Wear-resistant, variable diameter expansion tool and expansion methods

Abstract

The inventions provide apparatus and methods for radially expanding a tubular deployed in a subterranean well by moving an expansion tool axially through the well. An expansion tool apparatus may have wear faces attached to at least a portion of the outer periphery of a mandrel for contacting the interior surface of the pipe, tube, or screen during expansion. According to another aspect of the invention, an expansion tool has a controlled egress seal between the outer surface of the tool and the inside surface of the expandable tubular. According to another aspect of the invention, an automatically variable diameter expansion tool is provided having a variable diameter cone, which expands, and contracts based on input from one or more sensors. According to another aspect of the invention, an apparatus and method for expanding a length of screen assembly in a subterranean wellbore is provided.

1. An expansion cone apparatus for use in expanding a tubular in a subterranean well comprising:
 a cone body; 
 and at least one wear face attached to the cone body, the wear face made of a material harder than the cone body and comprising at least one ring including a plurality of wear face segments attached to one another by connectors. 
 
     
     
       2. An expansion cone apparatus as in  claim 1  wherein the cone body is 4140 steel. 
     
     
       3. An expansion cone apparatus as in  claim 1  wherein the at least one wear face is tungsten carbide. 
     
     
       4. An expansion cone apparatus as in  claim 1  wherein the at least one wear face is mechanically bonded to the cone body. 
     
     
       5. An expansion cone apparatus as in  claim 1 , the cone body having at least one niche therein for receiving the at least one wear face. 
     
     
       6. An expansion cone apparatus as in  claim 1  wherein the at least one wear face comprises at least one ring. 
     
     
       7. An expansion cone apparatus as in  claim 6  wherein each ring comprises a plurality of wear face segments attached to one another by connectors. 
     
     
       8. An expansion cone apparatus as in  claim 1 , the cone body having expansion slots therein. 
     
     
       9. An expansion cone apparatus as in  claim 1  wherein the at least one wear face is floatingly attached to the cone body. 
     
     
       10. An expansion cone apparatus as in  claim 1  wherein the expansion cone has an automatically-variable diameter, at least one sensor for detecting wellbore parameters operably connected to the variable diameter cone body whereby the cone body diameter automatically varies based on the detected parameters. 
     
     
       11. An expansion cone apparatus as in  claim 1 , the cone body having an exterior surface, a controlled egress seal on the exterior surface of the cone body for sealing contact with the tubular. 
     
     
       12. An expansion cone apparatus as in  claim 1 , the cone body having at least one pivotal joint assembly. 
     
     
       13. A method of downhole tubular expansion comprising of the steps of:
 positioning an expansion cone in a tubular positioned in a subterranean wellbore, the expansion cone having a cone body and at least one wear face attached to the cone body, the at least one wear face comprising at least one ring including a plurality of wear face segments attached to one another by connectors, the at least one wear face of material harder than the cone body; and  
 moving the expanded cone axially along the tubular thereby radially expanding the tubular. 
 
     
     
       14. A method of downhole tubular expansion as in  claim 13  wherein the cone body is ductile material. 
     
     
       15. A method of downhole tubular expansion as in  claim 13  wherein the at least one wear face is chemically bonded to the cone body. 
     
     
       16. A method of downhole tubular expansion as in  claim 13  wherein the at least one wear face is mechanically bonded to the cone body. 
     
     
       17. A method of downhole tubular expansion as in  claim 13 , the cone body having at least one niche therein for receiving the at least one wear face. 
     
     
       18. A method of downhole tubular expansion as in  claim 13  wherein the at least one wear face comprises at least one ring. 
     
     
       19. A method of downhole tubular expansion as in  claim 18  wherein each wear ring comprises a plurality of wear face segments attached to one another by connectors. 
     
     
       20. A method of downhole tubular expansion as in  claim 13 , the cone body having expansion slots therein. 
     
     
       21. A method of downhole tubular expansion as in  claim 13  wherein the at least one wear face is floatingly attached to the cone body. 
     
     
       22. A method of downhole tubular expansion as in  claim 13  wherein the expansion cone has an automatically variable diameter, further comprising the step of automatically varying the diameter of the cone as it is moved along the tubular. 
     
     
       23. A method of downhole tubular expansion as in  claim 13  the cone body having an exterior surface, a controlled egress seal on the exterior surface of the cone body for sealing contact with the tubular. 
     
     
       24. A method of downhole tubular expansion as in  claim 13  the cone body having at least one pivotal joint assembly. 
     
     
       25. An expansion tool apparatus for use in expanding a tubular in a subterranean wellbore comprising:
 an automatically variable diameter expansion cone tool; and 
 at least one sensor for detecting parameters within the wellbore, the at least one sensor operably connected to the variable diameter expansion cone tool, the diameter of the expansion cone tool automatically varying based on the detected parameters. 
 
     
     
       26. An expansion tool as in claim  25  87 further comprising at least one dilator operably connected to the expansion cone tool for expanding and contracting the expansion cone tool. 
     
     
       27. An expansion tool as in  claim 26  wherein the expansion cone tool has an interior surface, the at least one dilator connected to the interior surface. 
     
     
       28. An expansion tool as in  claim 27 , the at least one dilator operable within a preselected range of expansion force. 
     
     
       29. An expansion tool as in  claim 25  wherein the at least one sensor includes a contact stress sensor. 
     
     
       30. An expansion tool as in  claim 26  wherein the at least one dilator is an electromechanical dilator. 
     
     
       31. An expansion tool as in claim  25  87 wherein the expansion cone tool has expansion slots therein. 
     
     
       32. An expansion tool as in claim  25  87 further comprising at least one wear face attached to the expansion cone tool. 
     
     
       33. An expansion tool as in claim  25  87 further comprising a controlled egress seal on the expansion cone tool for sealing contact with the tubular. 
     
     
       34. An expansion tool as in claim  25  87 further comprising at least one pivotal joint assembly. 
     
     
       35. A method of downhole tubular expansion, the tubular disposed in a wellbore of a subterranean well, comprising of the steps of:
 positioning an automatically variable diameter expansion cone tool in the tubular; 
 expanding the cone expansion tool to a selected diameter; 
 advancing the cone expansion tool along the tubular, thereby radially expanding the tubular; and 
 automatically varying the diameter of the cone expansion tool as the cone expansion tool is advanced along the tubular. 
 
     
     
       36. A method of downhole tubular expansion as in  claim 35 , further comprising the steps of:
 detecting parameters within the wellbore; and 
 varying the diameter of the cone expansion tool based on the detected parameters. 
 
     
     
       37. A method of downhole tubular expansion as in claim  35  88, wherein the expansion cone expansion tool includes at lest least one dilator for controlling the diameter of the cone expansion tool. 
     
     
       38. A method of downhole tubular expansion as in  claim 37 , the at least one dilator operable within a preselected range of expansion force. 
     
     
       39. A method of downhole tubular expansion as in  claim 36 , wherein the step of detecting includes detecting the contact stress of the cone expansion tool. 
     
     
       40. A method as in claim  35  88, the expansion cone tool having at least one wear face. 
     
     
       41. A method as in claim  35  88, the expansion cone tool having a controlled egress seal on the expansion cone tool for sealing contact with the tubular. 
     
     
       42. A method as in claim  35  88, the expansion cone tool having at least one pivotal joint assembly. 
     
     
       43. An expansion cone apparatus for use in expanding a tubular in a subterranean well comprising:
 a cone body having an exterior surface; and 
 a controlled egress seal on the exterior surface of the cone body for sealing contact with the tubular. 
 
     
     
       44. An expansion cone apparatus as in  claim 43 , the controlled egress seal being a labyrinthine seal. 
     
     
       45. An expansion cone apparatus as in  claim 44  wherein the labyrinthine seal is of stainless steel. 
     
     
       46. An expansion cone apparatus as in  claim 43 , the controlled egress seal designed to direct fluid flow within a subterranean well. 
     
     
       47. An expansion cone apparatus as in  claim 43  the cone body having a forward end, the controlled egress seal located at the forward end of the cone. 
     
     
       48. An expansion cone apparatus as in  claim 43  wherein the sealing contact does not include physical contact between the tubular and the controlled egress seal. 
     
     
       49. An expansion cone apparatus as in  claim 43  further comprising at least one wear face attached to the cone body. 
     
     
       50. An expansion cone apparatus as in  claim 43  the diameter of the cone body is automatically variable. 
     
     
       51. An expansion cone apparatus as in  claim 43  further comprising at least one pivotal joint assembly. 
     
     
       52. A method of tubular expansion, the tubular positioned in the wellbore of a subterranean well, comprising the steps of:
 positioning an expansion cone in the tubular, the expansion cone having a cone body with an exterior surface and a controlled egress seal on the exterior surface for sealing contact with the tubular; 
 expanding the expansion cone; and 
 moving the expanded cone axially along the tubular thereby expanding the tubular. 
 
     
     
       53. A method of tubular expansion, as in  claim 52  wherein the controlled egress seal is a labyrinthine seal. 
     
     
       54. A method of tubular expansion, as in  claim 53  wherein the seal is stainless steel. 
     
     
       55. A method of tubular expansion as in  claim 52 , wherein the controlled egress seal directs fluid flow within the wellbore ahead of the expansion cone apparatus as it is moved axially along the tubular. 
     
     
       56. A method of tubular expansion as in  claim 52 , the cone body having a forward end, wherein the controlled egress seal is on the forward end of the cone body. 
     
     
       57. A method of tubular expansion as in  claim 52 , wherein the sealing contact does not include physical contact between the tubular and the controlled egress seal. 
     
     
       58. A method as in  claim 52 , the cone body having at least one wear face attached thereto. 
     
     
       59. A method as in  claim 52  wherein the diameter of the cone body is automatically variable, and further comprising the step of automatically varying the diameter of the cone body as it is moved along the tubular. 
     
     
       60. A method as in  claim 52 , the cone body further comprising at least one pivotal joint assembly. 
     
     
       61. A method of expanding a screen assembly in a subterranean wellbore, the method comprising the steps of:
 1. positioning, adjacent the screen assembly, an expansion tool having an upper and lower body, an anchoring mechanism located in the upper body, an expansion cone assembly located in the lower body, and a force generator operable to vary the distance between the anchoring mechanism and the expansion assembly; 
 2. radially expanding the expansion assembly; 
 3. setting the anchoring mechanism; 
 4. activating the force generator to lengthen the distance between the anchoring mechanism and the expansion assembly, thereby forcing the expansion assembly through the screen assembly and radially expanding the screen assembly; 
 5. retracting the anchoring mechanism; 
 6. activating the force generator to shorten the distance between the anchoring mechanism and the expansion assembly; and 
 7. repeating steps 3-6 as desired. 
 
     
     
       62. A method of expanding a screen assembly as in  claim 61  wherein the anchoring mechanism comprises a slip. 
     
     
       63. A method of expanding a screen assembly as in  claim 62  wherein the anchoring mechanism further comprises a packer. 
     
     
       64. A method of expanding a screen assembly as in  claim 61  wherein the force generator comprises a double-piston assembly. 
     
     
       65. A method of expanding a screen assembly as in  claim 61  wherein the anchoring mechanism and force generator are operable via fluid pressure. 
     
     
       66. A method of expanding a screen assembly as in  claim 61  wherein the screen expansion method is performed from the top down. 
     
     
       67. An expansion cone apparatus for use in expanding tubulars in a subterranean well comprising:
 an expansion cone body having multiple cone sections; and 
 at least one joint assembly pivotally connecting the cone sections. 
 
     
     
       68. An expansion cone apparatus as in claim  67  wherein the joint assembly is a knuckle joint. 
     
     
       69. An expansion cone apparatus as in claim  67 , the expansion cone body having a length, wherein multiple joint assemblies are spaced along the length of the cone body. 
     
     
       70. An expansion cone apparatus as in claim  68 , the expansion cone body having a length, wherein multiple joint assemblies are spaced along the length of the cone body. 
     
     
       71. An expansion cone apparatus as in claim  67  further comprising at least one wear face attached to the cone body. 
     
     
       72. An expansion cone apparatus as in claim  71  wherein the at least one wear face comprises at least one wear ring. 
     
     
       73. An expansion cone apparatus as in claim  67 , the expansion cone body having expansion slots therein. 
     
     
       74. An expansion cone apparatus as in claim  67  wherein the diameter of the expansion cone body is automatically variable. 
     
     
       75. An expansion cone apparatus as in claim  69  wherein the diameter of the expansion cone body is automatically variable. 
     
     
       76. An expansion cone apparatus as in claim  67 , further comprising a controlled egress seal mounted on the exterior surface of the cone body. 
     
     
       77. A method of tubular expansion, the tubular positioned in the wellbore of a subterranean well, comprising the steps of:
 positioning an expansion cone in the tubular, the expansion cone having an expansion cone body with multiple cone body sections and at least one joint assembly pivotally connecting the cone sections; 
 expanding the expansion cone; and 
 moving the expanded cone axially along the tubular thereby radially expanding the tubular. 
 
     
     
       78. A method as in  claim 77  wherein the at least one joint assembly is a knuckle joint. 
     
     
       79. A method as in  claim 77 , the expansion cone body having a length, wherein multiple joint assemblies are spaced along the length of the cone body. 
     
     
       80. A method as in claim  78 , the expansion cone body having a length, wherein multiple joint assemblies are spaced along the length of the cone body. 
     
     
       81. A method as in claim  77  the expansion cone further comprising at least one wear face attached to the cone body. 
     
     
       82. A method as in claim  81  wherein the at least one wear face comprises at least one wear ring. 
     
     
       83. A method as in claim  77 , the expansion cone body having expansion slots therein. 
     
     
       84. A method as in claim  77 , the diameter of the expansion cone body being automatically variable, and further comprising the step of automatically varying the diameter of the expansion cone. 
     
     
       85. A method as in claim  79 , the diameter of the expansion cone body being automatically variable, and further comprising the step of automatically varying the diameter of the expansion cone. 
     
     
       86. A method as in claim  77 , the expansion cone further comprising a controlled egress seal mounted on the exterior surface of the cone body. 
     
     
       87. An expansion tool apparatus as in claim 25 wherein the expansion tool comprises an expansion cone.  
     
     
       88. A method of downhole tubular expansion as in claim 35, wherein the expansion tool comprises an expansion cone.  
     
     
       89. A method of utilizing an expansion tool in conjunction with a sensor in a wellbore, comprising:
 running the expansion tool in an expandable tubular in the wellbore;   positioning the sensor proximate the expansion tool;   activating the expansion tool in order to expand the expandable tubular; and   operating the sensor to detect at least one parameter in the wellbore.    
     
     
       90. The method of claim 89, wherein the at least one parameter comprises temperature.  
     
     
       91. The method of claim 89, wherein the at least one parameter comprises expansion force.  
     
     
       92. The method of claim 89, wherein the at least one parameter comprises compression force.  
     
     
       93. The method of claim 89, wherein the at least one parameter comprises pressure.  
     
     
       94. The method of claim 89, wherein the at least one parameter comprises contact stress.  
     
     
       95. The method of claim 89, wherein the at least one parameter comprises diameter of the expansion tool.  
     
     
       96. The method of claim 95, further comprising mapping the diameter of the expanded tubular.  
     
     
       97. The method of claim 89, further comprising controlling the diameter of the expansion tool in response to one of the at least one parameters.  
     
     
       98. An expansion tool for expanding a tubular in a wellbore, comprising:
 an expansion member capable of being actuated outwardly when expansion of the tubular is desired; and   at least one sensor operably coupled to the expansion member for sensing a wellbore parameter.    
     
     
       99. The expansion tool of claim 98, wherein one of the at least one sensor comprises a sensor sensing temperature.  
     
     
       100. The expansion tool of claim 98, wherein one of the at least one sensor comprises a sensor sensing expansion force.  
     
     
       101. The expansion tool of claim 98, wherein one of the at least one sensor comprises a sensor sensing compression force.  
     
     
       102. The expansion tool of claim 98, wherein one of the at least one sensor comprises a sensor sensing pressure.  
     
     
       103. The expansion tool of claim 98, wherein one of the at least one sensor comprises a sensor sensing contact stress.  
     
     
       104. The expansion tool of claim 98, wherein one of the at least one sensor comprises a sensor sensing diameter of the expansion member.  
     
     
       105. The expansion tool of claim 98, wherein the expansion member is automatically actuated outwardly based on an input from the at least one sensor.  
     
     
       106. The expansion tool of claim 98, wherein the expansion member is capable of being actuated radially outwardly when expansion of the tubular is desired.  
     
     
       107. The expansion tool of claim 98, wherein the sensor is affixed to the expansion member.  
     
     
       108. An expansion cone apparatus for use in expanding a tubular in a subterranean well comprising:
 an automatically-variable diameter cone body;   at least one wear face attached to the cone body, the wear face made of a material harder than the cone body; and   at least one sensor for detecting wellbore parameters operably connected to the variable diameter cone body, whereby the cone body diameter automatically varies based on the detected parameters.    
     
     
       109. An expansion cone apparatus for use in expanding a tubular in a subterranean well comprising:
 a cone body having an exterior surface, the cone body comprising a controlled egress seal on the exterior surface for sealing contact with the tubular; and   at least one wear face attached to the cone body, the wear face made of a material harder than the cone body.    
     
     
       110. A method of downhole tubular expansion comprising of the steps of:
 positioning an expansion cone in a tubular positioned in a subterranean wellbore, the expansion cone having a cone body and at least one wear face chemically bonded to the cone body, the at least one wear face of material harder than the cone body; and   moving the expanded cone axially along the tubular thereby radially expanding the tubular.    
     
     
       111. A method of downhole tubular expansion comprising of the steps of:
 positioning an expansion cone in a tubular positioned in a subterranean wellbore, the expansion cone having a variable diameter cone body and at least one wear face attached to the cone body, the at least one wear face of material harder than the cone body;   moving the expanded cone axially along the tubular thereby radially expanding the tubular; and   automatically varying the diameter of the cone as it is moved along the tubular.