High pressure high temperature packer system, improved expansion assembly for a tubular expander tool, and method of tubular expansion

Abstract

A method and apparatus for creating a seal between two coaxial strings of pipe are provided. The method and apparatus have utility in one embodiment for sealing the annulus between the tubing and the casing within a hydrocarbon wellbore. According to the method of the present invention, an expander tool is positioned at a selected depth within the tubing, and then actuated in order to expand the tubing against the inner wall of the casing wall. Multiple configurations of the expander tool are disclosed. The expander tool is rotated in order to provide a fluid seal in the annulus. In this way, the tubing string becomes its own packer. In one embodiment, a seal ring is provided around the outer surface of the tubing to enhance the fluid seal. Further, a slip ring is provided around the outer surface of the tubing to provide a gripping means between the tubing and the casing.

1 . A method for sealing the annulus between two concentric tubulars disposed in a wellbore, the first tubular residing within the second tubular, comprising the steps of: 
 positioning an expander tool at the depth desired for sealing the annulus;    actuating the expander tool so that the expander tool acts against the inner surface of the first tubular;    expanding the first tubular so that an outer surface of the first tubular is in contact with an inner surface of the surrounding second tubular; and    rotating the expander tool so that radial contact is made between the outer surface of the first tubular and the inner surface of the second tubular, thereby creating a fluid seal in the annulus.    
     
     
         2 . The method for sealing the annulus between two concentric tubulars of  claim 1 , further comprising the step of: 
 translating the expander tool vertically within the wellbore while actuating the expander tool so as to expand the first tubular along a desired portion of its length.    
     
     
         3 . The method for sealing the annulus between two concentric tubulars of  claim 1 , wherein the first tubular is a tubular body in series with a string of tubing, and the second tubular is a string of casing.  
     
     
         4 . The method for sealing the annulus between two concentric tubulars of  claim 1 , wherein the first tubular is an upper portion of a first string of casing, and the second tubular is a lower portion of a second string of casing.  
     
     
         5 . The method for sealing the annulus between two concentric tubulars of claims  3  and  4 , wherein the tubular body defines an elongated tubular member comprising: 
 a top end;  
 a bottom end; and  
 at least one seal ring circumferentially fitted along the outer surface of the tubular body intermediate the top and bottom ends.  
 
     
     
         6 . The method for sealing the annulus between two concentric tubulars of  claim 5 , wherein the tubular body defines an elongated tubular member further comprising: 
 at least one slip member disposed along the outer surface of the tubular body intermediate the top and bottom ends for gripping between the tubular body and the surrounding casing.    
     
     
         7 . The method for sealing the annulus between two concentric tubulars of  claim 5 , wherein the seal ring is fabricated from an elastomeric material and serves to provide a fluid seal between the tubular body and the casing, thereby sealing the annulus.  
     
     
         8 . The method for sealing the annulus between two concentric tubulars of  claim 6 , wherein the slip member defines a ring circumferentially fitted along the outer surface of the tubular body, and has a plurality of teeth to provide a gripping means between the tubular body and the casing.  
     
     
         9 . The method for sealing the annulus between two concentric tubulars of  claim 6 , wherein the slip member defines a carbide material on the outer surface of the tubular body.  
     
     
         10 . The method for sealing the annulus between two concentric tubulars of  claim 5 , wherein the tubular body further comprises a positioning member for positioning the expander tool at the proper depth within the tubular body.  
     
     
         11 . The method for sealing the annulus between two concentric tubulars of  claim 10 , wherein the positioning member comprises a landing profile having a beveled member internal to said tubular body upon which the expander tool lands during the positioning step.  
     
     
         12 . The method for sealing the annulus between two concentric tubulars of  claim 3 , wherein the tubular body defines a joint of production tubing.  
     
     
         13 . The method for sealing the annulus between two concentric tubulars of  claim 1 , wherein the expander tool comprises: 
 a body having an upper portion and a lower portion;    a plurality of recesses disposed radially about the circumference of the body intermediate said upper and lower portions;    a piston disposed within each of said recesses; and    a roller coupled to each of said pistons, said roller having a plurality of lobes.    
     
     
         14 . The method for sealing the annulus between two concentric tubulars of  claim 13 , wherein: 
 said pistons are movable from a first recessed position essentially within said recess, to a second extended position away from said recess by a radial outward force applied from an interior of the body; and    said rollers are profiled to provide a top lobe, a bottom lobe, and an intermediate lobe, said top lobe and said bottom lobe having an essentially equal diameter which is greater than the diameter of said intermediate lobe.    
     
     
         15 . The method for sealing the annulus between two concentric tubulars of  claim 14 , wherein: 
 said expander tool further comprises a conduit internal to said body for transmitting fluid to said pistons so as to cause said radial outward force against said pistons; and    said body further comprises at least one nozzle through which fluid exits said body.    
     
     
         16 . The method for sealing the annulus between two concentric tubulars of  claim 14 , wherein: 
 said pistons further comprise at least one row, with at least three pistons per row, where said pistons are disposed substantially equidistantly about the circumference of the body on each row; and    each of said plurality of rollers further comprises an axle about which each of said rollers rotates above said respective pistons.    
     
     
         17 . The method for sealing the annulus between two concentric tubulars of  claim 14 , wherein the expander tool is sized to fit into the inner surface of the tubular body within the wellbore.  
     
     
         18 . The method for sealing the annulus between two concentric tubulars of  claim 13 , wherein: 
 said pistons are movable from a first recessed position essentially within said recess, to a second extended position away from said recess by a radial outward force applied from an interior of the body; and    said rollers have a tapered profile.    
     
     
         19 . The method for sealing the annulus between two concentric tubulars of  claim 18 , wherein: 
 said pistons further comprise at least one row, with at least three pistons per row, said pistons being disposed substantially equidistantly about the circumference of the body on each row; and    each of said plurality of rollers is permitted to at least partially rotate on said respective pistons.    
     
     
         20 . An expander tool for expanding a tubular body, the expander tool comprising: 
 a body;    a plurality of recesses disposed radially about the circumference of the body;    a piston disposed within each of said recesses; and    a roller coupled to each of said pistons, said roller having a plurality of lobes.    
     
     
         21 . The expander tool of  claim 20 , wherein: 
 said pistons are movable from a first recessed position essentially within said recess, to a second extended position away from said recess by a radial outward force applied from an interior of the body; and    said rollers are profiled to provide a top lobe, a bottom lobe, and an intermediate lobe, said top lobe and said bottom lobe having an essentially equal diameter which is greater than the diameter of said intermediate lobe.    
     
     
         22 . The expander tool of  claim 21 , wherein said expander tool further comprises a conduit internal to said body for transmitting fluid to said pistons so as to cause said radial outward force.  
     
     
         23 . The expander tool of  claim 22 , wherein said pistons of said expander tool are movable by a radial force applied from an interior of the housing.  
     
     
         24 . The expander tool of  claim 23 , wherein said body further comprises at least one nozzle through which fluid exits said body.  
     
     
         25 . The expander tool of  claim 24 , wherein each of said nozzles defines an orifice sized so that said pistons are moved from said first recessed position to said second extended position when said fluid reaches critical flow through said nozzles.  
     
     
         26 . The expander tool of  claim 22 , wherein: 
 said pistons further comprise at least one row of pistons, with a plurality of pistons on each row, and with said pistons being disposed equidistantly about the circumference of the housing on each row; and    said plurality of rollers further comprises an axle coupling each of said rollers to each of said pistons.    
     
     
         27 . The expander tool of  claim 26 , further comprising a set of piston-retaining plates disposed upon the body proximate each recess in order to prevent over travel of said pistons.  
     
     
         28 . The expander tool of  claim 22 , further comprising a rotational actuator coupled to said body for rotating said expander tool.  
     
     
         29 . An expansion assembly for an expander tool for expanding a surrounding tubular body, the expansion assembly being disposed within a recess in the body of the expander tool, and the expander tool having a bore therethrough, the expansion assembly comprising: 
 a piston disposed within the recess of the expander tool, the piston having a bottom surface and a top surface, the bottom surface being exposed to a radially outward force within the bore of the expander tool, and the piston being outwardly extendable from the body of the expander tool within the recess in response to the radially outward force;    an axle coupled to the top surface of the piston; and    a roller disposed on the piston to permit the roller to rotate about the axle, the roller having a plurality of lobes, and the roller being profiled to have a multi-lobe profile.    
     
     
         30 . The expansion assembly of  claim 29 , wherein the multi-lobe arrangement for the roller defines a top lobe, a bottom lobe, and an intermediate lobe, the top lobe and the bottom lobe having an essentially equal diameter which is greater than the diameter of the intermediate lobe.  
     
     
         31 . The expansion assembly of  claim 30 , wherein the radially outward forces are hydraulic forces from within the bore of the expander tool.  
     
     
         32 . The expansion assembly of  claim 31 , wherein the piston sealingly resides within the recess of the body of the expander.  
     
     
         33 . An expansion assembly for an expander tool for expanding a surrounding tubular body, the expansion assembly being disposed within a recess in the body of the expander tool, and the expander tool having a bore therethrough, the expansion assembly comprising: 
 a piston disposed within the recess of the expander tool, the piston having a bottom surface and a top surface, the bottom surface being exposed to a radially outward force within the bore of the expander tool, and the piston being outwardly extendable from the body of the expander tool within the recess in response to the radially outward force; and    a roller residing on the top surface of the piston, such that the roller is permitted to at least partially rotate upon the top surface of the piston when the piston is extended away from the body of the expander tool and the roller engages a surrounding tubular body.    
     
     
         34 . The expansion assembly of  claim 33 , wherein the top surface defines a bearing cavity for closely receiving the roller.  
     
     
         35 . The expansion assembly of  claim 34 , wherein the top surface bearing cavity defines a polished, bearing cradle for receiving the roller.  
     
     
         36 . The expansion assembly of  claim 34 , wherein the top surface further comprises a shoe for gravitationally receiving the roller at an end.  
     
     
         37 . The expansion assembly of  claim 36 , further comprising a headrest on the top surface of the piston, the headrest configured to receive a portion of the roller at an end opposite the shoe.  
     
     
         38 . The expansion assembly of  claim 37 , wherein the headrest defines a bearing cavity for closely receiving the upper portion of the roller.  
     
     
         39 . The expansion assembly of  claim 38 , wherein the headrest bearing cavity defines a polished, arcuate bearing cradle for receiving the roller.  
     
     
         40 . The expansion assembly of  claim 38 , further comprising a cap piece for covering the top surface of the piston, the cap piece providing structural support for the headrest.  
     
     
         41 . The expansion assembly of  claim 34 , wherein the roller defines a tapered body having an elongated tapered surface.  
     
     
         42 . The expansion assembly of  claim 41 , wherein the orientation of the roller is skewed relative to the longitudinal center axis of the bore of the expander tool.  
     
     
         43 . The expansion assembly of  claim 41 , wherein the radially outward forces are hydraulic forces from within the bore of the expander tool.  
     
     
         44 . The expansion assembly of  claim 43 , wherein the piston sealingly resides within the recess of the body of the expander.  
     
     
         45 . The expansion assembly of  claim 34 , wherein the radially outward forces are hydraulic forces from within the bore of the expander tool.  
     
     
         46 . The expansion assembly of  claim 45 , wherein the piston sealingly resides within the recess of the body of the expander.  
     
     
         47 . The expansion assembly of  claim 45 , further comprising a port within the piston so as to provide a path of fluid communication between the bore of the expander tool and the top surface, thereby providing lubrication between the roller and the top surface during an expansion operation.  
     
     
         48 . An expansion assembly for a hydraulic expander tool for expanding a surrounding tubular body, the expansion assembly being sealingly disposed within a recess in the body of the expander tool, and the expander tool having a bore therethrough, the expansion assembly comprising: 
 a piston residing within the recess of the expander tool, and being outwardly extendable from the body of the expander tool within the recess in response to hydraulic pressure within the bore of the expander tool, the piston comprising a bottom surface exposed to fluid pressure within the expander tool, and a top surface defining a bearing cavity; and    a roller residing on the bearing cavity of the piston, the roller having an outer surface resting on the bearing cavity itself such that engagement of the roller surface to and rotation within the surrounding tubular body causes the roller to at least partially rotate within the bearing cavity.    
     
     
         49 . The expansion assembly of  claim 48 , wherein: 
 the roller defines a tapered body having an elongated surface oriented to contact the surrounding tubular body at an angle during the expansion process; and    the orientation of the roller is skewed relative to the longitudinal center axis of the bore of the expander tool.    
     
     
         50 . The expansion assembly of  claim 49 , further comprising a shoe disposed upon the top surface of the piston for receiving a lower portion of the roller.  
     
     
         51 . The expansion assembly of  claim 50 , further comprising a headrest disposed upon the top surface of the piston for supporting an upper portion of the roller.  
     
     
         52 . The expansion assembly of  claim 51 , wherein: 
 the top surface bearing cavity defines an arcuate, polished bearing cradle for closely receiving a first end of the roller; and    the headrest defines an arcuate, polished bearing cradle for closely receiving a second end of the roller.    
     
     
         53 . The expansion assembly of  claim 52 , further comprising a port within the piston so as to provide a path of fluid communication between the bore of the expander tool and the top surface, thereby providing lubrication between the roller and the top surface during an expansion operation.  
     
     
         54 . The expansion assembly of  claim 53 , further comprising a cap piece for covering the top surface of the piston, the cap piece providing structural support for the headrest.  
     
     
         55 . A method for expanding a tubular body within a hydrocarbon wellbore, comprising the steps of: 
 attaching an expander tool to the lower end of a working string, the expander tool having a body and a plurality of recesses within the body, each recess receiving an expansion assembly, each expansion assembly comprising: 
 a piston residing within the recess of the expander tool, and being outwardly extendable from the body of the expander tool within the recess in response to radially outward forces within the bore of the expander tool, the piston comprising a bottom surface exposed to the radially outward forces within the expander tool, and a top surface defining a bearing cavity; and  
 a roller residing on the bearing cavity of the piston, the roller having an outer surface resting on the bearing cavity itself such that engagement of the roller surface to and rotation within the surrounding tubular body causes the roller to at least partially rotate within the bearing cavity;  
   running the working string with the expander tool into a wellbore; and    rotating the working string in order to radially expand a section of the surrounding tubular body within the wellbore.    
     
     
         56 . The method for expanding a tubular body within a wellbore of  claim 44 , 
 wherein the radially outward forces applied against the base of the piston are hydraulic forces; and    wherein the step of actuating the expansion assembly is accomplished by injecting hydraulic fluid under pressure into the working string.    
     
     
         57 . The method for expanding a tubular body within a wellbore of  claim 45 , 
 wherein the roller defines a tapered body having an elongated surface oriented to contact the surrounding tubular body at an angle during the expansion process; and    wherein the orientation of the roller is skewed relative to the longitudinal center axis of the bore of the expander tool.    
     
     
         58 . The method for expanding a tubular body within a wellbore of  claim 46 , further comprising a shoe disposed upon the top surface of the piston for receiving an end portion of the roller.  
     
     
         59 . The method for expanding a tubular body within a wellbore of  claim 47 , further comprising a headrest disposed upon the top surface of the piston for supporting a portion of the roller at an end opposite the shoe.  
     
     
         60 . The method for expanding a tubular body within a wellbore of  claim 48 , wherein: 
 the top surface bearing cavity defines an arcuate, polished bearing cradle for closely receiving a first end of the roller; and    the headrest defines an arcuate, polished bearing cradle for closely receiving a second end of the roller.    
     
     
         61 . The method for expanding a tubular body within a wellbore of  claim 49 , further comprising a cap piece for covering the top surface of the piston, the cap piece providing structural support for the headrest.  
     
     
         62 . The method for expanding a tubular body within a wellbore of  claim 46 , further comprising the step of translating the expander tool axially within the wellbore so as to expand the surrounding tubular body along a desired length.  
     
     
         63 . The method for expanding a tubular body within a wellbore of  claim 51 , further comprising the step of relieving hydraulic pressure from within the expander tool.  
     
     
         64 . The method for expanding a tubular body within a wellbore of  claim 52 , further comprising the step of removing the expander tool from the wellbore.  
     
     
         65 . A method for sealing the annulus between a string of production tubing and the casing within a wellbore, comprising the steps of: 
 positioning an expander tool at a selected depth within the production tubing;    actuating the expander tool so that the expander tool acts against the inner surface of the production tubing;    expanding the production tubing so that the outer surface of the production tubing is in contact with the inner surface of the casing; and    rotating the expander tool so that radial contact is made between the outer surface of the production tubing and the inner surface of the casing, thereby creating a fluid seal in the annulus.    
     
     
         66 . The method for sealing the annulus of  claim 54 , wherein said production tubing comprises therein an expandable portion having: 
 at least one elastomeric seal ring circumferentially fitted along the outer surface of said expandable portion intermediate top and bottom ends, the seal ring providing a fluid seal between the expandable portion and the casing after the expandable portion of the production tubing has been expanded, thereby sealing the annulus;    at least one slip ring disposed along the outer surface of the expandable portion intermediate the top and bottom ends, and spaced apart from the seal ring, the slip ring having gripping means between the tubular body and the casing; and    a landing profile having a beveled member internal to said expandable portion upon which the expander tool lands during the positioning step.    
     
     
         67 . The method for sealing the annulus of  claim 55 , wherein the expander tool comprises: 
 a body;    a plurality of recesses disposed radially about the circumference of the body;    a piston disposed within each of said recesses, each of said pistons being movable from a first recessed position essentially within said body, to a second extended position away from said body by a radial outward force applied from an interior of the body;    a roller coupled to each of said pistons, each of said rollers being profiled to provide a top lobe, a bottom lobe, and an intermediate lobe, said top lobe and said bottom lobe having an essentially equal diameter which is greater than the diameter of said intermediate lobe; and    a conduit internal to said body for transmitting fluid to said pistons so as to cause said radial outward force.    
     
     
         68 . The method for sealing the annulus of  claim 56 , wherein 
 said body further comprises at least one nozzle through which fluid exits said body;    said pistons are disposed equidistantly about the circumference of the body; and    said plurality of rollers further comprises an axle coupling each of said rollers to each of said pistons.    
     
     
         69 . The method for sealing the annulus of  claim 57 , further comprising the step of translating the expander tool vertically within the wellbore while expanding the production tubing so as to expand the expandable portion along a desired portion of its length.  
     
     
         70 . A method of completing a wellbore comprising the steps of: 
 providing a tubular;    applying a slip ring around said tubular;    applying a seal ring around said tubular proximate to said slip ring;    positioning the tubular into a casing of the wellbore;    positioning an expander tool in the tubular at a point proximate the slip ring and sealing ring;    applying hydraulic fluid internal to the expander tool; and    expanding, in response to the hydraulic fluid, portions of the tubular corresponding to the depths of the slip ring and sealing ring, whereby the tubular is placed into contact with the inner surface of the surrounding casing.    
     
     
         71 . The method of  claim 59 , wherein the step of positioning an expander tool further comprises the steps of: 
 providing an expander tool having a plurality of multi-lobed rollers for forming a contoured seal, wherein said roller has a top, a bottom and a center lobe.    
     
     
         72 . The method of  claim 60 , further comprising: 
 the step of rotating said expander within the tubular until said tubular is sealed to the inner surface of the surrounding casing.