Methods and Apparatus for Expanding Tubular Members

Abstract

A method for sealing a hole in a tubular in a wellbore comprising: (A) locating the tubular patch adjacent the hole; (B) (i) plastically expanding a first portion of the tubular patch above the hole into annular sealing engagement with the tubular to form a first annular seal and (ii) plastically expanding a second portion of the tubular patch below the hole in the tubular into annular sealing engagement with the tubular or the open hole to form a second annular seal thereby sealing the hole in the tubular. The patch may be a corrugated tube prior to expansion in order to pass through restrictions and may have a section with an increased wall thickness including a resilient seal.

1 . A tool for expanding a tubular member in a well, comprising: 
 a locating device for locating the tool in the tubular member to be expanded;    and    an expanding device for expanding the tubular member beyond its starting diameter, the expanding device comprising a radial array of expanding elements, each element, in use, acting on the tubular member to deform it radially outwardly;    wherein each element is moveable in an axial direction independently of the other elements in the array    
   
   
       2 . A tool as claimed in  claim 1 , wherein each element is tapered inwardly at one end.  
   
   
       3 . A tool as claimed in  claim 2 , wherein the array comprises a sectored cone-like structure when all of the elements are positioned at the same axial location in the member.  
   
   
       4 . A tool as claimed in any preceding claim, wherein each element is moveable radially outwardly independent of the other elements in the array.  
   
   
       5 . A tool as claimed in any preceding claim, wherein each element is rotatable about a longitudinal axis.  
   
   
       6 . A tool as claimed in  claim 5 , wherein each element is rotatable in use between a first position in which axial movement of the element causes no radial deformation of the tubular, and a second position in which axial movement causes radial deformation.  
   
   
       7 . A tool as claimed in  claim 6 , wherein the array is configurable such that the elements are axially distributed so multiple elements of the array can be rotated into the first position at the same time.  
   
   
       8 . A tool as claimed in  claim 7 , wherein the array is configurable for expansion by rotation of the elements into the respective second position.  
   
   
       9 . A tool as claimed in  claim 1 , wherein the elements comprise rollers.  
   
   
       10 . A tool as claimed in  claim 9 , wherein the tool further comprises a mandrel over which the rollers move during expansion of the tubular.  
   
   
       11 . A tool as claimed in  claim 10 , wherein the rollers move axially over the surface of the mandrel from one end to the other as the mandrel is moved through the tubular, the rollers being returned to the one end through the interior of the mandrel.  
   
   
       12 . A tool as claimed in  claim 10  or  11 , wherein the mandrel has a cone-like shape.  
   
   
       13 . A tool as claimed in any preceding claim, wherein electrical power and control signals for operation of the tool provided over a wireline cable.  
   
   
       14 . A tool as claimed in any preceding claim, wherein the locating device comprises a cone-like member that is forced into the tubular member to counteract the force required to move the expanding elements axially while deforming the tubular member.  
   
   
       15 . A tool as claimed in  claim 14 , wherein the cone-like member deforms the tubular member radially outwardly.  
   
   
       16 . A tool as claimed in  claim 15 , wherein the cone angle of the cone-like member is different to the corresponding angle on the expanding elements.  
   
   
       17 . A tool as claimed in any of claims  14 - 16 , comprising more than one cone-like member.  
   
   
       18 . A tool as claimed in any of claims  14 - 17 , wherein the expanding device and the cone-like member can each be operated as a locating device or as an expanding member so as to allow expansion to proceed in either direction.  
   
   
       19 . A method of expanding a tubular member in a well, comprising; 
 positioning an expansion tool in the tubular member in the well, the expansion tool comprising a radial array of expanding elements; and    moving the elements in an axial direction to act on the tubular and deform it in a radial direction, each at least on element moving in an axial direction independently of others in the array.    
   
   
       20 . A method as claimed in  claim 19 , further comprising positioning the tool in the tubular with the elements of the array positioned in a first position in which axial movement causes no radial deformation of the tubular, the elements of the array being moved to a second position such that axial movement causes deformation once the tool is in position.  
   
   
       21 . A method as claimed in  claim 20 , wherein the movement between the first and second positions is achieved by rotation of each element about a longitudinal axis.  
   
   
       22 . A method as claimed in any of claims  19 ,  20  or  21 , when performed using a tool as claimed in any of claims  1 - 18 .  
   
   
       23 . A method as claimed in any of claims  19 - 22 , comprising moving the elements so as to deform the tubular member in a non-axisymmetrical manner.  
   
   
       24 . A method as claimed in any of claims  19 - 23 , comprising deforming the tubular member against the wall of the well or a structure located therein.  
   
   
       25 . A method as claimed in  claim 24 , wherein deformation is performed so as to seal the annulus after expansion.  
   
   
       26 . A method as claimed in  claim 24 , when performed in open hole.  
   
   
       27 . A method as claimed in any of claims  19 - 23 , further comprising introducing a swelling material between the tubular member and the well wall so as to fill voids remaining after deformation of the tubular member.  
   
   
       28 . A system comprising a tool as claimed in any of claims  1 - 18  suspended on a wireline cable and connected to control equipment located at the surface so as to be operable in a well to expand tubular members located therein.