acme thread in order to optimally provide high tensile strength.




The second end


1140


of the force multiplier outer support member


525


is preferably adapted to extend within at least a portion of the liner hanger


595


. The second end


1140


of the force multiplier outer support member


525


preferably includes the sealing member


1150


and the force multiplier piston chamber


715


. The sealing member


1150


is preferably adapted to fluidicly seal the interface between the second end


1140


of the force multiplier outer support member


525


and the liner hanger


595


. The sealing member


1150


may comprise any number of conventional commercially available sealing members. In a preferred embodiment, the sealing member


1150


is an o-ring with seal backups available from Parker Seals in order to optimally provide a fluidic seal.




The force multiplier inner support member


530


is coupled to the second support member


515


and the first coupling


545


. The force multiplier inner support member


530


is movably coupled to the force multiplier piston


535


. The force multiplier inner support member


530


preferably has a substantially annular cross-section. The force multiplier inner support member


530


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the force multiplier inner support member


530


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the outer surface of the force multiplier inner support member


530


includes a nickel plating in order to provide an optimal dynamic seal with the force multiplier piston


535


. In a preferred embodiment, the force multiplier inner support member


530


further includes a first end


1155


, a second end


1160


, a first threaded portion


1165


, and a second threaded portion


1170


.




The first end


1155


of the force multiplier inner support member


530


preferably includes the first threaded portion


1165


and the fourth passage


700


. The first threaded portion


1165


of the first end


1155


of the force multiplier inner support member


530


is preferably adapted to be removably coupled to the third threaded portion


1085


of the second end


1070


of the second support member


515


. The first threaded portion


1165


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the first threaded portion


1165


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The second end


1160


of the force multiplier inner support member


530


preferably includes the second threaded portion


1170


, the fourth passage


700


, and the force multiplier exhaust passages


725


. The second threaded portion


1170


of the second end


1160


of the force multiplier inner support member


530


is preferably adapted to be removably coupled to the first coupling


545


. The second threaded portion


1170


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the second threaded portion


1170


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The force multiplier piston


535


is coupled to the force multiplier sleeve


540


. The force multiplier piston


535


is movably coupled to the force multiplier inner support member


530


. The force multiplier piston


535


preferably has a substantially annular cross-section. The force multiplier piston


535


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the force multiplier piston


535


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the force multiplier piston


535


further includes a first end


1175


, a second end


1180


, a first sealing member


1185


, a first threaded portion


1190


, and a second sealing member


1195


.




The first end


1175


of the force multiplier piston


535


preferably includes the first sealing member


1185


. The first sealing member


1185


is preferably adapted to fluidicly seal the dynamic interface between the inside surface of the force multiplier piston


535


and the outside surface of the inner force multiplier support member


530


. The first sealing member


1185


may include any number of conventional commercially available sealing members. In a preferred embodiment, the first sealing member


1185


is an o-ring with seal backups available from Parker Seals in order to optimally provide a dynamic seal.




The second end


1180


of the force multiplier piston


535


preferably includes the first threaded portion


1190


and the second sealing member


1195


. The first threaded portion


1190


is preferably adapted to be removably coupled to the force multiplier sleeve


540


. The first threaded portion


1190


may include any number of conventional commercially available threaded portions. In a preferred embodiment, the first threaded portion


1190


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength. The second sealing member


1195


is preferably adapted to fluidicly seal the interface between the second end


1180


of the force multiplier piston


535


and the force multiplier sleeve


540


. The second sealing member


1195


may include any number of conventional commercially available sealing members. In a preferred embodiment, the second sealing member


1195


is an o-ring sealing member available from Parker Seals in order to optimally provide a fluidic seal.




The force multiplier sleeve


540


is coupled to the force multiplier piston


535


. The force multiplier sleeve


540


is movably coupled to the first coupling


545


. The force multiplier sleeve


540


preferably has a substantially annular cross-section. The force multiplier sleeve


540


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the force multiplier sleeve


540


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the inner surface of the force multiplier sleeve


540


includes a nickel plating in order to provide an optimal dynamic seal with the outside surface of the first coupling


545


. In a preferred embodiment, the force multiplier sleeve


540


further includes a first end


1200


, a second end


1205


, and a first threaded portion


1210


.




The first end


1200


of the force multiplier sleeve


540


preferably includes the first threaded portion


1210


. The first threaded portion


1210


of the first end


1200


of the force multiplier sleeve


540


is preferably adapted to be removably coupled to the first threaded portion


1190


of the second end


1180


of the force multiplier piston


535


. The first threaded portion


1210


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the first threaded portion


1210


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The first coupling


545


is coupled to the force multiplier inner support member


530


and the third support member


550


. The first coupling


545


is movably coupled to the force multiplier sleeve


540


. The first coupling


545


preferably has a substantially annular cross-section. The first coupling


545


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the first coupling


545


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the first coupling


545


further includes the fourth passage


700


, a first end


1215


, a second end


1220


, a first inner sealing member


1225


, a first outer sealing member


1230


, a first threaded portion


1235


, a second inner sealing member


1240


, a second outer sealing member


1245


, and a second threaded portion


1250


.




The first end


1215


of the first coupling


545


preferably includes the first inner sealing member


1225


, the first outer sealing member


1230


, and the first threaded portion


1235


. The first inner sealing member


1225


is preferably adapted to fluidicly seal the interface between the first end


1215


of the first coupling


545


and the second end


1160


of the force multiplier inner support member


530


. The first inner sealing member


1225


may include any number of conventional commercially available sealing members. In a preferred embodiment, the first inner sealing member


1225


is an o-ring seal available from Parker Seals in order to optimally provide a fluidic seal. The first outer sealing member


1230


is preferably adapted to prevent foreign materials from entering the interface between the first end


1215


of the first coupling


545


and the second end


1205


of the force multiplier sleeve


540


. The first outer sealing member


1230


is further preferably adapted to fluidicly seal the interface between the first end


1215


of the first coupling


545


and the second end


1205


of the force multiplier sleeve


540


. The first outer sealing member


1230


may include any number of conventional commercially available sealing members. In a preferred embodiment, the first outer sealing member


1230


is a seal backup available from Parker Seals in order to optimally provide a barrier to foreign materials. The first threaded portion


1235


of the first end


1215


of the first coupling


545


is preferably adapted to be removably coupled to the second threaded portion


1170


of the second end


1160


of the force multiplier inner support member


530


. The first threaded portion


1235


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the first threaded portion


1235


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The second end


1220


of the first coupling


545


preferably includes the second inner sealing member


1240


, the second outer sealing member


1245


, and the second threaded portion


1250


. The second inner sealing member


1240


is preferably adapted to fluidicly seal the interface between the second end


1220


of the first coupling


545


and the third support member


550


. The second inner sealing member


1240


may include any number of conventional commercially available sealing members. In a preferred embodiment, the second inner sealing member


1240


is an o-ring available from Parker Seals in order to optimally provide a fluidic seal. The second outer sealing member


1245


is preferably adapted to fluidicly seal the dynamic interface between the second end


1220


of the first coupling


545


and the second end


1205


of the force multiplier sleeve


540


. The second outer sealing member


1245


may include any number of conventional commercially available sealing members. In a preferred embodiment, the second outer sealing member


1245


is an o-ring with seal backups available from Parker Seals in order to optimally provide a fluidic seal. The second threaded portion


1250


of the second end


1220


of the first coupling


545


is preferably adapted to be removably coupled to the third support member


550


. The second threaded portion


1250


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the second threaded portion


1250


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The third support member


550


is coupled to the first coupling


545


and the second coupling


605


. The third support member


550


is movably coupled to the spring spacer


555


, the preload spring


560


, the mandrel


580


, and the travel port sealing sleeve


600


. The third support member


550


preferably has a substantially annular cross-section. The third support member


550


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the third support member


550


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the outer surface of the third support member


550


includes a nickel plating in order to provide an optimal dynamic seal with the inside surfaces of the mandrel


580


and the travel port sealing sleeve


600


. In a preferred embodiment, the third support member


550


further includes a first end


1255


, a second end


1260


, a first threaded portion


1265


, and a second threaded portion


1270


.




The first end


1255


of the third support member


550


preferably includes the first threaded portion


1265


and the fourth passage


700


. The first threaded portion


1265


of the first end


1255


of the third support member


550


is preferably adapted to be removably coupled to the second threaded portion


1250


of the second end


1220


of the first coupling


545


. The first threaded portion


1265


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the first threaded portion


1265


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The second end


1260


of the third support member


550


preferably includes the second threaded portion


1270


and the fourth passage


700


, and the expansion cone travel indicator ports


740


. The second threaded portion


1270


of the second end


1260


of the third support member


550


is preferably adapted to be removably coupled to the second coupling


605


. The second threaded portion


1270


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the second threaded portion


1270


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The spring spacer


555


is coupled to the preload spring


560


. The spring spacer is movably coupled to the third support member


550


. The spring spacer


555


preferably has a substantially annular cross-section. The spring spacer


555


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the spring spacer


555


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion.




The preload spring


560


is coupled to the spring spacer


555


. The preload spring


560


is movably coupled to the third support member


550


. The preload spring


560


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the preload spring


560


is fabricated from alloys of chromium-vanadium or chromium-silicon in order to optimally provide a high preload force for sealing the interface between the expansion cone


585


and the liner hanger


595


. In a preferred embodiment, the preload spring


560


has a spring rate ranging from about 500 to 2000 lbf/in in order to optimally provide a preload force.




The lubrication fitting


565


is coupled to the lubrication packer sleeve


570


, the body of lubricant


575


and the mandrel


580


. The lubrication fitting


565


preferably has a substantially annular cross-section. The lubrication fitting


565


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the lubrication fitting


565


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. The lubrication fitting


565


preferably includes a first end


1275


, a second end


1280


, a lubrication injection fitting


1285


, a first threaded portion


1290


, and the first lubrication supply passage


795


.




The first end


1275


of the lubrication fitting


565


preferably includes the lubrication injection fitting


1285


, the first threaded portion


1290


and the first lubrication supply passage


795


. The lubrication injection fitting


1285


is preferably adapted to permit lubricants to be injected into the first lubrication supply passage


795


. The lubrication injection fitting


1285


may comprise any number of conventional commercially available injection fittings. In a preferred embodiment, the lubrication injection fitting


1285


is a model 1641-B grease fitting available from Alemite Corp. in order to optimally provide a connection for injecting lubricants. The first threaded portion


1290


of the first end


1275


of the lubrication fitting


565


is preferably adapted to be removably coupled to the mandrel


580


. The first threaded portion


1290


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the first threaded portion


1290


is a stub acme thread available from Halliburton Energy Services. The second end


1280


of the lubrication fitting


565


is preferably spaced above the outside surface of the mandrel


580


in order to define a portion of the first lubrication supply passage


795


.




The lubrication packer sleeve


570


is coupled to the lubrication fitting


565


and the body of lubricant


575


. The lubrication packer sleeve


570


is movably coupled to the liner hanger


595


. The lubrication packer sleeve


570


is preferably adapted to fluidicly seal the radial gap between the outside surface of the second end


1280


of the lubrication fitting


565


and the inside surface of the liner hanger


595


. The lubrication packer sleeve


570


is further preferably adapted to compress the body of lubricant


575


. In this manner, the lubricants within the body of lubricant


575


are optimally pumped to outer surface of the expansion cone


585


.




The lubrication packer sleeve


570


may comprise any number of conventional commercially available packer sleeves. In a preferred embodiment, the lubrication packer sleeve


570


is a 70 durometer packer available from Halliburton Energy Services in order to optimally provide a low pressure fluidic seal.




The body of lubricant


575


is fluidicly coupled to the first lubrication supply passage


795


and the second lubrication supply passage


800


. The body of lubricant


575


is movably coupled to the lubrication fitting


565


, the lubrication packer sleeve


570


, the mandrel


580


, the expansion cone


585


and the liner hanger


595


. The body of lubricant


575


preferably provides a supply of lubricant for lubricating the dynamic interface between the outside surface of the expansion cone


585


and the inside surface of the liner hanger


595


. The body of lubricant


575


may include any number of conventional commercially available lubricants. In a preferred embodiment, the body of lubricant


575


includes anti-seize 1500 available from Climax Lubricants and Equipment Co. in order to optimally provide high pressure lubrication.




In a preferred embodiment, during operation of the apparatus


500


, the body of lubricant


575


lubricates the interface between the interior surface of the expanded portion of the liner hanger


595


and the exterior surface of the expansion cone


585


. In this manner, when the expansion cone


585


is removed from the interior of the radially expanded liner hanger


595


, the body of lubricant


575


lubricates the dynamic interfaces between the interior surface of the expanded portion of the liner hanger


595


and the exterior surface of the expansion cone


585


. Thus, the body of lubricant


575


optimally reduces the force required to remove the expansion cone


585


from the radially expanded liner hanger


595


.




The mandrel


580


is coupled to the lubrication fitting


565


, the expansion cone


585


, and the centralizer


590


. The mandrel


580


is movably coupled to the third support member


550


, the body of lubricant


575


, and the liner hanger


595


. The mandrel


580


preferably has a substantially annular cross-section. The mandrel


580


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the mandrel


580


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the mandrel


580


further includes a first end


1295


, an intermediate portion


1300


, second end


1305


, a first threaded portion


1310


, a first sealing member


1315


, a second sealing member


1320


, and a second threaded portion


1325


, a first wear ring


1326


, and a second wear ring


1327


.




The first end


1295


of the mandrel


580


preferably includes the first threaded portion


1310


, the first sealing member


1315


, and the first wear ring


1326


. The first threaded portion


1310


is preferably adapted to be removably coupled to the first threaded portion


1290


of the first end


1275


of the lubrication fitting


565


. The first threaded portion


1310


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the first threaded portion


1310


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength. The first sealing member


1315


is preferably adapted to fluidicly seal the dynamic interface between the inside surface of the first end


1295


of the mandrel


580


and the outside surface of the third support member


550


. The first sealing member


1315


may comprise any number of conventional commercially available sealing members. In a preferred embodiment, the first sealing member


1315


is an o-ring with seal backups available from Parker Seals in order to optimally provide a dynamic fluidic seal. The first wear ring


1326


is preferably positioned within an interior groove formed in the first end


1295


of the mandrel


580


. The first wear ring


1326


is preferably adapted to maintain concentricity between and among the mandrel


580


and the third support member


550


during axial displacement of the mandrel


580


, reduce frictional forces, and support side loads. In a preferred embodiment, the first wear ring


1326


is a model GR2C wear ring available from Busak & Shamban.




The outside diameter of the intermediate portion


1300


of the mandrel


580


is preferably about 0.05 to 0.25 inches less than the inside diameter of the line hanger


595


. In this manner, the second lubrication supply passage


800


is defined by the radial gap between the intermediate portion


1300


of the mandrel


580


and the liner hanger


595


.




The second end


1305


of the mandrel


580


preferably includes the second sealing member


1320


, the second threaded portion


1325


, and the second wear ring


1327


. The second sealing member


1320


is preferably adapted to fluidicly seal the interface between the inside surface of the expansion cone


585


and the outside surface of the mandrel


580


. The second sealing member


1320


may comprise any number of conventional commercially available sealing members. In a preferred embodiment, the second sealing member


1320


is an o-ring sealing member available from Parker Seals in order to optimally provide a fluidic seal. The second threaded portion


1325


is preferably adapted to be removably coupled to the centralizer


590


. The second threaded portion


1325


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the second threaded portion


1325


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength. The second wear ring


1327


is preferably positioned within an interior groove formed in the second end


1305


of the mandrel


580


. The second wear ring


1327


is preferably adapted to maintain concentricity between and among the mandrel


580


and the third support member


550


during axial displacement of the mandrel


580


, reduce frictional forces, and support side loads. In a preferred embodiment, the second wear ring


1327


is a model GR2C wear ring available from Busak & Shamban.




The expansion cone


585


is coupled to the mandrel


580


and the centralizer


590


. The expansion cone


585


is fluidicly coupled to the second lubrication supply passage


800


. The expansion cone


585


is movably coupled to the body of lubricant


575


and the liner hanger


595


. The expansion cone


585


preferably includes a substantially annular cross-section. The expansion cone


585


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the expansion cone


585


is fabricated from cold worked tool steel in order to optimally provide high strength and wear resistance.




In a preferred embodiment, the expansion cone


585


is further provided substantially as described in one or more of the following: (1) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, which issued as U.S. Pat. No. 6,328,113, which claimed benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/108,558, filed on Nov. 16, 1998, (2) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claimed benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/111,293, filed on Dec. 7, 1998, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/119,611, filed Feb. 11, 1999, (4) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/121,702, filed on Feb. 25, 1999, (5) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application No. 60/121,907, filed Feb. 26, 1999, (6) U.S. Provisional Patent Application Serial No. 60/124,042, filed on Mar. 11, 1999, (7) U.S. Provisional Patent Application Serial No. 60/131,106, filed on Apr. 26, 1999, (8) U.S. Provisional Patent Application Serial No. 60/137,998, filed on Jun. 7, 1999, (9) U.S. Provisional Patent Application Serial No. 60/143,039, filed on Jul. 9, 1999, and (10) U.S. Provisional Patent Application Serial No. 60/146,203, filed on Jul. 29, 1999, the disclosures of which are incorporated by reference.




The centralizer


590


is coupled to the mandrel


580


and the expansion cone


585


. The centralizer


590


is movably coupled to the liner hanger


595


. The centralizer


590


preferably includes a substantially annular cross-section. The centralizer


590


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the centralizer


590


is fabricated from alloy steel having a minimum yield strength ranging from about 75,000 to 140,000 in order to optimally provide high strength and resistance to abrasion and fluid erosion. The centralizer


590


preferably includes a first end


1330


, a second end


1335


, a plurality of centralizer fins


1340


, and a threaded portion


1345


.




The second end


1335


of the centralizer


590


preferably includes the centralizer fins


1340


and the threaded portion


1345


. The centralizer fins


1340


preferably extend from the second end


1335


of the centralizer


590


in a substantially radial direction. In a preferred embodiment, the radial gap between the centralizer fins


1340


and the inside surface of the liner hanger


595


is less than about 0.06 inches in order to optimally provide centralization of the expansion cone


585


. The threaded portion


1345


is preferably adapted to be removably coupled to the second threaded portion


1325


of the second end


1305


of the mandrel


580


. The threaded portion


1345


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the threaded portion


1345


is a stub acme thread in order to optimally provide high tensile strength.




The liner hanger


595


is coupled to the outer collet support member


645


and the set screws


660


. The liner hanger


595


is movably coupled to the lubrication packer sleeve


570


, the body of lubricant


575


, the expansion cone


585


, and the centralizer


590


. The liner hanger


595


preferably has a substantially annular cross-section section. The liner hanger


595


preferably includes a plurality of tubular members coupled end to end. The axial length of the liner hanger


595


preferably ranges from about 5 to 12 feet. The liner hanger


595


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the liner hanger


595


is fabricated from alloy steel having a minimum yield strength ranging from about 40,000 to 125,000 psi in order to optimally provide high strength and ductility. The liner hanger


595


preferably includes a first end


1350


, an intermediate portion


1355


, a second end


1360


, a sealing member


1365


, a threaded portion


1370


, one or more set screw mounting holes


1375


, and one or more outside sealing portions


1380


.




The outside diameter of the first end


1350


of the liner hanger


595


is preferably selected to permit the liner hanger


595


and apparatus


500


to be inserted into another opening or tubular member. In a preferred embodiment, the outside diameter of the first end


1350


of the liner hanger


595


is selected to be about 0.12 to 2 inches less than the inside diameter of the opening or tubular member that the liner hanger


595


will be inserted into. In a preferred embodiment, the axial length of the first end


1350


of the liner hanger


595


ranges from about 8 to 20 inches.




The outside diameter of the intermediate portion


1355


of the liner hanger


595


preferably provides a transition from the first end


1350


to the second end


1360


of the liner hanger. In a preferred embodiment, the axial length of the intermediate portion


1355


of the liner hanger


595


ranges from about 0.25 to 2 inches in order to optimally provide reduced radial expansion pressures.




The second end


1360


of the liner hanger


595


includes the sealing member


1365


, the threaded portion


1370


, the set screw mounting holes


1375


and the outside sealing portions


1380


. The outside diameter of the second end


1360


of the liner hanger


595


is preferably about 0.10 to 2.00 inches less than the outside diameter of the first end


1350


of the liner hanger


595


in order to optimally provide reduced radial expansion pressures. The sealing member


1365


is preferably adapted to fluidicly seal the interface between the second end


1360


of the liner hanger and the outer collet support member


645


. The sealing member


1365


may comprise any number of conventional commercially available sealing members. In a preferred embodiment, the sealing member


1365


is an o-ring seal available from Parker Seals in order to optimally provide a fluidic seal. The threaded portion


1370


is preferably adapted to be removably coupled to the outer collet support member


645


. The threaded portion


1370


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the threaded portion


1370


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength. The set screw mounting holes


1375


are preferably adapted to receive the set screws


660


. Each outside sealing portion


1380


preferably includes a top ring


1385


, an intermediate sealing member


1395


, and a lower ring


1390


. The top and bottom rings,


1385


and


1390


, are preferably adapted to penetrate the inside surface of a wellbore casing. The top and bottom rings,


1385


and


1390


, preferably extend from the outside surface of the second end


1360


of the liner hanger


595


. In a preferred embodiment, the outside diameter of the top and bottom rings,


1385


and


1390


, are less than or equal to the outside diameter of the first end


1350


of the liner hanger


595


in order to optimally provide protection from abrasion when placing the apparatus


500


within a wellbore casing or other tubular member. In a preferred embodiment, the top and bottom rings,


1385


and


1390


are fabricated from alloy steel having a minimum yield strength of about 40,000 to 125,000 psi in order to optimally provide high strength and ductility. In a preferred embodiment, the top and bottom rings,


1385


and


1390


, are integrally formed with the liner hanger


595


. The intermediate sealing member


1395


is preferably adapted to seal the interface between the outside surface of the second end


1360


of the liner hanger


595


and the inside surface of a wellbore casing. The intermediate sealing member


1395


may comprise any number of conventional sealing members. In a preferred embodiment, the intermediate sealing member


1395


is a 50 to 90 durometer nitrile elastomeric sealing member available from Eutsler Technical Products in order to optimally provide a fluidic seal and shear strength.




The liner hanger


595


is further preferably provided substantially as described in one or more of the following: (1) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, which issued as U.S. Pat. No. 6,328,113, which claimed benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/108,558, filed on Nov. 16, 1998, (2) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claimed benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/111,293, filed on Dec. 7, 1998, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/119,611, filed Feb. 11, 1999, (4) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/121,702, filed on Feb. 25, 1999, (5) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application No. 60/121,907, filed Feb. 26, 1999, (6) U.S. Provisional Patent Application Serial No. 60/124,042, filed on Mar. 11, 1999, (7) U.S. Provisional Patent Application Serial No. 60/131,106, filed on Apr. 26, 1999, (8) U.S. Provisional Patent Application Serial No. 60/137,998, filed on Jun. 7, 1999, (9) U.S. Provisional Patent Application Serial No. 60/143,039, filed on Jul. 9, 1999, and (10) U.S. Provisional Patent Application Serial No. 60/146,203, filed on Jul. 29, 1999, the disclosures of which are incorporated by reference.




The travel port sealing sleeve


600


is movably coupled to the third support member


550


. The travel port sealing sleeve


600


is further initially positioned over the expansion cone travel indicator ports


740


. The travel port sealing sleeve


600


preferably has a substantially annular cross-section. The travel port sealing sleeve


600


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the travel port sealing sleeve


600


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. The travel port sealing sleeve preferably includes a plurality of inner sealing members


1400


. The inner sealing members


1400


are preferably adapted to seal the dynamic interface between the inside surface of the travel port sealing sleeve


600


and the outside surface of the third support member


550


. The inner sealing members


1400


may comprise any number of conventional commercially available sealing members. In a preferred embodiment, the inner sealing members


1400


are o-rings available from Parker Seals in order to optimally provide a fluidic seal. In a preferred embodiment, the inner sealing members


1400


further provide sufficient frictional force to prevent inadvertent movement of the travel port sealing sleeve


600


. In an alternative embodiment, the travel port sealing sleeve


600


is removably coupled to the third support member


550


by one or more shear pins. In this manner, accidental movement of the travel port sealing sleeve


600


is prevented.




The second coupling


605


is coupled to the third support member


550


and the collet mandrel


610


. The second coupling


605


preferably has a substantially annular cross-section. The second coupling


605


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the second coupling


605


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the second coupling


605


further includes the fourth passage


700


, a first end


1405


, a second end


1410


, a first inner sealing member


1415


, a first threaded portion


1420


, a second inner sealing member


1425


, and a second threaded portion


1430


.




The first end


1405


of the second coupling


605


preferably includes the first inner sealing member


1415


and the first threaded portion


1420


. The first inner sealing member


1415


is preferably adapted to fluidicly seal the interface between the first end


1405


of the second coupling


605


and the second end


1260


of the third support member


550


. The first inner sealing member


1415


may include any number of conventional commercially available sealing members. In a preferred embodiment, the first inner sealing member


1415


is an o-ring available from Parker Seals in order to optimally provide a fluidic seal. The first threaded portion


1420


of the first end


1415


of the second coupling


605


is preferably adapted to be removably coupled to the second threaded portion


1270


of the second end


1260


of the third support member


550


. The first threaded portion


1420


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the first threaded portion


1420


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The second end


1410


of the second coupling


605


preferably includes the second inner sealing member


1425


and the second threaded portion


1430


. The second inner sealing member


1425


is preferably adapted to fluidicly seal the interface between the second end


1410


of the second coupling


605


and the collet mandrel


610


. The second inner sealing member


1425


may include any number of conventional commercially available sealing members. In a preferred embodiment, the second inner sealing member


1425


is an o-ring available from Parker Seals in order to optimally provide a fluidic seal. The second threaded portion


1430


of the second end


1410


of the second coupling


605


is preferably adapted to be removably coupled to the collet mandrel


610


. The second threaded portion


1430


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the second threaded portion


1430


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The collet mandrel


610


is coupled to the second coupling


605


, the collet retaining adapter


640


, and the collet retaining sleeve shear pins


665


. The collet mandrel


610


is releasably coupled to the locking dogs


620


, the collet assembly


625


, and the collet retaining sleeve


635


. The collet mandrel


610


preferably has a substantially annular cross-section. The collet mandrel


610


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the collet mandrel


610


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the collet mandrel


610


further includes the fourth passage


700


, the collet release ports


745


, the collet release throat passage


755


, the fifth passage


760


, a first end


1435


, a second end


1440


, a first shoulder


1445


, a second shoulder


1450


, a recess


1455


, a shear pin mounting hole


1460


, a first threaded portion


1465


, a second threaded portion


1470


, and a sealing member


1475


.




The first end


1435


of the collet mandrel


610


preferably includes the fourth passage


700


, the first shoulder


1445


, and the first threaded portion


1465


. The first threaded portion


1465


is preferably adapted to be removably coupled to the second threaded portion


1430


of the second end


1410


of the second coupling


605


. The first threaded portion


1465


may include any number of conventional threaded portions. In a preferred embodiment, the first threaded portion


1465


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The second end


1440


of the collet mandrel


610


preferably includes the fourth passage


700


, the collet release ports


745


, the collet release throat passage


755


, the fifth passage


760


, the second shoulder


1450


, the recess


1455


, the shear pin mounting hole


1460


, the second threaded portion


1470


, and the sealing member


1475


. The second shoulder


1450


is preferably adapted to mate with and provide a reference position for the collet retaining sleeve


635


. The recess


1455


is preferably adapted to define a portion of the collet sleeve release chamber


805


. The shear pin mounting hole


1460


is preferably adapted to receive the collet retaining sleeve shear pins


665


. The second threaded portion


1470


is preferably adapted to be removably coupled to the collet retaining adapter


640


. The second threaded portion


1470


may include any number of conventional commercially available threaded portions. In a preferred embodiment, the second threaded portions


1470


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength. The sealing member


1475


is preferably adapted to seal the dynamic interface between the outside surface of the collet mandrel


610


and the inside surface of the collet retaining sleeve


635


. The sealing member


1475


may include any number of conventional commercially available sealing members. In a preferred embodiment, the sealing member


1475


is an o-ring available from Parker Seals in order to optimally provide a fluidic seal.




The load transfer sleeve


615


is movably coupled to the collet mandrel


610


, the collet assembly


625


, and the outer collet support member


645


. The load transfer sleeve


615


preferably has a substantially annular cross-section. The load transfer sleeve


615


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the load transfer sleeve


615


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the load transfer sleeve


615


further a first end


1480


and a second end


1485


.




The inside diameter of the first end


1480


of the load transfer sleeve


615


is preferably greater than the outside diameter of the collet mandrel


610


and less than the outside diameters of the second coupling


605


and the locking dog retainer


622


. In this manner, during operation of the apparatus


500


, the load transfer sleeve


615


optimally permits the flow of fluidic materials from the second annular chamber


735


to the third annular chamber


750


. Furthermore, in this manner, during operation of the apparatus


200


, the load transfer sleeve


615


optimally limits downward movement of the second coupling


605


relative to the collet assembly


625


.




The second end


1485


of the load transfer sleeve


615


is preferably adapted to cooperatively interact with the collet


625


. In this manner, during operation of the apparatus


200


, the load transfer sleeve


615


optimally limits downward movement of the second coupling


605


relative to the collet assembly


625


.




The locking dogs


620


are coupled to the locking dog retainer


622


and the collet assembly


625


. The locking dogs


620


are releasably coupled to the collet mandrel


610


. The locking dogs


620


are preferably adapted to lock onto the outside surface of the collet mandrel


610


when the collet mandrel


610


is displaced in the downward direction relative to the locking dogs


620


. The locking dogs


620


may comprise any number of conventional commercially available locking dogs. In a preferred embodiment, the locking dogs


620


include a plurality of locking dog elements


1490


and a plurality of locking dog springs


1495


.




In a preferred embodiment, each of the locking dog elements


1490


include an arcuate segment including a pair of external grooves for receiving the locking dog springs.


1495


. In a preferred embodiment, each of the locking dog springs


1495


are garter springs. During operation of the apparatus


500


, the locking dog elements


1490


are preferably radially inwardly displaced by the locking dog springs


1495


when the locking dogs


620


are relatively axially displaced past the first shoulder


1445


of the collet mandrel


610


. As a result, the locking dogs


620


are then engaged by the first shoulder


1445


of the collet mandrel


610


.




The locking dog retainer


622


is coupled to the locking dogs


620


and the collet assembly


625


. The locking dog retainer


622


preferably has a substantially annular cross-section. The locking dog retainer


622


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the locking dog retainer


622


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the locking dog retainer


622


further includes a first end


1500


, a second end


1505


, and a threaded portion


1510


.




The first end


1500


of the locking dog retainer


622


is preferably adapted to capture the locking dogs


620


. In this manner, when the locking dogs


620


latch onto the first shoulder


1445


of the collet mandrel


610


, the locking dog retainer


622


transmits the axial force to the collet assembly


625


.




The second end


1505


of the locking dog retainer preferably includes the threaded portion


1510


. The threaded portion


1510


is preferably adapted to be removably coupled to the collet assembly


625


. The threaded portion


1510


may comprise any number of conventional commercially available threaded portions. In a preferred embodiment, the threaded portions


1510


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The collet assembly


625


is coupled to the locking dogs


620


and the locking dog retainer


622


. The collet assembly


625


is releasably coupled to the collet mandrel


610


, the outer collet support member


645


, the collet retaining sleeve


635


, the load transfer sleeve


615


, and the collet retaining adapter


640


.




The collet assembly


625


preferably has a substantially annular cross-section. The collet assembly


625


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the collet assembly


625


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the collet assembly


625


includes a collet body


1515


, a plurality of collet arms


1520


, a plurality of collet upsets


1525


, flow passages


1530


, and a threaded portion


1535


.




The collet body


1515


preferably includes the flow passages


1530


and the threaded portion


1535


. The flow passages


1530


are preferably adapted to convey fluidic materials between the second annular chamber


735


and the third annular chamber


750


. The threaded portion


1535


is preferably adapted to be removably coupled to the threaded portion


1510


of the second end


1505


of the locking dog retainer


622


. The threaded portion


1535


may include any number of conventional commercially available threaded portions. In a preferred embodiment, the threaded portion


1535


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The collet arms


1520


extend from the collet body


1515


in a substantially axial direction. The collet upsets


1525


extend from the ends of corresponding collet arms


1520


in a substantially radial direction. The collet upsets


1525


are preferably adapted to mate with and cooperatively interact with corresponding slots provided in the collet retaining adapter


640


and the liner hanger setting sleeve


650


. In this manner, the collet upsets


1525


preferably controllably couple the collet retaining adapter


640


to the outer collet support member


645


and the liner hanger setting sleeve


650


. In this manner, axial and radial forces are optimally coupled between the collet retaining adapter


640


, the outer collet support member


645


and the liner hanger setting sleeve


650


. The collet upsets


1525


preferably include a flat outer surface


1540


and an angled outer surface


1545


. In this manner, the collet upsets


1525


are optimally adapted to be removably coupled to the slots provided in the collet retaining adapter


640


and the liner hanger setting sleeve


650


.




The collet retaining sleeve


635


is coupled to the collet retaining sleeve shear pins


665


. The collet retaining sleeve


635


is movably coupled to the collet mandrel


610


and the collet assembly


625


. The collet retaining sleeve


635


preferably has a substantially annular cross-section. The collet retaining sleeve


635


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the collet retaining sleeve


635


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the collet retaining sleeve


635


includes the collet sleeve passages


775


, a first end


1550


, a second end


1555


, one or more shear pin mounting holes


1560


, a first shoulder


1570


, a second shoulder


1575


, and a sealing member


1580


.




The first end


1550


of the collet retaining sleeve


635


preferably includes the collet sleeve passages


775


, the shear pin mounting holes


1560


, and the first shoulder


1570


. The collet sleeve passages


775


are preferably adapted to convey fluidic materials between the second annular chamber


735


and the third annular chamber


750


. The shear pin mounting holes


1560


are preferable adapted to receive corresponding shear pins


665


. The first shoulder


1570


is preferably adapted to mate with the second shoulder


1450


of the collet mandrel


610


.




The second end


1555


of the collet retaining sleeve


635


preferably includes the collet sleeve passages


775


, the second shoulder


1575


, and the sealing member


1580


. The collet sleeve passages


775


are preferably adapted to convey fluidic materials between the second annular chamber


735


and the third annular chamber


750


. The second shoulder


1575


of the second end


1555


of the collet retaining sleeve


635


and the recess


1455


of the second end


1440


of the collet mandrel


610


are preferably adapted to define the collet sleeve release chamber


805


. The sealing member


1580


is preferably adapted to seal the dynamic interface between the outer surface of the collet mandrel


610


and the inside surface of the collet retaining sleeve


635


. The sealing member


1580


may include any number of conventional commercially available sealing members. In a preferred embodiment, the sealing member


1580


is an o-ring available from Parker Seals in order to optimally provide a fluidic seal.




The collet retaining adapter


640


is coupled to the collet mandrel


610


. The collet retaining adapter


640


is movably coupled to the liner hanger setting sleeve


650


, the collet retaining sleeve


635


, and the collet assembly


625


. The collet retaining adapter


640


preferably has a substantially annular cross-section. The collet retaining adapter


640


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the collet retaining adapter


640


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the collet retaining adapter


640


includes the fifth passage


760


, the sixth passages


765


, a first end


1585


, an intermediate portion


1590


, a second end


1595


, a plurality of collet slots


1600


, a sealing member


1605


, a first threaded portion


1610


, and a second threaded portion


1615


.




The first end


1585


of the collet retaining adapter


640


preferably includes the collet slots


1600


. The collet slots


1600


are preferably adapted to cooperatively interact with and mate with the collet upsets


1525


. The collet slots


1600


are further preferably adapted to be substantially aligned with corresponding collet slots provided in the liner hanger setting sleeve


650


. In this manner, the slots provided in the collet retaining adapter


640


and the liner hanger setting sleeve


650


are removably coupled to the collet upsets


1525


.




The intermediate portion


1590


of the collet retaining adapter


640


preferably includes the sixth passages


765


, the sealing member


1605


, and the first threaded portion


1610


. The sealing member


1605


is preferably adapted to fluidicly seal the interface between the outside surface of the collet retaining adapter


640


and the inside surface of the liner hanger setting sleeve


650


. The sealing member


1605


may include any number of conventional commercially available sealing members. In a preferred embodiment, the sealing member


1605


is an o-ring available from Parker Seals in order to optimally provide a fluidic seal. The first threaded portion


1610


is preferably adapted to be removably coupled to the second threaded portion


1470


of the second end


1440


of the collet mandrel


610


. The first threaded portion


1610


may include any number of conventional commercially available threaded portions. In a preferred embodiment, the first threaded portion


1610


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The second end


1595


of the collet retaining adapter


640


preferably includes the fifth passage


760


and the second threaded portion


1615


. The second threaded portion


1615


is preferably adapted to be removably coupled to a conventional SSR plug set, or other similar device.




The outer collet support member


645


is coupled to the liner hanger


595


, the set screws


660


, and the liner hanger setting sleeve


650


. The outer collet support member


645


is releasably coupled to the collet assembly


625


. The outer collet support member


645


is movably coupled to the load transfer sleeve


615


. The outer collet support member


645


preferably has a substantially annular cross-section. The outer collet support member


645


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the outer collet support member


645


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the outer collet support member


645


includes a first end


1620


, a second end


1625


, a first threaded portion


1630


, set screw mounting holes


1635


, a recess


1640


, and a second threaded portion


1645


.




The first end


1620


of the outer collet support member


645


preferably includes the first threaded portion


1630


and the set screw mounting holes


1635


. The first threaded portion


1630


is preferably adapted to be removably coupled to the threaded portion


1370


of the second end


1360


of the liner hanger


595


. The first threaded portion


1630


may include any number of conventional commercially available threaded portions. In a preferred embodiment, the first threaded portion


1630


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength. The set screw mounting holes


1635


are preferably adapted to receive corresponding set screws


660


.




The second end


1625


of the outer collet support member


645


preferably includes the recess


1640


and the second threaded portion


1645


. The recess


1640


is preferably adapted to receive a portion of the end of the liner hanger setting sleeve


650


. In this manner, the second end


1625


of the outer collet support member


645


overlaps with a portion of the end of the liner hanger setting sleeve


650


. The second threaded portion


1645


is preferably adapted to be removably coupled to the liner hanger setting sleeve


650


. The second threaded portion


1645


may include any number of conventional commercially available threaded portions. In a preferred embodiment, the second threaded portion


1645


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The liner hanger setting sleeve


650


is coupled to the outer collet support member


645


. The liner hanger setting sleeve


650


is releasably coupled to the collet assembly


625


. The liner hanger setting sleeve


650


is movably coupled to the collet retaining adapter


640


. The liner hanger setting sleeve


650


preferably has a substantially annular cross-section. The liner hanger setting sleeve


650


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the liner hanger setting sleeve


650


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to optimally provide high strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the liner hanger setting sleeve


650


includes a first end


1650


, a second end


1655


, a recessed portion


1660


, a plurality of collet slots


1665


, a threaded portion


1670


, an interior shoulder


1672


, and a threaded portion


1673


.




The first end


1650


of the liner hanger setting sleeve


650


preferably includes the recessed portion


1660


, the plurality of collet slots


1665


and the threaded portion


1670


. The recessed portion


1660


of the first end


1650


of the liner hanger setting sleeve


650


is preferably adapted to mate with the recessed portion


1640


of the second end


1625


of the outer collet support member


645


. In this manner, the first end


1650


of the liner hanger setting sleeve


650


overlaps and mates with the second end


1625


of the outer collet support member


645


. The recessed portion


1660


of the first end


1650


of the liner hanger setting sleeve


650


further includes the plurality of collet slots


1665


. The collet slots


1665


are preferably adapted to mate with and cooperatively interact with the collet upsets


1525


. The collet slots


1665


are further preferably adapted to be aligned with the collet slots


1600


of the collet retaining adapted


640


. In this manner, the collet retaining adapter


640


and the liner hanger setting sleeve


650


preferably cooperatively interact with and mate with the collet upsets


1525


. The threaded portion


1670


is preferably adapted to be removably coupled to the second threaded portion


1645


of the second end


1625


of the outer collet support member


645


. The threaded portion


1670


may include any number of conventional threaded portions. In a preferred embodiment, the threaded portion


1670


is a stub acme thread available from Halliburton Energy Services in order to optimally provide high tensile strength.




The second end


1655


of the liner hanger setting sleeve


650


preferably includes the interior shoulder


1672


and the threaded portion


1673


. In a preferred embodiment, the threaded portion


1673


is adapted to be coupled to conventional tubular members. In this manner tubular members are hung from the second end


1655


of the liner hanger setting sleeve


650


. The threaded portion


1673


may be any number of conventional commercially available threaded portions. In a preferred embodiment, the threaded portion


1673


is a stub acme thread available from Halliburton Energy Services in order to provide high tensile strength.




The crossover valve shear pins


655


are coupled to the second support member


515


. The crossover valve shear pins


655


are releasably coupled to corresponding ones of the crossover valve members


520


. The crossover valve shear pins


655


may include any number of conventional commercially available shear pins. In a preferred embodiment, the crossover valve shear pins


655


are ASTM B16 Brass H02 condition shear pins available from Halliburton Energy Services in order to optimally provide consistency.




The set screws


660


coupled to the liner hanger


595


and the outer collet support member


645


. The set screws


660


may include any number of conventional commercially available set screws.




The collet retaining sleeve shear pins


665


are coupled to the collet mandrel


610


. The collet retaining shear pins


665


are releasably coupled to the collet retaining sleeve


635


. The collet retaining sleeve shear pins


665


may include any number of conventional commercially available shear pins. In a preferred embodiment, the collet retaining sleeve shear pins


665


are ASTM B16 Brass H02 condition shear pins available from Halliburton Energy Services in order to optimally provide consistent shear force values.




The first passage


670


is fluidicly coupled to the second passages


675


and the secondary throat passage


695


. The first passage


670


is preferably defined by the interior of the first support member


505


. The first passage


670


is preferably adapted to convey fluidic materials such as, for example, drilling mud, cement, and/or lubricants. In a preferred embodiment, the first passage


670


is adapted to convey fluidic materials at operating pressures and flow rates ranging from about 0 to 10,000 psi and 0 to 650 gallons/minute.




The second passages


675


are fluidicly coupled to the first passage


670


, the third passage


680


, and the crossover valve chambers


685


. The second passages


675


are preferably defined by a plurality of radial openings provided in the second end


1010


of the first support member


505


. The second passages


675


are preferably adapted to convey fluidic materials such as, for example, drilling mud, cement and/or lubricants. In a preferred embodiment, the second passages


675


are adapted to convey fluidic materials at operating pressures and flow rates ranging from about 0 to 10,000 psi and 0 to 650 gallons/minute.




The third passage


680


is fluidicly coupled to the second passages


675


and the force multiplier supply passages


790


. The third passage


680


is preferably defined by the radial gap between the second end


1010


of the first support member


505


and the first end


1060


of the second support member


515


. The third passage


680


is preferably adapted to convey fluidic materials such as, for example, drilling mud, cement, and/or lubricants. In a preferred embodiment, the third passage


680


is adapted to convey fluidic materials at operating pressures and flow rates ranging from about 0 to 10,000 psi and 0 to 200 gallons/minute.




The crossover valve chambers


685


are fluidicly coupled to the third passage


680


, the corresponding inner crossover ports


705


, the corresponding outer crossover ports


710


, and the corresponding seventh passages


770


. The crossover valve chambers


685


are preferably defined by axial passages provided in the second support member


515


. The crossover valve chambers


685


are movably coupled to corresponding crossover valve members


520


. The crossover valve chambers


685


preferably have a substantially constant circular cross-section.




In a preferred embodiment, during operation of the apparatus


500


. one end of one or more of the crossover valve chambers


685


is pressurized by fluidic materials injected into the third passage


680


. In this manner, the crossover valve shear pins


655


are sheared and the crossover valve members


520


are displaced. The displacement of the crossover valve members


520


causes the corresponding inner and outer crossover ports,


705


and


710


, to be fluidicly coupled. In a particularly preferred embodiment, the crossover valve chambers


685


are pressurized by closing the primary and/or the secondary throat passages,


690


and


695


, using conventional plugs or balls, and then injecting fluidic materials into the first, second and third passages


670


,


675


and


680


.




The primary throat passage


690


is fluidicly coupled to the secondary throat passage


695


and the fourth passage


700


. The primary throat passage


690


is preferably defined by a transitionary section of the interior of the second support member


515


in which the inside diameter transitions from a first inside diameter to a second, and smaller, inside diameter. The primary throat passage


690


is preferably adapted to receive and mate with a conventional ball or plug. In this manner, the first passage


670


optimally fluidicly isolated from the fourth passage


700


.




The secondary throat passage


695


is fluidicly coupled to the first passage


670


and the primary throat passage


695


. The secondary throat passage


695


is preferably defined by another transitionary section of the interior of the second support member


515


in which the inside diameter transitions from a first inside diameter to a second, and smaller, inside diameter. The secondary throat passage


695


is preferably adapted to receive and mate with a conventional ball or plug. In this manner, the first passage


670


optimally fluidicly isolated from the fourth passage


700


.




In a preferred embodiment, the inside diameter of the primary throat passage


690


is less than or equal to the inside diameter of the secondary throat passage


695


. In this manner, if required, a primary plug or ball can be placed in the primary throat passage


690


, and then a larger secondary plug or ball can be placed in the secondary throat passage


695


. In this manner, the first passage


670


is optimally fluidicly isolated from the fourth passage


700


.




The fourth passage


700


is fludicly coupled to the primary throat passage


690


, the seventh passage


770


, the force multiplier exhaust passages


725


, the collet release ports


745


, and the collet release throat passage


755


. The fourth passage


700


is preferably defined by the interiors of the second support member


515


, the force multiplier inner support member


530


, the first coupling


545


, the third support member


550


, the second coupling


605


, and the collet mandrel


610


. The fourth passage


700


is preferably adapted to convey fluidic materials such as, for example, drilling mud, cement, and/or lubricants. In a preferred embodiment, the fourth passage


700


is adapted to convey fluidic materials at operating pressures and flow rates ranging from about 0 to 10,000 psi and 0 to 650 gallons/minute.




The inner crossover ports


705


are fludicly coupled to the fourth passage


700


and the corresponding crossover valve chambers


685


. The inner crossover ports


705


are preferably defined by substantially radial openings provided in an interior wall of the second support member


515


. The inner crossover ports


705


are preferably adapted to convey fluidic materials such as, for example, drilling mud, cement, and lubricants. In a preferred embodiment, the inner crossover ports


705


are adapted to convey fluidic materials at operating pressures and flow rates ranging from about 0 to 10,000 psi and 0 to 50 gallons/minute.




In a preferred embodiment, during operation of the apparatus


500


, the inner crossover ports


705


are controllably fluidicly coupled to the corresponding crossover valve chambers


685


and outer crossover ports


710


by displacement of the corresponding crossover valve members


520


. In this manner, fluidic materials within the fourth passage


700


are exhausted to the exterior of the apparatus


500


.




The outer crossover ports


710


are fludicly coupled to corresponding crossover valve chambers


685


and the exterior of the apparatus


500


. The outer crossover ports


710


are preferably defined by substantially radial openings provided in an exterior wall of the second support member


515


. The outer crossover ports


710


are preferably adapted to convey fluidic materials such as, for example, drilling mud, cement, and lubricants. In a preferred embodiment, the outer crossover ports


710


are adapted to convey fluidic materials at operating pressures and flow rates ranging from about 0 to 10,000 psi and 0 to 50 gallons/minute.




In a preferred embodiment, during operation of the apparatus


500


, the outer crossover ports


710


are controllably fluidicly coupled to the corresponding crossover valve chambers


685


and inner crossover ports


705


by displacement of the corresponding crossover valve members


520


. In this manner, fluidic materials within the fourth passage


700


are exhausted to the exterior of the apparatus


500


.




The force multiplier piston chamber


715


is fluidicly coupled to the third passage


680


. The force multiplier piston chamber


715


is preferably defined by the annular region defined by the radial gap between the force multiplier inner support member


530


and the force multiplier outer support member


525


and the axial gap between the end of the second support member


515


and the end of the lubrication fitting


565


.




In a preferred embodiment, during operation of the apparatus, the force multiplier piston chamber


715


is pressurized to operating pressures ranging from about 0 to 10,000 psi. The pressurization of the force multiplier piston chamber


715


preferably displaces the force multiplier piston


535


and the force multiplier sleeve


540


. The displacement of the force multiplier piston


535


and the force multiplier sleeve


540


in turn preferably displaces the mandrel


580


and expansion cone


585


. In this manner, the liner hanger


595


is radially expanded. In a preferred embodiment, the pressurization of the force multiplier piston chamber


715


directly displaces the mandrel


580


and the expansion cone


585


. In this manner, the force multiplier piston


535


and the force multiplier sleeve


540


may be omitted. In a preferred embodiment, the lubrication fitting


565


further includes one or more slots


566


for facilitating the passage of pressurized fluids to act directly upon the mandrel


580


and expansion cone


585


.




The force multiplier exhaust chamber


720


is fluidicly coupled to the force multiplier exhaust passages


725


. The force multiplier exhaust chamber


720


is preferably defined by the annular region defined by the radial gap between the force multiplier inner support member


530


and the force multiplier sleeve


540


and the axial gap between the force multiplier piston


535


and the first coupling


545


. In a preferred embodiment, during operation of the apparatus


500


, fluidic materials within the force multiplier exhaust chamber


720


are exhausted into the fourth passage


700


using the force multiplier exhaust passages


725


. In this manner, during operation of the apparatus


500


, the pressure differential across the force multiplier piston


535


is substantially equal to the difference in operating pressures between the force multiplier piston chamber


715


and the fourth passage


700


.




The force multiplier exhaust passages


725


are fluidicly coupled to the force multiplier exhaust chamber


720


and the fourth passage


700


. The force multiplier exhaust passages


725


are preferably defined by substantially radial openings provided in the second end


1160


of the force multiplier inner support member


530


.




The second annular chamber


735


is fluidicly coupled to the third annular chamber


750


. The second annular chamber


735


is preferably defined by the annular region defined by the radial gap between the third support member


550


and the liner hanger


595


and the axial gap between the centralizer


590


and the collet assembly


625


. In a preferred embodiment, during operation of the apparatus


500


, fluidic materials displaced by movement of the mandrel


580


and expansion cone


585


are conveyed from the second annular chamber


735


to the third annular chamber


750


, the sixth passages


765


, and the sixth passage


760


. In this manner, the operation of the apparatus


500


is optimized.




The expansion cone travel indicator ports


740


are fluidicly coupled to the fourth passage


700


. The expansion cone travel indicator ports


740


are controllably fluidicly coupled to the second annular chamber


735


. The expansion cone travel indicator ports


740


are preferably defined by radial openings in the third support member


550


. In a preferred embodiment, during operation of the apparatus


500


, the expansion cone travel indicator ports


740


are further controllably fluidicly coupled to the force multiplier piston chamber


715


by displacement of the travel port sealing sleeve


600


caused by axial displacement of the mandrel


580


and expansion cone


585


. In this manner, the completion of the radial expansion process is indicated by a pressure drop caused by fluidicly coupling the force multiplier piston chamber


715


with the fourth passage


700


.




The collet release ports


745


are fluidicly coupled to the fourth passage


700


and the collet sleeve release chamber


805


. The collet release ports


745


are controllably fluidicly coupled to the second and third annular chambers,


735


and


750


. The collet release ports


745


are defined by radial openings in the collet mandrel


610


. In a preferred embodiment, during operation of the apparatus


500


, the collet release ports


745


are controllably pressurized by blocking the collet release throat passage


755


using a conventional ball or plug. The pressurization of the collet release throat passage


755


in turn pressurizes the collet sleeve release chamber


805


. The pressure differential between the pressurized collet sleeve release chamber


805


and the third annular chamber


750


then preferably shears the collet shear pins


665


and displaces the collet retaining sleeve


635


in the axial direction.




The third annular chamber


750


is fluidicly coupled to the second annular chamber


735


and the sixth passages


765


. The third annular chamber


750


is controllably fluidicly coupled to the collet release ports


745


. The third annular chamber


750


is preferably defined by the annular region defined by the radial gap between the collet mandrel


610


and the collet assembly


625


and the first end


1585


of the collet retaining adapter and the axial gap between the collet assembly


625


and the intermediate portion


1590


of the collet retaining adapter


640


.




The collet release throat passage


755


is fluidicly coupled to the fourth passage


700


and the fifth passage


760


. The collet release throat passage


755


is preferably defined by a transitionary section of the interior of the collet mandrel


610


including a first inside diameter that transitions into a second smaller inside diameter. The collet release throat passage


755


is preferably adapted to receive and mate with a conventional sealing plug or ball. In this manner, the fourth passage


700


is optimally fluidicly isolated from the fifth passage


760


. In a preferred embodiment, the maximum inside diameter of the collet release throat passage


755


is less than or equal to the minimum inside diameters of the primary and secondary throat passages,


690


and


695


.




In a preferred embodiment, during operation of the apparatus


500


, a conventional sealing plug or ball is placed in the collet release throat passage


755


. The fourth passage


700


and the collet release ports


745


are then pressurized. The pressurization of the collet release throat passage


755


in turn pressurizes the collet sleeve release chamber


805


. The pressure differential between the pressurized collet sleeve release chamber


805


and the third annular chamber


750


then preferably shears the collet shear pins


665


and displaces the collet retaining sleeve


635


in the axial direction.




The fifth passage


760


is fluidicly coupled to the collet release throat passage


755


and the sixth passages


765


. The fifth passage


760


is preferably defined by the interior of the second end


1595


of the collet retaining adapter


640


.




The sixth passages


765


are fluidicly coupled to the fifth passage


760


and the third annular chamber


750


. The sixth passages


765


are preferably defined by approximately radial openings provided in the intermediate portion


1590


of the collet retaining adapter


640


. In a preferred embodiment, during operation of the apparatus


500


, the sixth passages


765


fluidicly couple the third annular passage


750


to the fifth passage


760


. In this manner, fluidic materials displaced by axial movement of the mandrel


580


and expansion cone


585


are exhausted to the fifth passage


760


.




The seventh passages


770


are fluidicly coupled to corresponding crossover valve chambers


685


and the fourth passage


700


. The seventh passages


770


are preferably defined by radial openings in the intermediate portion


1065


of the second support member


515


. During operation of the apparatus


700


, the seventh passage


770


preferably maintain the rear portions of the corresponding crossover valve chamber


685


at the same operating pressure as the fourth passage


700


. In this manner, the pressure differential across the crossover valve members


520


caused by blocking the primary and/or the secondary throat passages,


690


and


695


, is optimally maintained.




The collet sleeve passages


775


are fluidicly coupled to the second annular chamber


735


and the third annular chamber


750


. The collet sleeve passages


775


are preferably adapted to convey fluidic materials between the second annular chamber


735


and the third annular chamber


750


. The collet sleeve passages


735


are preferably defined by axial openings provided in the collet sleeve


635


.




The force multiplier supply passages


790


are fluidicly coupled to the third passage


680


and the force multiplier piston chamber


715


. The force multiplier supply passages


790


are preferably defined by a plurality of substantially axial openings in the second support member


515


. During operation of the apparatus


500


, the force multiplier supply passages


790


preferably convey pressurized fluidic materials from the third passage


680


to the force multiplier piston chamber


715


.




The first lubrication supply passage


795


is fludicly coupled to the lubrication fitting


1285


and the body of lubricant


575


. The first lubrication supply passage


795


is preferably defined by openings provided in the lubrication fitting


565


and the annular region defined by the radial gap between the lubrication fitting


565


and the mandrel


580


. During operation of the apparatus


500


, the first lubrication passage


795


is preferably adapted to convey lubricants from the lubrication fitting


1285


to the body of lubricant


575


.




The second lubrication supply passage


800


is fludicly coupled to the body of lubricant


575


and the expansion cone


585


. The second lubrication supply passage


800


is preferably defined by the annular region defined by the radial gap between the expansion mandrel


580


and the liner hanger


595


. During operation of the apparatus


500


, the second lubrication passage


800


is preferably adapted to convey lubricants from the body of lubricant


575


to the expansion cone


585


. In this manner, the dynamic interface between the expansion cone


585


and the liner hanger


595


is optimally lubricated.




The collet sleeve release chamber


805


is fluidicly coupled to the collet release ports


745


. The collet sleeve release chamber


805


is preferably defined by the annular region bounded by the recess


1455


and the second shoulder


1575


. During operation of the apparatus


500


, the collet sleeve release chamber


805


is preferably controllably pressurized. This manner, the collet release sleeve


635


is axially displaced.




Referring to

FIGS. 4A

to


4


G, in a preferred embodiment, during operation of the apparatus


500


, the apparatus


500


is coupled to an annular support member


2000


having an internal passage


2001


, a first coupling


2005


having an internal passage


2010


, a second coupling


2015


, a third coupling


2020


having an internal passage


2025


, a fourth coupling


2030


having an internal passage


2035


, a tail wiper


2050


having an internal passage


2055


, a lead wiper


2060


having an internal passage


2065


, and one or more tubular members


2070


. The annular support member


2000


may include any number of conventional commercially available annular support members. In a preferred embodiment, the annular support member


2000


further includes a conventional controllable vent passage for venting fluidic materials from the internal passage


2001


. In this manner, during placement of the apparatus


500


in the wellbore


2000


, fluidic materials in the internal passage


2001


are vented thereby minimizing surge pressures.




The first coupling


2005


is preferably removably coupled to the second threaded portion


1615


of the collet retaining adapter


640


and the second coupling


2015


. The first coupling


2005


may comprise any number of conventional commercially available couplings. In a preferred embodiment, the first coupling


2005


is an equalizer case available from Halliburton Energy Services in order to optimally provide containment of the equalizer valve.




The second coupling


2015


is preferably removably coupled to the first coupling


2005


and the third coupling


2020


. The second coupling


2015


may comprise any number of conventional commercially available couplings. In a preferred embodiment, the second coupling


2015


is a bearing housing available from Halliburton Energy Services in order to optimally provide containment of the bearings.




The third coupling


2020


is preferably removably coupled to the second coupling


2015


and the fourth coupling


2030


. The third coupling


2020


may comprise any number of conventional commercially available couplings. In a preferred embodiment, the third coupling


2020


is an SSR swivel mandrel available from Halliburton Energy Services in order to optimally provide for rotation of tubular members positioned above the SSR plug set.




The fourth coupling


2030


is preferably removably coupled to the third coupling


2020


and the tail wiper


2050


. The fourth coupling


2030


may comprise any number of conventional commercially available couplings. In a preferred embodiment, the fourth coupling


2030


is a lower connector available from Halliburton Energy Services in order to optimally provide a connection to a SSR plug set.




The tail wiper


2050


is preferably removably coupled to the fourth coupling


2030


and the lead wiper


2060


. The tail wiper


2050


may comprise any number of conventional commercially available tail wipers. In a preferred embodiment, the tail wiper


2050


is an SSR top plug available from Halliburton Energy Services in order to optimally provide separation of cement and drilling mud.




The lead wiper


2060


is preferably removably coupled to the tail wiper


2050


. The lead wiper


2060


may comprise any number of conventional commercially available tail wipers. In a preferred embodiment, the lead wiper


2060


is an SSR bottom plug available from Halliburton Energy Services in order to optimally provide separation of mud and cement.




In a preferred embodiment, the first coupling


2005


, the second coupling


2015


, the third coupling


2020


, the fourth coupling


2030


, the tail wiper


2050


, and the lead wiper


2060


are a conventional SSR wiper assembly available from Halliburton Energy Services in order to optimally provide separation of mud and cement.




The tubular member


2070


are coupled to the threaded portion


1673


of the liner hanger setting sleeve


650


. The tubular member


2070


may include one or more tubular members. In a preferred embodiment, the tubular member


2070


includes a plurality of conventional tubular members coupled end to end.




The apparatus


500


is then preferably positioned in a wellbore


2100


having a preexisting section of wellbore casing


2105


using the annular support member


2000


. The wellbore


2100


and casing


2105


may be oriented in any direction from the vertical to the horizontal. In a preferred embodiment, the apparatus


500


is positioned within the wellbore


2100


with the liner hanger


595


overlapping with at least a portion of the preexisting wellbore casing


2105


. In a preferred embodiment, during placement of the apparatus


500


within the wellbore


2100


, fluidic materials


2200


within the wellbore


2100


are conveyed through the internal passage


2065


, the internal passage


2055


, the internal passage


2035


, the internal passage


2025


, the internal passage


2010


, the fifth passage


760


, the collet release throat passage


755


, the fourth passage


700


, the primary throat passage


690


, the secondary throat passage


695


, the first passage


670


, and the internal passage


2001


. In this manner, surge pressures during insertion and placement of the apparatus


500


within the wellbore


2000


are minimized. In a preferred embodiment, the internal passage


2001


further includes a controllable venting passage for conveying fluidic materials out of the internal passage


2001


.




Referring to

FIGS. 5A

to


5


C, in a preferred embodiment, in the event of an emergency after placement of the apparatus


500


within the wellbore


2000


, the liner hanger


595


, the outer collet support member


645


, and the liner hanger setting sleeve


650


are decoupled from the apparatus


500


by first placing a ball


2300


within the collet release throat passage


755


. A quantity of a fluidic material


2305


is then injected into the fourth passage


700


, the collet release ports


745


, and the collet sleeve release chamber


805


. In a preferred embodiment, the fluidic material


2305


is a non-hardenable fluidic material such as, for example, drilling mud. Continued injection of the fluidic material


2305


preferably pressurizes the collet sleeve release chamber


805


. In a preferred embodiment, the collet sleeve release chamber


805


is pressurized to operating pressures ranging from about 1,000 to 3,000 psi in order to optimally provide a positive indication of the shifting of the collet retaining sleeve


635


as indicated by a sudden pressure drop. The pressurization of the collet sleeve release chamber


805


preferably applies an axial force to the collet retaining sleeve


635


. The axial force applied to the collet retaining sleeve


635


preferably shears the collet retaining sleeve shear pins


665


. The collet retaining sleeve


635


then preferably is displaced in the axial direction


2310


away from the collet upsets


1525


. In a preferred embodiment, the collet retaining sleeve


635


is axially displaced when the operating pressure within the collet sleeve release chamber


805


is greater than about 1650 psi. In this manner, the collet upsets


1525


are no longer held in place within the collet slots


1600


and


1665


by the collet retaining sleeve


635


.




In a preferred embodiment, the collet mandrel


610


is then displaced in the axial direction


2315


causing the collet upsets


1525


to be moved in a radial direction


2320


out of the collet slots


1665


. The liner hanger


595


, the outer collet support member


645


, and the liner hanger setting sleeve


650


are thereby decoupled from the remaining portions of the apparatus


500


. The remaining portions of the apparatus


500


are then removed from the wellbore


2100


. In this manner, in the event of an emergency during operation of the apparatus, the liner hanger


595


, the outer collet support member


645


, and the liner hanger setting sleeve


650


are decoupled from the apparatus


500


. This provides an reliable and efficient method of recovering from an emergency situation such as, for example, where the liner hanger


595


, and/or outer collet support member


645


, and/or the liner hanger setting sleeve


650


become lodged within the wellbore


2100


and/or the wellbore casing


2105


.




Referring to

FIGS. 6A

to


6


C, in a preferred embodiment, after positioning the apparatus


500


within the wellbore


2100


, the lead wiper


2060


is released from the apparatus


500


by injecting a conventional ball


2400


into an end portion of the lead wiper


2060


using a fluidic material


2405


. In a preferred embodiment, the fluidic material


2405


is a non-hardenable fluidic material such as, for example, drilling mud.




Referring to

FIGS. 7A

to


7


G, in a preferred embodiment, after releasing the lead wiper


2060


from the apparatus


500


, a quantity of a hardenable fluidic sealing material


2500


is injected from the apparatus


500


into the wellbore


2100


using the internal passage


2001


, the first passage


670


, the secondary throat passage


695


, the primary throat passage


690


, the fourth passage


700


, the collet release throat passage


755


, the fifth passage


760


, the internal passage


2010


, the internal passage


2025


, the internal passage


2035


, and the internal passage


2055


. In a preferred embodiment, the hardenable fluidic sealing material


2500


substantially fills the annular space surrounding the liner hanger


595


. The hardenable fluidic sealing material


2500


may include any number of conventional hardenable fluidic sealing materials such as, for example, cement or epoxy resin. In a preferred embodiment, the hardenable fluidic sealing material includes oil well cement available from Halliburton Energy Services in order to provide an optimal seal for the surrounding formations and structural support for the liner hanger


595


and tubular members


2070


. In an alternative embodiment, the injection of the hardenable fluidic sealing material


2500


is omitted.




As illustrated in

FIG. 7C

, in a preferred embodiment, prior to the initiation of the radial expansion process, the preload spring


560


exerts a substantially constant axial force on the mandrel


580


and expansion cone


585


. In this manner, the expansion cone


585


is maintained in a substantially stationary position prior to the initiation of the radial expansion process. In a preferred embodiment, the amount of axial force exerted by the preload spring


560


is varied by varying the length of the spring spacer


555


. In a preferred embodiment, the axial force exerted by the preload spring


560


on the mandrel


580


and expansion cone


585


ranges from about 500 to 2,000 lbf in order to optimally provide an axial preload force on the expansion cone


585


to ensure metal to metal contact between the outside diameter of the expansion cone


585


and the interior surface of the liner hanger


595


.




Referring to

FIGS. 8A

to


8


C, in a preferred embodiment, after injecting the hardenable fluidic sealing material


2500


out of the apparatus


500


and into the wellbore


2100


, the tail wiper


2050


is preferably released from the apparatus


500


by injecting a conventional wiper dart


2600


into the tail wiper


2050


using a fluidic material


2605


. In a preferred embodiment, the fluidic material


2605


is a non-hardenable fluidic material such as, for example, drilling mud.




Referring to

FIGS. 9A

to


9


H, in a preferred embodiment, after releasing the tail wiper


2050


from the apparatus


500


, a conventional ball plug


2700


is placed in the primary throat passage


690


by injecting a fluidic material


2705


into the first passage


670


. In a preferred embodiment, a conventional ball plug


2710


is also placed in the secondary throat passage


695


. In this manner, the first passage


670


is optimally fluidicly isolated from the fourth passage


700


. In a preferred embodiment, the differential pressure across the ball plugs


2700


and/or


2710


ranges from about 0 to 10,000 psi in order to optimally fluidicly isolate the first passage


670


from the fourth passage


700


. In a preferred embodiment, the fluidic material


2705


is a non-hardenable fluidic material. In a preferred embodiment, the fluidic material


2705


includes one or more of the following: drilling mud, water, oil and lubricants.




The injected fluidic material


2705


preferably is conveyed to the crossover valve chamber


685


through the first passage


670


, the second passages


675


, and the third passage


680


. The injected fluidic material


2705


is also preferably conveyed to the force multiplier piston chamber


715


through the first passage


670


, the second passages


675


, the third passage


680


, and the force multiplier supply passages


790


. The fluidic material


2705


injected into the crossover valve chambers


685


preferably applies an axial force on one end of the crossover valve members


520


. In a preferred embodiment, the axial force applied to the crossover valve members


520


by the injected fluidic material


2705


shears the crossover valve shear pins


655


. In this manner, one or more of the crossover valve members


520


are displaced in the axial direction thereby fluidicly coupling the fourth passage


700


, the inner crossover ports


705


, the crossover valve chambers


685


, the outer crossover ports


710


, and the region outside of the apparatus


500


. In this manner, fluidic materials


2715


within the apparatus


500


are conveyed outside of the apparatus. In a preferred embodiment, the operating pressure of the fluidic material


2705


is gradually increased after the placement of the sealing ball


2700


and/or the sealing ball


2710


in the primary throat passage


690


and/or the secondary throat passage


695


in order to minimize stress on the apparatus


500


. In a preferred embodiment, the operating pressure required to displace the crossover valve members


520


ranges from about 500 to 3,000 psi in order to optimally prevent inadvertent or premature shifting the crossover valve members


520


. In a preferred embodiment, the one or more of the crossover valve members


520


are displaced when the operating pressure of the fluidic material


2705


is greater than or equal to about 1860 psi. In a preferred embodiment, the radial expansion of the liner hanger


595


does not begin until one or more of the crossover valve members


520


are displaced in the axial direction. In this manner, the operation of the apparatus


500


is precisely controlled. Furthermore, in a preferred embodiment, the outer crossover ports


710


include controllable variable orifices in order to control the flow rate of the fluidic materials conveyed outside of the apparatus


500


. In this manner, the rate of the radial expansion process is optimally controlled.




In a preferred embodiment, after displacing one or more of the crossover valve members


520


, the operating pressure of the fluidic material


2705


is gradually increased until the radial expansion process begins. In an exemplary embodiment, the radial expansion process begins when the operating pressure of the fluidic material


2705


within the force multiplier piston chamber


715


is greater than about 3200 psi. The operating pressure within the force multiplier piston chamber


715


preferably causes the force multiplier piston


535


to be displaced in the axial direction. The axial displacement of the force multiplier piston


535


preferably causes the force multiplier sleeve


540


to be displaced in the axial direction. Fluidic materials


2720


within the force multiplier exhaust chamber


720


are then preferably exhausted into the fourth passage


700


through the force multiplier exhaust passages


725


. In this manner, the differential pressure across the force multiplier piston


535


is maximized. In an exemplary embodiment, the force multiplier piston


535


includes about 11.65 square inches of surface area in order to optimally increase the rate of radial expansion of the liner hanger


595


by the expansion cone


585


. In a preferred embodiment, the operating pressure within the force multiplier piston chamber


715


ranges from about 1,000 to 10,000 psi during the radial expansion process in order to optimally provide radial expansion of the liner hanger


595


.




In a preferred embodiment, the axial displacement of the force multiplier sleeve


540


causes the force multiplier sleeve


540


to drive the mandrel


580


and expansion cone


585


in the axial direction. In a preferred embodiment, the axial displacement of the expansion cone


585


radially expands the liner hanger


595


into contact with the preexisting wellbore casing


2105


. In a preferred embodiment, the operating pressure within the force multiplier piston chamber


715


also drives the mandrel


580


and expansion cone


585


in the axial direction. In this manner, the axial force for axially displacing the mandrel


580


and expansion cone


585


preferably includes the axial force applied by the force multiplier sleeve


540


and the axial force applied by the operating pressure within the force multiplier piston chamber


715


. In an alternative preferred embodiment, the force multiplier piston


535


and the force multiplier sleeve


540


are omitted and the mandrel


580


and expansion cone


585


are driven solely by fluid pressure.




The radial expansion of the liner hanger


595


preferably causes the top rings


1385


and the lower rings


1390


of the liner hanger


595


to penetrate the interior walls of the preexisting wellbore casing


2105


. In this manner, the liner hanger


595


is optimally coupled to the wellbore casing


2105


. In a preferred embodiment, during the radial expansion of the liner hanger


595


, the intermediate sealing members


1395


of the liner hanger


595


fluidicly seal the interface between the radially expanded liner hanger


595


and the interior surface of the wellbore casing


2105


.




During the radial expansion process, the dynamic interface between the exterior surface of the expansion cone


585


and the interior surface of the liner hanger


595


is preferably lubricated by lubricants supplied from the body of lubricant


575


through the second lubrication supply passage


800


. In this manner, the operational efficiency of the apparatus


500


during the radial expansion process is optimized. In a preferred embodiment, the lubricants supplied by the body of lubricant


575


through the second lubrication passage


800


are injected into the dynamic interface between the exterior surface of the expansion cone


585


and the interior surface of the liner hanger


595


substantially as disclosed in one or more of the following: (1) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, which issued as U.S. Pat. No. 6,328,113, which claimed benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/108,558, filed on Nov. 16, 1998, (2) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claimed benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/111,293, filed on Dec. 7, 1998, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/119,611, filed Feb. 11, 1999, (4) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/121,702, filed on Feb. 25, 1999, (5) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application No. 60/121,907, filed Feb. 26, 1999, (6) U.S. Provisional Patent Application Serial No. 60/124,042, filed on Mar. 11, 1999, (7) U.S. Provisional Patent Application Serial No. 60/131,106, filed on Apr. 26, 1999, (8) U.S. Provisional Patent Application Serial No. 60/137,998, filed on Jun. 7, 1999, (9) U.S. Provisional Patent Application Serial No. 60/143,039, filed on Jul. 9, 1999, and (10) U.S. Provisional Patent Application Serial No. 60/146,203, filed on Jul. 29, 1999, the disclosures of which are incorporated by reference.




In a preferred embodiment, the expansion cone


585


is reversible. In this manner, if one end of the expansion cone


585


becomes excessively worn, the apparatus


500


can be disassembled and the expansion cone


585


reversed in order to use the un-worn end of the expansion cone


585


to radially expand the liner hanger


595


. In a preferred embodiment, the expansion cone


585


further includes one or more surface inserts fabricated from materials such as, for example, tungsten carbide, in order to provide an extremely durable material for contacting the interior surface of the liner hanger


595


during the radial expansion process.




During the radial expansion process, the centralizer


590


preferably centrally positions the mandrel


580


and the expansion cone


585


within the interior of the liner hanger


595


. In this manner, the radial expansion process is optimally provided.




During the radial expansion process, fluidic materials


2725


within the second annular chamber


735


are preferably conveyed to the fifth passage


760


through the collet sleeve passages


775


, the flow passages


1530


, the third annular chamber


750


, and the sixth passages


765


. In this manner, the axial displacement of the mandrel


580


and the expansion cone


585


are optimized.




Referring to

FIGS. 10A

to


10


E, in a preferred embodiment, the radial expansion of the liner hanger


595


is stopped by fluidicly coupling the force multiplier piston chamber


715


with the fourth passage


700


. In particular, during the radial expansion process, the continued axial displacement of the mandrel


580


and the expansion cone


585


, caused by the injection of the fluidic material


2705


, displaces the travel port sealing sleeve


600


and causes the force multiplier piston chamber


715


to be fluidicly coupled to the fourth passage


700


through the expansion cone travel indicator ports


740


. In a preferred embodiment, the travel port sealing sleeve


600


is removably coupled to the third support member


550


by one or more shear pins. In this manner, accidental movement of the travel port sealing sleeve


600


is prevented.




In a preferred embodiment, the fluidic coupling of the force multiplier piston chamber


715


with the fourth passage


700


reduces the operating pressure within the force multiplier piston chamber


715


. In a preferred embodiment, the reduction in the operating pressure within the force multiplier piston chamber


715


stops the axial displacement of the mandrel


580


and the expansion cone


585


. In this manner, the radial expansion of the liner hanger


595


is optimally stopped. In an alternative preferred embodiment, the drop in the operating pressure within the force multiplier piston chamber


715


is remotely detected and the injection of the fluidic material


2705


is reduced and/or stopped in order to gradually reduce and/or stop the radial expansion process. In this manner, the radial expansion process is optimally controlled by sensing the operating pressure within the force multiplier piston chamber


715


.




In a preferred embodiment, after the completion of the radial expansion process, the hardenable fluidic sealing material


2500


is cured. In this manner, a hard annular outer layer of sealing material is formed in the annular region around the liner hanger


595


. In an alternative embodiment, the hardenable fluidic sealing material


2500


is omitted.




Referring to

FIGS. 11A

to


11


E, in a preferred embodiment, the liner hanger


595


, the outer collet support member


645


, and the liner hanger setting sleeve


650


are then decoupled from the apparatus


500


. In a preferred embodiment, the liner hanger


595


, the collet retaining adapter


640


, the outer collet support member


645


, and the liner hanger setting sleeve


650


are decoupled from the apparatus


500


by first displacing the annular support member


2000


, the first support member


505


, the second support member


515


, the force multiplier outer support member


525


, the force multiplier inner support member


530


, the first coupling


545


, the third support member


550


, the second coupling


605


, the collet mandrel


610


, and the collet retaining adapter


640


in the axial direction


2800


relative to the liner hanger


595


, the outer collet support member


645


, and the liner hanger setting sleeve


650


.




In particular, as illustrated in

FIG. 11D

, the axial displacement of the collet mandrel


610


in the axial direction


2800


preferably displaces the collet retaining sleeve


635


in the axial direction


2800


relative to the collet upsets


1525


. In this manner, the collet upsets


1525


are no longer held in the collet slots


1665


by the collet retaining sleeve


635


. Furthermore, in a preferred embodiment, the axial displacement of the collet mandrel


610


in the axial direction


2800


preferably displaces the first shoulder


1445


in the axial direction


2800


relative to the locking dogs


620


. In this manner, the locking dogs


620


lock onto the first shoulder


1445


when the collet mandrel


610


is then displaced in the axial direction


2805


. In a preferred embodiment, axial displacement of the collet mandrel of about 1.50 inches displaces the collet retaining sleeve


635


out from under the collet upsets


1525


and also locks the locking dogs


620


onto the first shoulder


1445


of the collet mandrel


610


. Furthermore, the axial displacement of the collet retaining adapter


640


in the axial direction


2800


also preferably displaces the slots


1600


away from the collet upsets


1525


.




In a preferred embodiment, the liner hanger


595


, the collet retaining adapter


640


, the outer collet support member


645


, and the liner hanger setting sleeve


650


are then decoupled from the apparatus


500


by displacing the annular support member


2000


, the first support member


505


, the second support member


515


, the force multiplier outer support member


525


, the force multiplier inner support member


530


, the first coupling


545


, the third support member


550


, the second coupling


605


, the collet mandrel


610


, and the collet retaining adapter


640


in the axial direction


2805


relative to the liner hanger


595


, the outer collet support member


645


, and the liner hanger setting sleeve


650


. In particular, the subsequent axial displacement of the collet mandrel


610


in the axial direction


2805


preferably pulls and decouples the collet upsets


1525


from the collet slots


1665


. In a preferred embodiment, the angled outer surfaces


1545


of the collet upsets


1525


facilitate the decoupling process.




In an alternative embodiment, if the locking dogs


620


do not lock onto the first shoulder


1445


of the collet mandrel


610


, then the annular support member


2000


, the first support member


505


, the second support member


515


, the force multiplier outer support member


525


, the force multiplier inner support member


530


, the first coupling


545


, the third support member


550


, the second coupling


605


, the collet mandrel


610


, and the collet retaining adapter


640


are then displaced back in the axial direction


2800


and rotated. The rotation of the annular support member


2000


, the first support member


505


, the second support member


515


, the force multiplier outer support member


525


, the force multiplier inner support member


530


, the first coupling


545


, the third support member


550


, the second coupling


605


, the collet mandrel


610


, and the collet retaining adapter


640


preferably misaligns the collet slots


1600


and


1665


.




In this manner, a subsequent displacement of the in the axial direction


2805


pushes the collet upsets


1525


out of the collet slots


1665


in the liner hanger setting sleeve


650


. In a preferred embodiment, the amount of rotation ranges from about 5 to 40 degrees. In this manner, the liner hanger


595


, the outer collet support member


645


, and the liner hanger setting sleeve


650


are then decoupled from the apparatus


500


.




In a preferred embodiment, the removal of the apparatus


500


from the interior of the radially expanded liner hanger


595


is facilitated by the presence of the body of lubricant


575


. In particular, the body of lubricant


575


preferably lubricates the interface between the interior surface of the radially expanded liner hanger


595


and the exterior surface of the expansion cone


585


. In this manner, the axial force required to remove the apparatus


500


from the interior of the radially expanded liner hanger


595


is minimized.




Referring to

FIGS. 12A

to


12


C, after the removal of the remaining portions of the apparatus


500


, a new section of wellbore casing is provided that preferably includes the liner hanger


595


, the outer collet support member


645


, the liner hanger setting sleeve


650


, the tubular members


2070


and an outer annular layer of cured material


2900


.




In an alternative embodiment, the interior of the radially expanded liner hanger


595


is used as a polished bore receptacle (“PBR”). In an alternative embodiment, the interior of the radially expanded liner hanger


595


is machined and then used as a PBR. In an alternative embodiment, the first end


1350


of the liner hanger


595


is threaded and coupled to a PBR.




In a preferred embodiment, all surfaces of the apparatus


500


that provide a dynamic seal are nickel plated in order to provide optimal wear resistance.




Referring to

FIGS. 13A

to


13


G, an alternative embodiment of an apparatus


3000


for forming or repairing a wellbore casing, pipeline or structural support will be described. The apparatus


3000


preferably includes the first support member


505


, the debris shield


510


, the second support member


515


, the one or more crossover valve members


520


, the force multiplier outer support member


525


, the force multiplier inner support member


530


, the force multiplier piston


535


, the force multiplier sleeve


540


, the first coupling


545


, the third support member


550


, the spring spacer


555


, the preload spring


560


, the lubrication fitting


565


, the lubrication packer sleeve


570


, the body of lubricant


575


, the mandrel


580


, the expansion cone


585


, the centralizer


590


, the liner hanger


595


, the travel port sealing sleeve


600


, the second coupling


605


, the collet mandrel


610


, the load transfer sleeve


615


, the one or more locking dogs


620


, the locking dog retainer


622


, the collet assembly


625


, the collet retaining sleeve


635


, the collet retaining adapter


640


, the outer collet support member


645


, the liner hanger setting sleeve


650


, the one or more crossover valve shear pins


655


, the one or more collet retaining sleeve shear pins


665


, the first passage


670


, the one or more second passages


675


, the third passage


680


, the one or more crossover valve chambers


685


, the primary throat passage


690


, the secondary throat passage


695


, the fourth passage


700


, the one or more inner crossover ports


705


, the one or more outer crossover ports


710


, the force multiplier piston chamber


715


, the force multiplier exhaust chamber


720


, the one or more force multiplier exhaust passages


725


, the second annular chamber


735


, the one or more expansion cone travel indicator ports


740


, the one or more collet release ports


745


, the third annular chamber


750


, the collet release throat passage


755


, the fifth passage


760


, the one or more sixth passages


765


, the one or more seventh passages


770


, the one or more collet sleeve passages


775


, the one or more force multiplier supply passages


790


, the first lubrication supply passage


795


, the second lubrication supply passage


800


, the collet sleeve release chamber


805


, and a standoff adaptor


3005


.




Except as described below, the design and operation of the first support member


505


, the debris shield


510


, the second support member


515


, the one or more crossover valve members


520


, the force multiplier outer support member


525


, the force multiplier inner support member


530


, the force multiplier piston


535


, the force multiplier sleeve


540


, the first coupling


545


, the third support member


550


, the spring spacer


555


, the preload spring


560


, the lubrication fitting


565


, the lubrication packer sleeve


570


, the body of lubricant


575


, the mandrel


580


, the expansion cone


585


, the centralizer


590


, the liner hanger


595


, the travel port sealing sleeve


600


, the second coupling


605


, the collet mandrel


610


, the load transfer sleeve


615


, the one or more locking dogs


620


, the locking dog retainer


622


, the collet assembly


625


, the collet retaining sleeve


635


, the collet retaining adapter


640


, the outer collet support member


645


, the liner hanger setting sleeve


650


, the one or more crossover valve shear pins


655


, the one or more collet retaining sleeve shear pins


665


, the first passage


670


, the one or more second passages


675


, the third passage


680


, the one or more crossover valve chambers


685


, the primary throat passage


690


, the secondary throat passage


695


, the fourth passage


700


, the one or more inner crossover ports


705


, the one or more outer crossover ports


710


, the force multiplier piston chamber


715


, the force multiplier exhaust chamber


720


, the one or more force multiplier exhaust passages


725


, the second annular chamber


735


, the one or more expansion cone travel indicator ports


740


, the one or more collet release ports


745


, the third annular chamber


750


, the collet release throat passage


755


, the fifth passage


760


, the one or more sixth passages


765


, the one or more seventh passages


770


, the one or more collet sleeve passages


775


, the one or more force multiplier supply passages


790


, the first lubrication supply passage


795


, the second lubrication supply passage


800


, and the collet sleeve release chamber


805


of the apparatus


3000


are preferably provided as described above with reference to the apparatus


500


in

FIGS. 2A

to


12


C.




Referring to

FIGS. 13A

to


13


C, the standoff adaptor


3005


is coupled to the first end


1005


of the first support member


505


. The standoff adaptor


3005


preferably has a substantially annular cross-section. The standoff adaptor


3005


may be fabricated from any number of conventional commercially available materials. In a preferred embodiment, the standoff adaptor


3005


is fabricated from alloy steel having a minimum yield strength of about 75,000 to 140,000 psi in order to optimally provide high tensile strength and resistance to abrasion and fluid erosion. In a preferred embodiment, the standoff adaptor


3005


includes a first end


3010


, a second end


3015


, an intermediate portion


3020


, a first threaded portion


3025


, one or more slots


3030


, and a second threaded portion


3035


.




The first end


3010


of the standoff adaptor


3005


preferably includes the first threaded portion


3025


. The first threaded portion


3025


is preferably adapted to be removably coupled to a conventional tubular support member. The first threaded portion


3025


may be any number of conventional threaded portions. In a preferred embodiment, the first threaded portion


3025


is a 4½″ API IF JT BOX thread in order to optimally provide tensile strength.




The intermediate portion


3020


of the standoff adaptor


3005


preferably includes the slots


3030


. The outside diameter of the intermediate portion


3020


of the standoff adaptor


3005


is preferably greater than the outside diameter of the liner hanger


595


in order to optimally protect the sealing members


1395


, and the top and bottom rings,


1380


and


1390


, from abrasion when positioning and/or rotating the apparatus


3000


within a wellbore, or other tubular member. The intermediate portion


3020


of the standoff adaptor


3005


preferably includes a plurality of axial slots


3030


equally positioned about the circumference of the intermediate portion


3020


in order to optimally permit wellbore fluids and other materials to be conveyed along the outside surface of the apparatus


3000


.




The second end of the standoff adaptor


3005


preferably includes the second threaded portion


3035


. The second threaded portion


3035


is preferably adapted to be removably coupled to the first threaded portion


1015


of the first end


1005


of the first support member


505


. The second threaded portion


3035


may be any number of conventional threaded portions. In a preferred embodiment, the second threaded portion


3035


is a 4½″ API IF JT PIN thread in order to optimally provide tensile strength.




Referring to

FIGS. 13D and 13E

, in the apparatus


3000


, the second end


1360


of the liner hanger


595


is preferably coupled to the first end


1620


of the outer collet support member


645


using a threaded connection


3040


. The threaded connection


3040


is preferably adapted to provide a threaded connection having a primary metal-to-metal seal


3045




a


and a secondary metal-to-metal seal


3045




b


in order to optimally provide a fluidic seal. In a preferred embodiment, the threaded connection


3040


is a DS HST threaded connection available from Halliburton Energy Services in order to optimally provide high tensile strength and a fluidic seal for high operating temperatures.




Referring to

FIGS. 13D and 13F

, in the apparatus


3000


, the second end


1625


of the outer collet support member


645


is preferably coupled to the first end


1650


of the liner hanger setting sleeve


650


using a substantially permanent connection


3050


. In this manner, the tensile strength of the connection between the second end


1625


of the outer collet support member


645


and the first end


1650


of the liner hanger setting sleeve


650


is optimized. In a preferred embodiment, the permanent connection


3050


includes a threaded connection


3055


and a welded connection


3060


. In this manner, the tensile strength of the connection between the second end


1625


of the outer collet support member


645


and the first end


1650


of the liner hanger setting sleeve


650


is optimized.




Referring to

FIGS. 13D

,


13


E and


13


F, in the apparatus


3000


, the liner hanger setting sleeve


650


further preferably includes an intermediate portion


3065


having one or more axial slots


3070


. In a preferred embodiment, the outside diameter of the intermediate portion


3065


of the liner hanger setting sleeve


650


is greater than the outside diameter of the liner hanger


595


in order to protect the sealing elements


1395


and the top and bottom rings,


1385


and


1390


, from abrasion when positioning and/or rotating the apparatus


3000


within a wellbore casing or other tubular member. The intermediate portion


3065


of the liner hanger setting sleeve


650


preferably includes a plurality of axial slots


3070


equally positioned about the circumference of the intermediate portion


3065


in order to optimally permit wellbore fluids and other materials to be conveyed along the outside surface of the apparatus


3000


.




In several alternative preferred embodiments, the apparatus


500


and


3000


are used to fabricate and/or repair a wellbore casing, a pipeline, or a structural support. In several other alternative embodiments, the apparatus


500


and


3000


are used to fabricate a wellbore casing, pipeline, or structural support including a plurality of concentric tubular members coupled to a preexisting tubular member.




An apparatus for coupling a tubular member to a preexisting structure has been described that includes a first support member including a first fluid passage, a manifold coupled to the support member including: a second fluid passage coupled to the first fluid passage including a throat passage adapted to receive a plug, a third fluid passage coupled to the second fluid passage, and a fourth fluid passage coupled to the second fluid passage, a second support member coupled to the manifold including a fifth fluid passage coupled to the second fluid passage, an expansion cone coupled to the second support member, a tubular member coupled to the first support member including one or more sealing members positioned on an exterior surface, a first interior chamber defined by the portion of the tubular member above the manifold, the first interior chamber coupled to the fourth fluid passage, a second interior chamber defined by the portion of the tubular member between the manifold and the expansion cone, the second interior chamber coupled to the third fluid passage, a third interior chamber defined by the portion of the tubular member below the expansion cone, the third interior chamber coupled to the fifth fluid passage, and a shoe coupled to the tubular member including: a throat passage coupled to the third interior chamber adapted to receive a wiper dart, and a sixth fluid passage coupled to the throat passage. In a preferred embodiment, the expansion cone is slidingly coupled to the second support member. In a preferred embodiment, the expansion cone includes a central aperture that is coupled to the second support member.




A method of coupling a tubular member to a preexisting structure has also been described that includes positioning a support member, an expansion cone, and a tubular member within a preexisting structure, injecting a first quantity of a fluidic material into the preexisting structure below the expansion cone, and injecting a second quantity of a fluidic material into the preexisting structure above the expansion cone. In a preferred embodiment, the injecting of the first quantity of the fluidic material includes: injecting a hardenable fluidic material. In a preferred embodiment, the injecting of the second quantity of the fluidic material includes: injecting a non-hardenable fluidic material. In a preferred embodiment, the method further includes fluidicly isolating an interior portion of the tubular member from an exterior portion of the tubular member. In a preferred embodiment, the method further includes fluidicly isolating a first interior portion of the tubular member from a second interior portion of the tubular member. In a preferred embodiment, the expansion cone divides the interior of the tubular member tubular member into a pair of interior chambers. In a preferred embodiment, one of the interior chambers is pressurized. In a preferred embodiment, the method further includes a manifold for distributing the first and second quantities of fluidic material. In a preferred embodiment, the expansion cone and manifold divide the interior of the tubular member tubular member into three interior chambers. In a preferred embodiment, one of the interior chambers is pressurized.




An apparatus has also been described that includes a preexisting structure and an expanded tubular member coupled to the preexisting structure. The expanded tubular member is coupled to the preexisting structure by the process of: positioning a support member, an expansion cone, and the tubular member within the preexisting structure, injecting a first quantity of a fluidic material into the preexisting structure below the expansion cone, and injecting a second quantity of a fluidic material into the preexisting structure above the expansion cone. In a preferred embodiment, the injecting of the first quantity of the fluidic material includes: injecting a hardenable fluidic material. In a preferred embodiment, the injecting of the second quantity of the fluidic material includes: injecting a non-hardenable fluidic material. In a preferred embodiment, the apparatus further includes fluidicly isolating an interior portion of the tubular member from an exterior portion of the tubular member. In a preferred embodiment, the apparatus further includes fluidicly isolating a first interior portion of the tubular member from a second interior portion of the tubular member. In a preferred embodiment, the expansion cone divides the interior of the tubular member into a pair of interior chambers. In a preferred embodiment, one of the interior chambers is pressurized. In a preferred embodiment, the apparatus further includes a manifold for distributing the first and second quantities of fluidic material. In a preferred embodiment, the expansion cone and manifold divide the interior of the tubular member into three interior chambers. In a preferred embodiment, one of the interior chambers is pressurized.




An apparatus for coupling two elements has also been described that includes a support member including one or more support member slots, a tubular member including one or more tubular member slots, and a coupling for removably coupling the tubular member to the support member, including:




a coupling body movably coupled to the support member, one or more coupling arms extending from the coupling body and coupling elements extending from corresponding coupling arms adapted to mate with corresponding support member and tubular member slots. In a preferred embodiment, the coupling elements include one or more angled surfaces. In a preferred embodiment, the coupling body includes one or more locking elements for locking the coupling body to the support member. In a preferred embodiment, the apparatus further includes a sleeve movably coupled to the support member for locking the coupling elements within the support member and tubular member slots. In a preferred embodiment, the apparatus further includes one or more shear pins for removably coupling the sleeve to the support member. In a preferred embodiment, the apparatus further includes a pressure chamber positioned between the support member and the sleeve for axially displacing the sleeve relative to the support member.




A method of coupling a first member to a second member has also been described that includes forming a first set of coupling slots in the first member, forming a second set of coupling slots in the second member, aligning the first and second pairs of coupling slots and inserting coupling elements into each of the pairs of coupling slots. In a preferred embodiment, the method further includes movably coupling the coupling elements to the first member. In a preferred embodiment, the method further includes preventing the coupling elements from being removed from each of the pairs of coupling slots. In a preferred embodiment, the first and second members are decoupled by the process of: rotating the first member relative to the second member, and axially displacing the first member relative to the second member. In a preferred embodiment, the first and second members are decoupled by the process of: permitting the coupling elements to be removed from each of the pairs of coupling slots, and axially displacing the first member relative to the second member in a first direction. In a preferred embodiment, permitting the coupling elements to be removed from each of the pairs of coupling slots includes: axially displacing the first member relative to the second member in a second direction. In a preferred embodiment, the first and second directions are opposite. In a preferred embodiment, permitting the coupling elements to be removed from each of the pairs of coupling slots includes: pressurizing an interior portion of the first member.




An apparatus for controlling the flow of fluidic materials within a housing has also been described that includes a first passage within the housing, a throat passage within the housing fluidicly coupled to the first passage adapted to receive a plug, a second passage within the housing fluidicly coupled to the throat passage, a third passage within the housing fluidicly coupled to the first passage, one or more valve chambers within the housing fluidicly coupled to the third passage including moveable valve elements, a fourth passage within the housing fluidicly coupled to the valve chambers and a region outside of the housing, a fifth passage within the housing fluidicly coupled to the second passage and controllably coupled to the valve chambers by corresponding valve elements, and a sixth passage within the housing fluidicly coupled to the second passage and the valve chambers. In a preferred embodiment, the apparatus further includes: one or more shear pins for removably coupling the valve elements to corresponding valve chambers. In a preferred embodiment, the third passage has a substantially annular cross section. In a preferred embodiment, the throat passage includes: a primary throat passage, and a larger secondary throat passage fluidicly coupled to the primary throat passage. In a preferred embodiment, the apparatus further includes: a debris shield positioned within the third passage for preventing debris from entering the valve chambers. In a preferred embodiment, the apparatus further includes: a piston chamber within the housing fluidicly coupled to the third passage, and a piston movably coupled to and positioned within the piston chamber.




A method of controlling the flow of fluidic materials within a housing including an inlet passage and an outlet passage has also been described that includes injecting fluidic materials into the inlet passage, blocking the inlet passage, and opening the outlet passage. In a preferred embodiment, opening the outlet passage includes: conveying fluidic materials from the inlet passage to a valve element, and displacing the valve element. In a preferred embodiment, conveying fluidic materials from the inlet passage to the valve element includes: preventing debris from being conveyed to the valve element. In a preferred embodiment, the method further includes conveying fluidic materials from the inlet passage to a piston chamber. In a preferred embodiment, conveying fluidic materials from the inlet passage to the piston chamber includes: preventing debris from being conveyed to the valve element.




An apparatus has also been described that includes a first tubular member, a second tubular member positioned within and coupled to the first tubular member, a first annular chamber defined by the space between the first and second tubular members, an annular piston movably coupled to the second tubular member and positioned within the first annular chamber, an annular sleeve coupled to the annular piston and positioned within the first annular chamber, a third annular member coupled to the second annular member and positioned within and movably coupled to the annular sleeve, a second annular chamber defined by the space between the annular piston, the third annular member, the second tubular member, and the annular sleeve, an inlet passage fluidicly coupled to the first annular chamber, and an outlet passage fluidicly coupled to the second annular chamber. In a preferred embodiment, the apparatus further includes: an annular expansion cone movably coupled to the second tubular member and positioned within the first annular chamber. In a preferred embodiment, the first tubular member includes: one or more sealing members coupled to an exterior surface of the first tubular member. In a preferred embodiment, the first tubular member includes: one or more ring members coupled to an exterior surface of the first tubular member.




A method of applying an axial force to a first piston positioned within a first piston chamber has also been described that includes applying an axial force to the first piston using a second piston positioned within the first piston chamber. In a preferred embodiment, the method further includes applying an axial force to the first piston by pressurizing the first piston chamber. In a preferred embodiment, the first piston chamber is a substantially annular chamber. In a preferred embodiment, the method further includes coupling an annular sleeve to the second piston, and applying the axial force to the first piston using the annular sleeve. In a preferred embodiment, the method further includes pressurizing the first piston chamber. In a preferred embodiment, the method further includes coupling the second piston to a second chamber, and depressurizing the second chamber.




An apparatus for radially expanding a tubular member has also been described that includes a support member, a tubular member coupled to the support member, a mandrel movably coupled to the support member and positioned within the tubular member, an annular expansion cone coupled to the mandrel and movably coupled to the tubular member for radially expanding the tubular member, and a lubrication assembly coupled to the mandrel for supplying a lubricant to the annular expansion cone, including:




a sealing member coupled to the annular member, a body of lubricant positioned in an annular chamber defined by the space between the sealing member, the annular member, and the tubular member, and a lubrication supply passage fluidicly coupled to the body of lubricant and the annular expansion cone for supplying a lubricant to the annular expansion cone. In a preferred embodiment, the tubular member includes: one or more sealing members positioned on an outer surface of the tubular member. In a preferred embodiment, the tubular member includes: one or more ring member positioned on an outer surface of the tubular member. In a preferred embodiment, the apparatus further includes: a centralizer coupled to the mandrel for centrally positioning the expansion cone within the tubular member. In a preferred embodiment, the apparatus further includes: a preload spring assembly for applying an axial force to the mandrel. In a preferred embodiment, the preload spring assembly includes: a compressed spring, and an annular spacer for compressing the compressed spring.




A method of operating an apparatus for radially expanding a tubular member including an expansion cone has also been described that includes lubricating the interface between the expansion cone and the tubular member, centrally positioning the expansion cone within the tubular member, and applying a substantially constant axial force to the tubular member prior to the beginning of the radial expansion process.




An apparatus has also been described that includes a support member, a tubular member coupled to the support member, an annular expansion cone movably coupled to the support member and the tubular member and positioned within the tubular member for radially expanding the tubular member, and a preload assembly for applying an axial force to the annular expansion cone, including: a compressed spring coupled to the support member for applying the axial force to the annular expansion cone, and a spacer coupled to the support member for controlling the amount of spring compression.




An apparatus for coupling a tubular member to a preexisting structure has also been described that includes a support member, a manifold coupled to the support member for controlling the flow of fluidic materials within the apparatus, a radial expansion assembly movably coupled to the support member for radially expanding the tubular member, and a coupling assembly for removably coupling the tubular member to the support member. In a preferred embodiment, the apparatus further includes a force multiplier assembly movably coupled to the support member for applying an axial force to the radial expansion assembly. In a preferred embodiment, the manifold includes: a throat passage adapted to receive a ball, and a valve for controlling the flow of fluidic materials out of the apparatus. In a preferred embodiment, the manifold further includes: a debris shield for preventing the entry of debris into the apparatus. In a preferred embodiment, the radial expansion assembly includes: a mandrel movably coupled to the support member, and an annular expansion cone coupled to the mandrel. In a preferred embodiment, the radial expansion assembly further includes: a lubrication assembly coupled to the mandrel for providing a lubricant to the interface between the expansion cone and the tubular member. In a preferred embodiment, the radial expansion assembly further includes: a preloaded spring assembly for applying an axial force to the mandrel. In a preferred embodiment, the tubular member includes one or more coupling slots, the support member includes one or more coupling slots, and the coupling assembly includes: a coupling body movably coupled to the support member, and one or more coupling elements coupled to the coupling body for engaging the coupling slots of the tubular member and the support member.




An apparatus for coupling a tubular member to a preexisting structure has also been described that includes an annular support member including a first passage, a manifold coupled to the annular support member, including: a throat passage fluidicly coupled to the first passage adapted to receive a fluid plug, a second passage fluidicly coupled to the throat passage, a third passage fluidicly coupled to the first passage, a fourth passage fluidicly coupled to the third passage, one or more valve chambers fluidicly coupled to the fourth passage including corresponding movable valve elements, one or more fifth passages fluidicly coupled to the second passage and controllably coupled to corresponding valve chambers by corresponding movable valve elements, one or more sixth passages fludicly coupled to a region outside of the manifold and to corresponding valve chambers, one or more seventh passages fluidicly coupled to corresponding valve chambers and the second passage, and one or more force multiplier supply passages fluidicly coupled to the fourth passage, a force multiplier assembly coupled to the annular support member, including: a force multiplier tubular member coupled to the manifold, an annular force multiplier piston chamber defined by the space between the annular support member and the force multiplier tubular member and fluidicly coupled to the force multiplier supply passages, an annular force multiplier piston positioned in the annular force multiplier piston chamber and movably coupled to the annular support member, a force multiplier sleeve coupled to the annular force multiplier piston, a force multiplier sleeve sealing member coupled to the annular support member and movably coupled to the force multiplier sleeve for sealing the interface between the force multiplier sleeve and the annular support member, an annular force multiplier exhaust chamber defined by the space between the annular force multiplier piston, the force multiplier sleeve, and the force multiplier sleeve sealing member, and a force multiplier exhaust passage fluidicly coupled to the annular force multiplier exhaust chamber and the interior of the annular support member, an expandable tubular member, a radial expansion assembly movably coupled to the annular support member, including: an annular mandrel positioned within the annular force multiplier piston chamber, an annular expansion cone coupled to the annular mandrel and movably coupled to the expandable tubular member, a lubrication assembly coupled to the annular mandrel for supplying lubrication to the interface between the annular expansion cone and the expandable tubular member, a centralizer coupled to the annular mandrel for centering the annular expansion cone within the expandable tubular member, and a preload assembly movably coupled to the annular support member for applying an axial force to the annular mandrel, and a coupling assembly coupled to the annular support member and releasably coupled to the expandable tubular member, including: a tubular coupling member coupled to the expandable tubular member including one or more tubular coupling member slots, an annular support member coupling interface coupled to the annular support member including one or more annular support member coupling interface slots, and a coupling device for releasably coupling the tubular coupling member to the annular support member coupling interface, including: a coupling device body movably coupled to the annular support member, one or more resilient coupling device arms extending from the coupling device body, and one or more coupling device coupling elements extending from corresponding coupling device arms adapted to removably mate with corresponding tubular coupling member and annular support member coupling slots.




A method of coupling a tubular member to a pre-existing structure has also been described that includes positioning an expansion cone and the tubular member within the preexisting structure using a support member, displacing the expansion cone relative to the tubular member in the axial direction, and decoupling the support member from the tubular member. In a preferred embodiment, displacing the expansion cone includes: displacing a force multiplier piston, and applying an axial force to the expansion cone using the force multiplier piston. In a preferred embodiment, displacing the expansion cone includes: applying fluid pressure to the expansion cone. In a preferred embodiment, displacing the force multiplier piston includes: applying fluid pressure to the force multiplier piston. In a preferred embodiment, the method further includes applying fluid pressure to the expansion cone. In a preferred embodiment, the decoupling includes: displacing the support member relative to the tubular member in a first direction, and displacing the support member relative to the tubular member in a second direction. In a preferred embodiment, decoupling includes: rotating the support member relative to the tubular member, and displacing the support member relative to the tubular member in an axial direction. In a preferred embodiment, the method further includes prior to displacing the expansion cone, injecting a hardenable fluidic material into the preexisting structure. In a preferred embodiment, the method further includes prior to decoupling, curing the hardenable fluidic sealing material.




An apparatus has also been described that includes a preexisting structure, and a radially expanded tubular member coupled to the preexisting structure by the process of: positioning an expansion cone and the tubular member within the preexisting structure using a support member, displacing the expansion cone relative to the tubular member in the axial direction, and decoupling the support member from the tubular member. In a preferred embodiment, displacing the expansion cone includes: displacing a force multiplier piston, and applying an axial force to the expansion cone using the force multiplier piston. In a preferred embodiment, displacing the expansion cone includes: applying fluid pressure to the expansion cone. In a preferred embodiment, displacing the force multiplier piston includes: applying fluid pressure to the force multiplier piston. In a preferred embodiment, the method further includes applying fluid pressure to the expansion cone. In a preferred embodiment, the decoupling includes: displacing the support member relative to the tubular member in a first direction, and displacing the support member relative to the tubular member in a second direction. In a preferred embodiment, decoupling includes: rotating the support member relative to the tubular member, and displacing the support member relative to the tubular member in an axial direction. In a preferred embodiment, the method further includes prior to displacing the expansion cone, injecting a hardenable fluidic material into the preexisting structure. In a preferred embodiment, the method further includes prior to decoupling, curing the hardenable fluidic sealing material.




Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.



Claims
  • 1. A method of operating an apparatus for radially expanding a tubular member comprising an expansion cone, comprising:lubricating the interface between the expansion cone and the tubular member; centrally positioning the expansion cone within the tubular member; and applying a substantially constant contact force to the tubular member prior to a beginning of a radial expansion process using the expansion cone.
  • 2. The method of claim 1, further comprising:coupling the tubular member and the expansion cone to a support member.
  • 3. The method of claim 2, further comprising:applying a substantially constant axial force of between about 500 to 2,000 lbf from the support member to the expansion cone to preload the expansion cone against the interior surface of the tubular member prior to the radial expansion of the tubular member.
  • 4. The method of claim 3, wherein the application of the substantially constant axial force from the support member to the expansion cone seals the interface between the expansion cone and the tubular member prior to the radial expansion of the tubular member.
  • 5. The method of claim 2, further comprising:during the radial expansion of the tubular member, displacing the expansion cone relative to the support member.
  • 6. The method of claim 1, wherein lubricating the interface between the expansion cone and the tubular member comprises:pumping a lubricant into the interface between the expansion cone and the tubular member.
  • 7. The method of claim 1, wherein the expansion cone comprises an annular expansion cone.
  • 8. The method of claim 1, wherein the expansion cone comprises a reversible expansion cone.
  • 9. The method of claim 1, wherein the expansion cone includes one or more outer conical surfaces for engaging the interior surface of the tubular member.
  • 10. The method of claim 1, wherein the expansion cone includes one or more hard inserts for contacting the interior surface of the tubular member during the radial expansion process.
  • 11. The method of claim 1, further comprising:coupling the tubular member and the expansion cone to a support member; applying a substantially constant axial force of between about 500 to 2,000 lbf from the support member to the expansion cone to preload the expansion cone against the interior surface of the tubular member prior to the radial expansion of the tubular member; and during the radial expansion of the tubular member, displacing the expansion cone relative to the support member.
  • 12. The method of claim 1, wherein lubricating the interface between the expansion cone and the tubular member comprises:pumping a lubricant into the interface between the expansion cone and the tubular member; wherein the expansion cone comprises an annular expansion cone; and wherein the expansion cone comprises a reversible expansion cone.
  • 13. The method of claim 1, wherein the tubular member comprises a wellbore casing.
  • 14. The method of claim 1, wherein the tubular member comprises a pipeline.
  • 15. The method of claim 1, wherein the tubular member comprises a structural support.
  • 16. A method of operating an apparatus for radially expanding and plastically deforming a tubular member including an annular expansion cone, comprising:coupling the tubular member and the annular expansion cone to a support member; applying a substantially constant axial force of between about 500 to 2,000 lbf from the support member to the annular expansion cone to preload the annular expansion cone against the interior surface of the tubular member prior to the radial expansion and plastic deformation of the tubular member to seal the interface between the annular expansion cone and the tubular member; pumping a lubricant into the interface between the annular expansion cone and the tubular member; centrally positioning the annular expansion cone within the tubular member; and during the radial expansion and plastic deformation of the tubular member, displacing the annular expansion cone relative to the support member.
  • 17. The method of claim 16, wherein the expansion cone comprises a reversible expansion cone.
  • 18. The method of claim 16, wherein the expansion cone includes a plurality of outer conical surfaces for engaging the interior surface of the tubular member.
  • 19. The method of claim 16, wherein the expansion cone includes one or more hard inserts for contacting the interior surface of the tubular member during the radial expansion process.
  • 20. A method of operating an apparatus for radially expanding a tubular member including an expansion cone, comprising:lubricating the interface between the expansion cone and the tubular member; centrally positioning the expansion cone within the tubular member; applying a substantially constant axial force to the tubular member prior to a beginning of a radial expansion process; coupling the tubular member and the expansion cone to a support member; and applying a substantially constant axial force of between about 500 to 2,000 lbf from the support member to the expansion cone to preload the expansion cone against the interior surface of the tubular member prior to the radial expansion of the tubular member.
  • 21. A method of operating an apparatus for radially expanding a tubular member including an expansion cone, comprising:lubricating the interface between the expansion cone and the tubular member; centrally positioning the expansion cone within the tubular member; applying a substantially constant axial force to the tubular member prior to a beginning of a radial expansion process; coupling the tubular member and the expansion cone to a support member; and applying a substantially constant axial force of between about 500 to 2,000 lbf from the support member to the expansion cone to preload the expansion cone against the interior surface of the tubular member prior to the radial expansion of the tubular member; wherein the application of the substantially constant axial force from the support member to the expansion cone seals the interface between the expansion cone and the tubular member prior to the radial expansion of the tubular member.
  • 22. A method of operating an apparatus for radially expanding a tubular member including an expansion cone, comprising:lubricating the interface between the expansion cone and the tubular member; centrally positioning the expansion cone within the tubular member; and applying a substantially constant axial force to the tubular member prior to a beginning of a radial expansion process; wherein the expansion cone includes one or more hard inserts for contacting the interior surface of the tubular member during the radial expansion process.
  • 23. A method of operating an apparatus for radially expanding a tubular member including an expansion cone, comprising:lubricating the interface between the expansion cone and the tubular member; centrally positioning the expansion cone within the tubular member; applying a substantially constant axial force to the tubular member prior to a beginning of a radial expansion process; coupling the tubular member and the expansion cone to a support member; applying a substantially constant axial force of between about 500 to 2,000 lbf from the support member to the expansion cone to preload the expansion cone against the interior surface of the tubular member prior to the radial expansion of the tubular member; and during the radial expansion of the tubular member, displacing the expansion cone relative to the support member.
  • 24. A method of operating an apparatus for radially expanding a tubular member including an expansion device for radially expanding and plastically deforming the tubular member, comprising:lubricating the interface between the expansion device and the tubular member; centrally positioning the expansion device within the tubular member; applying a substantially constant axial force to the tubular member prior to a beginning of a radial expansion process; coupling the tubular member and the expansion device to a support member; and applying a substantially constant axial force of between about 500 to 2,000 lbf from the support member to the expansion device to preload the expansion device against the interior surface of the tubular member prior to the radial expansion of the tubular member.
  • 25. A method of operating an apparatus for radially expanding a tubular member including an expansion device for radially expanding and plastically deforming the tubular member, comprising:lubricating the interface between the expansion device and the tubular member; centrally positioning the expansion device within the tubular member; applying a substantially constant axial force to the tubular member prior to a beginning of a radial expansion process; coupling the tubular member and the expansion device to a support member; and applying a substantially constant axial force of between about 500 to 2,000 lbf from the support member to the expansion device to preload the expansion device against the interior surface of the tubular member prior to the radial expansion of the tubular member; wherein the application of the substantially constant axial force from the support member to the expansion device seals the interface between the expansion device and the tubular member prior to the radial expansion of the tubular member.
  • 26. A method of operating an apparatus for radially expanding a tubular member including an expansion device for radially expanding and plastically deforming the tubular member, comprising:lubricating the interface between the expansion device and the tubular member; centrally positioning the expansion device within the tubular member; and applying a substantially constant axial force to the tubular member prior to a beginning of a radial expansion process; wherein the expansion device includes one or more hard inserts for contacting the interior surface of the tubular member during the radial expansion process.
  • 27. A method of operating an apparatus for radially expanding a tubular member including an expansion device for radially expanding and plastically deforming the tubular member, comprising:lubricating the interface between the expansion device and the tubular member; centrally positioning the expansion device within the tubular member; applying a substantially constant axial force to the tubular member prior to a beginning of a radial expansion process; coupling the tubular member and the expansion device to a support member; applying a substantially constant axial force of between about 500 to 2,000 lbf from the support member to the expansion device to preload the expansion device against the interior surface of the tubular member prior to the radial expansion of the tubular member; and during the radial expansion of the tubular member, displacing the expansion device relative to the support member.
  • 28. A method of operating an apparatus for radially expanding and plastically deforming a tubular member including an expansion device for radially expanding and plastically deforming the tubular member, comprising:coupling the tubular member and the expansion device to a support member; applying a substantially constant axial force of between about 500 to 2,000 lbf from the support member to the expansion device to preload the expansion device against the interior surface of the tubular member prior to the radial expansion and plastic deformation of the tubular member to seal the interface between the expansion device and the tubular member; pumping a lubricant into the interface between the expansion device and the tubular member; centrally positioning the expansion device within the tubular member; and during the radial expansion and plastic deformation of the tubular member, displacing the expansion device relative to the support member.
  • 29. The method of claim 28, wherein the expansion device comprises a reversible expansion device.
  • 30. The method of claim 28, wherein the expansion device comprises a plurality of outer conical surfaces for engaging the interior surface of the tubular member.
  • 31. The method of claim 28, wherein the expansion device includes one or more hard inserts for contacting the interior surface of the tubular member during the radial expansion process.
  • 32. A method of operating an apparatus for radially expanding a tubular member comprising an expansion device for radially expanding and plastically deforming the tubular member, comprising:lubricating the interface between the expansion device and the tubular member; centrally positioning the expansion device within the tubular member; and applying a substantially constant contact force to the tubular member prior to a beginning of a radial expansion process using the expansion device.
CROSS REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, which claimed the benefit of the filing date of (1) U.S. Provisional Patent Application Serial No. 60/121,841, filed on Feb. 26, 1999 and (2) U.S. Provisional Patent Application Serial No. 60/154,047, filed on Sep. 16, 1999, the disclosures of which are incorporated herein by reference. This application is related to the following co-pending applications: (1) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, which issued as U.S. Pat. No. 6,328,113, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/108,558, filed on Nov. 16, 1998, (2) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/111,293, filed on Dec. 7, 1998, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/119,611, filed on Feb. 11, 1999, (4) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application Serial No. 60/121,702, filed on Feb. 25, 1999, (5) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. Provisional Patent Application No. 60/121,907, filed on Feb. 26, 1999, (6) U.S. Provisional Patent Application Serial No. 60/124,042, filed on Mar. 11, 1999, (7) U.S. Provisional Patent Application Serial No. 60/131,106, filed on Apr. 26, 1999, (8) U.S. Provisional Patent Application Serial No. 60/137,998, filed on Jun. 7, 1999, (9) U.S. Provisional Patent Application Serial No. 60/143,039, filed on Jul. 9, 1999, and (10) U.S. Provisional Patent Application Serial No. 60/146,203, filed on Jul. 29, 1999.

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Provisional Applications (2)
Number Date Country
60/154047 Sep 1999 US
60/121841 Feb 1999 US