Methods and apparatus for top to bottom expansion of tubulars within a wellbore

Abstract

One illustrative method for top to bottom expansion of tubulars within a wellbore comprises positioning the tubular, with an expansion mandrel positioned therein, within the well and expanding the tubular by forcing the expansion mandrel through the tubular in a down-hole direction of the well while forcing well fluid displaced by the expansion of the tubular into the formation.

What is claimed: 
     
         1 . A method of expanding a tubular within a well located in a formation, comprising:
 positioning the tubular, with an expansion mandrel positioned therein, within the well; and   expanding the tubular by forcing the expansion mandrel through the tubular in a down-hole direction of the well while forcing well fluid displaced by the expansion of the tubular into the formation.   
     
     
         2 . The method of  claim 1 , wherein the well fluid displaced by the expansion of the tubular are forced into the formation at a location below a bottom of the tubular. 
     
     
         3 . The method of  claim 1 , wherein the well comprises an existing casing and wherein positioning the tubular comprises positioning the tubular adjacent the existing casing and wherein expanding the tubular comprises expanding the tubular toward the existing casing and wherein the well fluid displaced by the expansion of the tubular comprises well fluids positioned between the tubular and the existing casing. 
     
     
         4 . The method of  claim 1 , wherein the existing casing comprises a plurality of perforations. 
     
     
         5 . The method of  claim 1 , wherein the well comprises an open bore hole section that exposes a portion of the formation and wherein positioning the tubular comprises positioning the tubular adjacent the open bore hole section and wherein expanding the tubular comprises expanding the tubular toward the open bore hole section and wherein the well fluid displaced by the expansion of the tubular comprises well fluids positioned between the tubular and the open bore hole section. 
     
     
         6 . The method of  claim 1  wherein the tubular comprises a plurality of sections of pipe. 
     
     
         7 . The method of  claim 1 , wherein, prior to positioning the tubular within the well, the method comprises:
 coupling a release sub to an upper end of the tubular; and   coupling a guide nose to a lower end of the tubular.   
     
     
         8 . A method of expanding a tubular within a well located in a formation, comprising:
 positioning an expansion assembly within a tubular, the expansion assembly comprising an expansion cone, a cone mandrel and a cone guide assembly, wherein the expansion cone is positioned adjacent the cone mandrel and an upper end of the cone mandrel and the cone guide is positioned on the cone mandrel adjacent a lower end of the cone mandrel;   positioning the tubular, with the expansion assembly positioned therein, within the well; and   expanding the tubular by forcing the expansion assembly through the tubular in a down-hole direction of the well such that the expansion cone engages and radially expands the tubular while forcing well fluid displaced by the expansion of the tubular into the formation.   
     
     
         9 . The method of  claim 8 , wherein, prior to positioning the expansion assembly within the tubular, the method comprises coupling a float collar to a lower end of the cone mandrel, the float collar comprising an inverted check valve that, when closed, is adapted to block a flow of fluid through the inverted check valve in a down-hole direction of the well and wherein the method comprises positioning the expansion assembly within the well comprises positioning the expansion assembly having the float collar coupled thereto within the tubular. 
     
     
         10 . An apparatus, comprising:
 at least one tubular;   a release sub operatively coupled to a first end of the tubular;   an expansion cone operatively coupled to a first end of a cone mandrel, the combination of the expansion cone and the cone mandrel positioned within the tubular below the release sub; and   a float collar operatively coupled to a second end of the cone mandrel, the float collar comprising an inverted check valve that, when closed, is adapted to block a flow of fluid through the inverted check valve in a down-hole direction of the well.   
     
     
         11 . The apparatus of  claim 10 , wherein the tubular comprises a plurality of sections of pipe. 
     
     
         12 . The apparatus of  claim 10 , wherein the cone mandrel comprises a flange at an upper end of the cone mandrel and a cone retaining sleeve that is coupled to an outer surface of the cone mandrel, wherein the expansion cone is positioned above the cone retaining sleeve and wherein a portion of the expansion cone engages the flange. 
     
     
         13 . The apparatus of  claim 12 , wherein the cone retaining sleeve is coupled to the outer surface of the cone mandrel by a threaded connection. 
     
     
         14 . The apparatus of  claim 10 , wherein the at least one tubular comprises a pre-expanded portion and an expandable portion, wherein the expansion cone is adapted to be positioned within the pre-expanded portion of the tubular prior to any expansion of the expandable portion of the tubular. 
     
     
         15 . The apparatus of  claim 10  wherein the at least one tubular comprises a plurality of tubulars. 
     
     
         16 . The apparatus of  claim 10 , further comprising a plurality of separate elastomer bands positioned around the outer surface of the at least one tubular. 
     
     
         17 . The apparatus of  claim 10 , wherein the at least one tubular comprises:
 a first tubular that comprises a pre-expanded portion and an expandable portion;   a second tubular that comprises a pre-expanded portion and an expandable portion; and   an intermediate tubular that is operatively coupled to both the first tubular and the second tubular, the intermediate tubular having an inside diameter that is greater than a maximum outside diameter of the expansion cone.   
     
     
         18 . The apparatus of  claim 10  wherein the at least one tubular is adapted to be positioned against a formation in an uncased section of a wellbore. 
     
     
         19 . The apparatus of  claim 10 , wherein the at least one tubular is a single length of pipe.