CA2510448C - Hybrid threaded connection for expandable tubulars - Google Patents
Hybrid threaded connection for expandable tubulars Download PDFInfo
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- CA2510448C CA2510448C CA2510448A CA2510448A CA2510448C CA 2510448 C CA2510448 C CA 2510448C CA 2510448 A CA2510448 A CA 2510448A CA 2510448 A CA2510448 A CA 2510448A CA 2510448 C CA2510448 C CA 2510448C
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- Prior art keywords
- threads
- pin
- tubular
- box
- connection
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- 238000000034 method Methods 0.000 claims abstract description 82
- 230000013011 mating Effects 0.000 claims abstract description 41
- 239000000463 material Substances 0.000 claims abstract description 24
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- 238000010168 coupling process Methods 0.000 claims abstract description 19
- 238000005859 coupling reaction Methods 0.000 claims abstract description 19
- 239000002184 metal Substances 0.000 claims description 20
- 238000007789 sealing Methods 0.000 claims description 12
- 238000003754 machining Methods 0.000 claims description 10
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- 238000005553 drilling Methods 0.000 description 3
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Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/10—Setting of casings, screens, liners or the like in wells
- E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
- E21B43/106—Couplings or joints therefor
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/02—Couplings; joints
- E21B17/04—Couplings; joints between rod or the like and bit or between rod and rod or the like
- E21B17/042—Threaded
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/10—Setting of casings, screens, liners or the like in wells
- E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L15/00—Screw-threaded joints; Forms of screw-threads for such joints
- F16L15/001—Screw-threaded joints; Forms of screw-threads for such joints with conical threads
- F16L15/003—Screw-threaded joints; Forms of screw-threads for such joints with conical threads with sealing rings
Abstract
An expandable threaded connection between segments of expandable tubulars that allows the threaded tubular connection to withstand the stresses and deformations imposed on the connection by the tubular expansion process is disclosed. The present invention is a unique hybrid threaded connection that utilizes two complementary thread segments to form the expandable threaded connection. The first segment of the threaded connection utilizes standard box and pin threads such that the threads on the pin member in the area of the first segment fully engage the mating threads on the box member. The second segment of the threaded connection has the threads machined on the pin member in a manner such that material is removed from the stab flank of the pin threads to reduce the standard width of the pin threads. In contrast to the pin threads of the second segment, the box threads of the second segment are standard thread width and, thus, are the same thread width as the box threads in the first segment. The use of the reduced thread width in the pin threads of the second segment allows for a loose fit between the pin threads of the second segment and the box threads of the second segment. As the threaded connection is expanded, the loose fit between the pin and box threads of the second segment allows radial and axial movement between the pin and box threads of the second segments of the threaded connection without causing disengagement of the threaded connection. The disclosed hybrid threaded connection thus utilizes multiple thread segments in which the second thread segment accommodates the stresses and deformations generated by the radial expansion process while the threads of the first segment maintain the coupling strength and the pressure integrity of the threaded connection.
Description
HYBRID T'HREADED CONNECTION FOR EXPANDABLE TUBULARS
2 The present invention relates to threaded tubular connections particularly useful in
3 the oil and gas industry. In particular, the invention relates to an expandable tubular
4 threaded connection having a unique hybrid thread design.
7 In the conventional drilling of an oil and gas well, a series of tubulars, typically 8 strings of casing, liner, and/or screen segments connected together, are sequentially 9 installed in the well bore until the depth of the producing zone of the formation is reached. Standard practice requires that each succeeding string of tubulars placed in the 11 well bore has an outside diameter smaller than the preceding string of tubulars and/or 12 bore hole such that the tubular segments can be passed through the preceding string of 13 tubulars and/or bore hole to their downhole location. The reduction in the diameter of 14 each successive string of tubular segments placed in the well bore results in a significant reduction in the diameter of the tubular through which hydrocarbons can be carried to the 16 surface. More importantly, to achieve the desired tubular diameter in the producing zone, 17 the initial bore hole size at the surface must be sufficiently large to allow for a large 18 diameter casing. The large initial bore hole size requires increased drilling time and 19 increased material costs, including increased use of materials such as drilling mud and casing cement.
21 The technology of expandable tubulars addresses these shortcomings in the 22 conventional casing/liner/screen hanging operations. Technology that allows the 23 permanent expansion of tubulars in oil and gas wells is rapidly developing.
Through DM_US\4562686.v2 2 I radial expansion of tubular segments until the outer wall of those segments contacts the 2 inner wall of the host pipe, it is possible to create a tight fit between the expandable 3 tubulars and the host pipe that holds the tubular segments in place and creates an annular 4 seal. Further, it is possible to achieve a well bore of virtually uniform diameter (i.e., a monobore well) by the radial expansion of successive strings of tubular segments. The 6 expandable tubulars are radially expanded by various means known in the art, including, 7 but not limited to, pulling or pushing fixed or variable diameter expansion cones through 8 the tubular, extruding the tubular off of a hydraulically-actuated expansion tool, or 9 rotating an expansion tool while pulling or pushing it through the tubular.
The tubular segments to be expanded are typically coupled together using I 1 threaded connections in which the male end, or pin member, of one tubular is threadably 12 connected to the female end, or box member, of an adjacent tubular.
Alternatively, the 13 ends of the adjacent tubulars may have a pin member at each end, with the box member 14 being formed by a short coupling threaded onto one of the pin members. When a conventional threaded connection is made up, the nose of the pin member is typically in 16 contact with or very close to the back of the box member. This threaded engagement 17 between properly secured pin and box members creates a conventional tubular joint that 18 effectively maintains a secure mechanical connection that holds the tubular segments 19 together and that effectively seals the internal tubular area from the formation and vice versa. Often, the sealing ability of the threaded engagement is augmented through the 21 use of Teflon rings or other deformable seal rings entrapped in the thread area as well 22 as the metal-to-metal seal formed by the contact between the pin and box members.
DM_US\4562686.v2 3 1 Problems have arisen, however, at the threaded connection point between tubular 2 segments during and after expansion when using conventional threaded tubular 3 connections and seals currently available in the industry. When the tubular string is 4 radially expanded, a conventional threaded connection changes dimensionally in a way that can prevent the pin and box members from maintaining proper engagement and 6 sealing. The radial expansion of a conventional threaded connection can cause the pin 7 and box members to radially separate. Essentially, because the radius of curvature of the 8 pin member is different than the radius of curvature of the box member during the 9 expansion process, the pin and box members experience different displacements that the threads of a typical threaded connection cannot accommodate. As a result, the radial 11 expansion weakens the coupling strength of the connections and degrades or lowers the 12 pressure holding integrity of the connections. The threaded connection point thus 13 becomes a source of potential weakness in the tubing string and of potential leaks during 14 and after expansion of the tubular string.
Additionally, the radial expansion of the tubular string causes the pin and box 16 members to undergo axial movement. The amount of axial movement experienced by the 17 pin and box members is dependent on numerous factors, including, but not limited to, the 18 amount of radial expansion of the tubular string, the geometry of the threaded connection 19 (e.g., whether the pin and box members have any thin wall sections), and the method of radial expansion employed.
21 As deeper wells and more difficult completions are attempted using expandable 22 tubulars, the threaded connections that hold the expandable tubulars together must 23 address these known problems and must be able to accommodate the higher pressures DM_US\4562686.v2 4 1 faced in such applications. What is needed is a threaded connection for expandable 2 tubulars that maintains the coupling strength and the pressure integrity of the connection 3 so that it will withstand high pressure during and after expansion. It is an object of the 4 present invention to provide an apparatus and method for creating a threaded connection between segments of expandable tubulars that maintains the coupling strength and the 6 pressure integrity of the expanded connection during and after expansion.
Those and 7 other objectives will become apparent to those of skill in the art from a review of the 8 specification below.
An expandable threaded connection between segments of expandable tubulars 11 that allows the threaded tubular connection to withstand the stresses and deformations 12 imposed on the connection by the tubular expansion process is disclosed.
The present 13 invention is a unique hybrid threaded connection that utilizes two complementary thread 14 segments to form the expandable threaded connection. The first segment of the threaded connection encompasses the area of the threaded connection between the back of the box 16 member and approximately the mid-point of the threaded connection. The first segment 17 of the threaded connection utilizes standard box and pin threads such that the threads on 18 the pin member in the area of the first segment fully engage the mating threads on the 19 box member in the area of the first segment. Additionally, the first segment of the threaded connection comprises a radial metal-to-metal seal, a resilient seal, and a thread 21 seal. All of these seals are fully activated upon make-up of the threaded connection.
22 The second segment of the threaded connection begins where the first segment 23 ends (i.e., at approximately the mid-point of the threaded connection) and extends to the DM_US\4562686.v2 5 l face of the box member. The second segment of the threaded connection has the threads 2 machined on the pin member in a manner such that the pin thread width is reduced. In 3 machining the threads of the pin member in the area of the second segment, material is 4 removed from the stab flank of the pin threads to reduce the standard width of the pin threads. In contrast to the pin threads of the second segment, the box threads of the 6 second segment are standard thread width and, thus, are the same thread width as the box 7 threads in the first segment.
8 The use of the reduced thread width in the pin threads of the second segment 9 allows for a loose fit between the pin threads of the second segment and the box threads of the second segment. As the threaded connection is expanded, the loose fit between the 11 pin and box threads of the second segment allows radial and axial movement between the 12 pin and box threads of the second segments of the threaded connection without causing 13 disengagement of the threaded connection. Thus, the disclosed hybrid threaded 14 connection utilizes multiple thread segments in which the second thread segment accommodates the stresses and deformations generated by the radial expansion process 16 while the threads of the first segment maintain pressure integrity where the metal to metal 17 seal, the resilient seal, and the thread seal are all fully engaged upon make-up of the 18 threaded connection.
19 Additionally, in the preferred embodiment the disclosed threaded connection utilizes a sleeve in the area of the back of the pin member that is placed onto a machined 21 land that is machined into the outer diameter of the pin member. When placed on this 22 land, the sleeve has an outer diameter substantially the same as the outer diameter of the 23 box member such that upon make-up of the threaded connection, the sleeve abuts the box DM_US\4562686.v2 6 1 member. The use of such a sleeve protects the face of the box member from being 2 damaged during running-in of the tubular string.
3 In another aspect, the invention provides an expandable threaded tubular 4 connection, comprising:
a first tubular segment with a box member, the box member comprising interengageable 6 threads that have load flanks and stab flanks of a constant pitch; and 7 a second tubular segment with a pin member, the pin member comprising 8 interengageable threads for engaging said box member, the interengageable threads of the 9 pin member having a first thread segment and a second thread segment, the first and second thread segments comprising multiple turns of threads;
11 wherein the first thread segment comprises load flanks and stab flanks of a first pitch, 12 the first pitch being constant across the first thread segment;
13 wherein the second thread segment comprises load flanks and stab flanks of a second 14 pitch, the second pitch being constant across the second thread segment, the threads of the second thread segment having a reduced axial thickness relative to the threads of the 16 first thread segment;
17 wherein the first and second pitch is equal to the pitch of the threads of the box member;
18 and 19 wherein the load flanks of the first and second thread segments are fully engaged with the load flanks of the box member upon makeup of the connection.
21 In another aspect, the invention provides an expandable threaded tubular 22 connection, comprising:
23 a first tubular segment with a box member, the box member comprising interengageable 24 threads that have load flanks and stab flanks of a constant pitch;
a second tubular segment with a pin member, the pin member comprising 26 interengageable threads for engaging said box member, the interengageable threads of the 27 pin member having a first thread segment and a second thread segment, the first and 28 second thread segments comprising multiple turns of threads;
1 wherein the threads of the first thread segment of the pin member fully engage 2 corresponding mating threads on the box member upon make-up of the threaded 3 connection;
4 wherein the threads of the second thread segment are formed such that material is removed from the stab flank of the pin threads of the second thread segment to reduce the 6 axial thickness of the threads relative to the axial thickness of the threads of the first 7 segment;
8 wherein the load flanks of the threads of the second thread segment is in full 9 engagement with the mating flanks of the threads of the box member upon makeup of the connection;
11 wherein the threads of the first thread segment comprises load flanks and stab flanks of 12 a first constant pitch and the second thread segment comprises load flanks and stab flanks 13 of a second constant pitch, the first constant pitch being equal to the pitch of the load 14 flanks and stab flanks of the threads of the box member; and wherein the reduced axial thickness of the threads of the second thread segment of the 16 pin member causes a gap to be formed between the stab flank of the pin threads and the 17 adjacent flank of the box threads when the threads of the second thread segment are 18 engaged with the corresponding mating threads of the box member upon make-up of the 19 threaded connection;
a machined land area in the outside diameter of the second tubular in the area adjacent 21 the external shoulder of the pin member; and 22 a sleeve secured around the second tubular on the machined land area.
23 In another aspect, the invention provides an expandable threaded tubular 24 connection, comprising:
a first tubular segment with a pin member, the pin member comprising interengageable 26 threads, the interengageable threads having a first thread segment and a second thread 27 segment;
28 a second tubular segment with a pin member, the pin member comprising 29 interengageable threads, the interengageable threads having a first thread segment and a second thread segment;
7a 1 wherein the first and second thread segments of the pin members each comprise 2 multiple turns of threads;
3 wherein the first thread segments of the pin members each comprise load flanks and 4 stab flanks of a first pitch, the first pitch being constant across the first thread segments of the pin members;
6 wherein the second thread segments of the pin members each comprise load flanks and 7 stab flanks of a second pitch, the second pitch being constant across the second thread 8 segments of the pin members;
9 wherein the threads of the second thread segments of each pin member are formed such that material is removed from the stab flank of the pin threads of the second thread 11 segments to reduce the axial thickness of the threads relative to the axial thickness of the 12 threads of the first segment;
13 a coupling member comprising box members on both ends of the coupling member, the 14 box members having interengageable threads designed to engage the pin threads of the pin members of the first tubular and the second tubular upon make-up of the threaded 16 connection;
17 wherein the threads of the box members have load flanks and stab flanks of a constant 18 pitch;
19 wherein the load flanks of the threads of the first and second thread segments are in contact with the mating flanks of the threads of the box members upon makeup of the 21 connection; and 22 wherein the reduced axial thickness of the threads of the second thread segments of each 23 pin member causes a gap to be formed between the stab flank of the pin threads and the 24 adjacent flanks of the box threads when the threads of the second thread segments of each pin member are fully engaged with the corresponding mating threads of the box 26 members of the coupling member upon make-up of the threaded connection.
27 In another aspect, the invention provides a method of forming a connection 28 between expandable tubulars, the method comprising:
7b 1 providing a box member in a first tubular segment, the box member including 2 interengageable threads;
3 providing a pin member on a second tubular segment, the pin member including 4 interengageable threads suitable for threadedly engaging the box member;
machining the threads of the pin member such that the pin member has a first thread 6 segment and a second thread segment, wherein the threads of the second thread segment 7 are machined such that material is removed from the stab flank of the pin threads to 8 reduce the width of the threads;
9 inserting the pin member of the second tubular into the box member of the first tubular;
causing the threads of the first thread segment of the pin member to fully engage 11 corresponding mating threads on the box member upon make-up of the threaded 12 connection; and 13 creating a gap between the stab flank of the pin threads and the adjacent flank of the box 14 threads when the pin threads of the second thread segment are engaged with the corresponding mating threads of the box member upon make-up of the threaded 16 connection.
17 In another aspect, the invention provides a method of forming a connection 18 between expandable tubulars, the method comprising:
19 providing a pin member on a first tubular segment, the pin member including interengageable threads;
21 providing a box member on a second tubular segment, the box member including 22 interengageable threads suitable for threadedly engaging the pin member;
23 machining the threads of the box member such that the box member has a first thread 24 segment and a second thread segment, wherein the threads of the second thread segment are machined such that material is removed from the flank of the box threads adjacent the 26 stab flank of the pin threads to reduce the width of the threads;
27 inserting the pin member of the first tubular into the box member of the second tubular;
7c 1 causing the threads of the first thread segment of the box member to fully engage 2 corresponding mating threads on the pin member upon make-up of the threaded 3 connection; and 4 creating a gap between the stab flank of the pin threads and the adjacent flank of the box threads when the threads of the second thread segment are engaged with the 6 corresponding mating threads of the pin member upon make-up of the threaded 7 connection.
8 In another aspect, the invention provides an expandable threaded tubular 9 connection, comprising:
a first tubular segment with a box member, the box member comprising interengageable 11 threads that have load flanks and stab flanks of a constant pitch;
12 a second tubular segment with a pin member, the pin member comprising 13 interengageable threads for engaging said box member, the interengageable threads of the 14 pin member having a plurality of thread segments, the plurality of thread segments comprising multiple turns of threads;
16 wherein one or more of the thread segments of the pin member comprise threads having 17 a reduced axial thickness relative to the axial thickness of the threads of the box member;
18 wherein the multiple turns of threads of the plurality of thread segments each have load 19 flanks and stab flanks of a constant pitch, the pitch being equal to the pitch of the load flanks and stab flanks of the threads of the box member; and 21 wherein the load flanks of the multiple turns of threads of the plurality of thread 22 segments are in full engagement with the mating flanks of the threads of the box member 23 upon makeup of the connection.
24 In another aspect, the invention provides an expandable threaded tubular connection, comprising:
26 a first tubular segment with a pin member, the pin member comprising interengageable 27 threads that have load flanks and stab flanks of a constant pitch;
7d 1 a second tubular segment with a box member, the box member comprising 2 interengageable threads for engaging said pin member, the interengageable threads of the 3 box member having a plurality of thread segments comprising multiple turns of thread;
4 wherein one or more of the thread segments of the box member comprises threads having a reduced axial thickness relative to the axial thickness of the threads of the pin 6 member;
7 wherein the multiple turns of threads of the plurality of thread segments each have load 8 flanks and stab flanks of a constant pitch, the pitch being equal to the pitch of the load 9 flanks and stab flanks of the threads of the pin member; and wherein the load flanks of the threads of the plurality of thread segments are in full 11 engagement with the mating flanks of the threads of the pin member upon makeup of the 12 connection.
13 In another aspect, the invention provides a method of forming a connection 14 between expandable tubulars, the method comprising:
providing a box member in a first tubular segment, the box member including 16 interengageable threads;
17 providing a pin member on a second tubular segment, the pin member including 18 interengageable threads suitable for threadedly engaging the box member;
19 machining the threads of the pin member such that the pin member has a plurality of thread segments, wherein the threads of one or more thread segments of the pin member 21 are machined such that material is removed from the stab flank of the pin threads to 22 reduce the width of the threads;
23 inserting the pin member of the second tubular into the box member of the first tubular;
24 causing the threads of one or more thread segments of the pin member to fully engage corresponding mating threads on the box member upon make-up of the threaded 26 connection; and 27 creating a gap between the stab flank of the reduced thread width pin threads and the 28 adjacent flank of the box threads when the reduced thread width pin threads are engaged 7e I with the corresponding mating threads of the box member upon make-up of the threaded 2 connection.
3 In another aspect, the invention provides a method of forming a connection 4 between expandable tubulars, the method comprising:
providing a pin member on a first tubular segment, the pin member including 6 interengageable threads;
7 providing a box member on a second tubular segment, the box member including 8 interengageable threads suitable for threadedly engaging the pin member;
9 machining the threads of the box member such that the box member has a plurality of thread segments, wherein the threads of one or more thread segments of the box member 11 are machined such that material is removed from the flank of the box threads adjacent the 12 stab flank of the pin threads to reduce the width of the threads;
13 inserting the pin member of the first tubular into the box member of the second tubular;
14 causing the threads of one or more thread segments of the box member to fully engage corresponding mating threads on the pin member upon make-up of the threaded 16 connection; and 17 creating a gap between the stab flank of the pin threads and the adjacent flank of the 18 reduced thread width box threads when the reduced thread width threads of the box 19 member are engaged with the corresponding mating threads of the pin member upon make-up of the threaded connection.
BRIEF DESCRIPTION OF THE DRAWINGS
The following figures form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better 26 understood by reference to one or more of these figures in combination with the detailed 27 description of specific embodiments presented herein.
28 Figure 1 is a side view of an expandable tubular with pin and box threads 7f 1 machined into the expandable tubular.
2 Figure 2 is a side view of a hybrid threaded connection for expandable tubulars 3 showing the first and second thread segments according to one embodiment of the 4 present invention.
Figure 3 is a close up view of the pin and box threads of the second segment of 6 the hybrid threaded connection of Figure 2 according to one embodiment of the present 7 invention.
8 Figure 4 is a close up view of the pin and box threads of the first segment of the 9 hybrid threaded connection of Figure 2 according to one embodiment of the present invention.
11 Figure 5 is a side view of a hybrid threaded connection for expandable tubulars 12 showing the first and second thread segments according to an alternative embodiment of 13 the present invention in which the hybrid threaded connection is machined on pre-14 expanded tubular ends.
7g 1 Figure 6 is a side view of a hybrid threaded connection for expandable tubulars 2 showing the first and second thread segments according to an alternative embodiment of 3 the present invention in which the hybrid threaded connection is made up using a separate 4 coupling member.
7 The following examples are included to demonstrate preferred embodiments of 8 the invention. It should be appreciated by those of skill in the art that the techniques 9 disclosed in the examples that follow represent techniques discovered by the inventors to function well in the practice of the invention, and thus can be considered to constitute 11 preferred modes for its practice. However, those of skill in the art should, in light of the 12 present disclosure, appreciate that many changes can be made in the specific 13 embodiments that are disclosed and still obtain a like or similar result without departing 14 from the spirit and scope of the invention.
Referring to Figure 1, an expandable tubular 1 is shown. In the typical 16 application, multiple expandable tubulars I are connected together and sequentially 17 installed in the well bore until the depth of the producing zone of the formation is 18 reached. To accomplish this, expandable tubular 1 includes pin member 10 and box 19 member 20. Pin member 10 includes helical threads 12 and 14 extending along its length as discussed in more detail with reference to Figures 2 and 3. Box member 20 includes 21 helical mating threads 22 that are shaped and sized to mate with helical threads 12 and 14 22 on pin member 10 during make-up of a threaded connection between separate tubular 23 joints or segments. The interengaged threads of pin member 10 with the corresponding DM_US\4562686.v2 8 1 threads of box member 20 on an adjacent joint provide a threaded connection upon final 2 make-up. In this way, multiple segments of expandable tubulars can be threadably 3 connected.
4 The helical threads can be machined on plain end tubulars, tubulars with both ends upset, tubulars with one plain end and one upset end, or other connection types as 6 typically used in the oil and gas industry. Additionally, the helical threads can be 7 selected from a broad range of thread types used in the industry. One of skill in the art 8 can appreciate that the present invention is not limited in application to only certain kinds 9 of tubular ends or thread types.
Figure 2 is a side view of the hybrid threaded connection for expandable tubulars 11 of the present invention. As can be seen in Figure 2, the hybrid threaded connection 12 utilizes two complementary thread segments, Segment 1 and Segment 2, to form the 13 threaded connection. In Segment 1, the pin threads 14 are sized and shaped to fully 14 engage the box threads 22 upon make-up of the threaded connection. In contrast, in Segment 2, the pin threads 12 are specially machined to have a reduced thread width such 16 that when the connection is made-up, the pin threads 12 do not fully engage the box 17 threads 22. The result is the creation of a small gap 25 between the stab flank of the pin 18 threads 12 and the adjacent flank of the box threads 22. This small gap 25 allows radial 19 and axial movement between the pin and box threads of Segment 2 without causing disengagement of the threaded connection as the connection is expanded.
21 In the preferred embodiment of the present invention, the pin threads 12 of 22 Segment 2 are machined on the pin member 10 in a manner such that the pin thread width 23 is reduced by approximately one-third of the original, standard thread width. In DM_US\4562686.v2 9 I machining the pin threads 12 in the area of Segment 2, material is removed from the stab 2 flank of the pin threads 12 to reduce the standard width of the pin threads 12. In contrast 3 to the pin threads 12 of Segment 2, the box threads 22 of Segment 2 are standard thread 4 width and, thus, are the same thread width as the box threads 22 in Segment 1.
Although the width of the pin threads 12 of Segment 2 is reduced by 6 approximately one-third of standard width in the preferred embodiment, one of skill in 7 the art will appreciate that the pin thread width may be reduced by more than one-third or 8 less than one-third of the standard thread width depending on numerous factors, 9 including, but not limited to, the geometry of the expansion tool performing the tubular expansion, the amount of bending experienced by the threaded connection, the wall 11 thickness of the expandable tubulars, the grade of material used for the expandable 12 tubulars, and the percent expansion of the tubulars.
13 Additionally, one of skill in the art will appreciate that alternative embodiments 14 exists in which the pin threads may be of a uniform width across the entire length of the pin member 10 while the box threads of the box member 20 may be machined such that 16 the box member 20 has multiple thread segments, including a thread segment wherein the 17 box threads have a reduced thread width such that a gap is formed between the stabbing 18 flank of the pin threads and the adjacent flank on the box threads, for accomplishing the 19 objectives of the present invention.
Further, although the preferred embodiment utilizes a pin member 10 comprising 21 two thread segments, one of skill in the art will appreciate that alternative embodiments 22 exist in which a pin member (or box member) with more than two thread segments 23 having varying thread widths may be used to accomplish the objectives of the present DM_US\4562686.v2 10 1 invention. Moreover, although the preferred embodiment utilizes threads of a uniform 2 width reduction in Segment 2 of either the pin or box member, one of skill in the art will 3 appreciate that the threads of Segment 2 of either the pin member or the box member 4 could be cut such that the reduction in width of the threads progressively increases (i.e., the threads could be cut at an accelerating lead resulting in each "shaved"
thread having a 6 slightly smaller width than the preceding thread).
7 Figure 2 also shows the four-point seal that is created in the disclosed threaded 8 connection upon make-up of the connection. Specifically, upon make-up of the disclosed 9 threaded connection, radial metal-to-metal seals 30 and 40 will be created by the area of engagement between the pin member 10 and the box member 20 as shown in Figure 2, 11 while the engagement of pin threads 14 and box threads 22 in the area of Segment I will 12 also create a "thread seal." Additionally, a resilient seal ring 35, such as a Teflon ring, 13 may be placed in a groove between the pin and box threads in Segment 1. The use of a 14 resilient seal ring 35 augments the sealing capacity of the threaded connection. The resilient seal ring 35 can be selected from any suitable downhole sealing material known 16 in the industry, and can be shaped and sized to effect the greatest possible sealing 17 arrangement. Thus, as shown in Figure 2, the disclosed hybrid threaded connection 18 utilizes multiple thread segments, Segments 1 and 2, in which the threads of Segment 2 19 accommodate the stresses and deformations generated by the radial expansion process while the threads of Segment I maintain pressure integrity where the metal-to-metal seal 21 30, the resilient seal ring 35, and the seal between engaged threads 14 and 22 are all fully 22 activated upon make-up of the threaded connection.
DM US\4562686.v2 11 1 Figure 2 also discloses the use of a sleeve 55 that resides on a machined land 50 2 that is machined into the outer diameter of the expandable tubular 1 adjacent the pin 3 member 10. In the preferred embodiment, the sleeve 55 has an outer diameter 4 substantially identical to the outer diameter of the box member 20 and abuts up against, but does not cover, the end of box member 20. The benefits of utilizing sleeve 55 on 6 machined land 50 are discussed in more detail below with reference to Figure 3.
7 Figure 3 is a close up view of the pin threads 12 and the box threads 22 of 8 Segment 2 of the hybrid threaded connection of Figure 2. Figure 3 shows the gap 25 9 created by the engagement of the box threads 22 with the reduced width pin threads 12 in more detail.
11 Figure 3 also shows the use of sleeve 55 on machined land 50 in more detail. In 12 the preferred embodiment, box member 20 is machined on an area of the expandable 13 tubular 1 that has a slightly larger outer diameter than the remaining portion of the 14 expandable tubular 1. The outer diameter of the box member 20 is then "turned down" to the desired outside diameter - which is slightly larger than the outside diameter of the pin 16 member 10 in the preferred embodiment. This special turned down box member 20 will 17 allow for a better inspection of the box member 20 by different methods of non-18 destructive testing. The pin member 10 is machined on the other end of the expandable 19 tubular I such that the outside diameter of the pin member 10 is the same as that of the expandable tubular I outside diameter.
21 Machined land 50 is machined into the outer diameter of the expandable tubular 1 22 such that sleeve 55 can be secured on the pin end of the expandable tubular 1 on the 23 machined land 50 by a shrink fit method or any other suitable method such as the use of DM_US\4562686.v2 12 1 epoxy compounds. Machined land 50 extends from the external shoulder of pin member 2 10 to a point on the expandable tubular I that is approximately 2.0 inches from the 3 threaded connection. One of skill in the art will appreciate that the length of machined 4 land 50 can be greater than or less than 2.0 inches and still achieve the objectives of the present invention. In the preferred embodiment, sleeve 55 has an outside diameter equal 6 to that of box member 20. Sleeve 55 can be made of steel or other suitable material, 7 including resilient materials.
8 During the running in of the tubular string in a well, the pin member 10 will be 9 run in the "pin up" position, i.e., the position in which the pin nose is pointing towards the surface of the well. This is done to facilitate the movement of the expansion cone or 11 tool through the threaded connection as is customary with such applications. In this 12 position, box member 20 will be facing downward. Because the outside diameter of box 13 member 20 is slightly larger than the outside diameter of pin member 10, it is possible 14 that box member 20 may get "hung up" or damaged during the running in of the tubular string. Such damage can weaken the connection, as most expandable tubulars are thin-16 walled. Because the sleeve 55 outside diameter is machined to equal that of the box 17 member 20 outside diameter, the sleeve 55 serves to protect the exposed end of the box 18 member 20, thus reducing or eliminating the risk of damaging the face of the box 19 member 20 while running the string inside the host tubular or borehole.
Moreover, because sleeve 55 is not designed to cover box member 20, sleeve 55 21 does not increase the effective wall thickness of box member 20 and, thus, does not affect 22 the expansion capabilities of the tubular in the area of box member 20 and does not 23 interfere with the metal-to-metal contact between a host pipe and an expanded tubular.
DM_US\4562686.v2 13 I Although sleeve 55 is used in the preferred embodiment of the present invention, one of 2 skill in the art will appreciate that alternative embodiments of the present invention may 3 not use sleeve 55 or machined land 50.
4 Figure 4 is a close up view of the pin threads 14 and the box threads 22 of Segment I of the hybrid threaded connection of Figure 2. As Figure 4 shows, the pin 6 threads 14 of Segment 1 are standard width such that they fully engage the box threads 22 7 in the area of Segment 1. Figure 4 also shows the metal-to-metal seal 30 and resilient 8 seal 35 that are created or are functional when threads 14 and 22 are fully engaged upon 9 make-up of the threaded connection.
In an alternative embodiment of the present invention shown in Figure 5, pin 11 threads 12 and 14 and box threads 22 could be machined on pre-expanded ends of 12 expandable tubulars to reduce the amount of expansion of the connection versus the 13 amount of expansion of the tubular itself. The use of pre-expanded ends on expandable 14 tubulars is disclosed and claimed in United States Patent 7 125 053.
In another alternative embodiment of the present invention shown in Figure 6, pin 16 members 10 could be machined on both ends of the expandable tubulars I such that a 17 coupling member 100 is used to form a threaded and coupled connection. In such a 18 connection, coupling member 100 would serve as the box members 20 with box threads 19 22 that would engage pin threads 12 and 14 consistent with the teachings of the present,.
invention. Generally, the inside diameter of coupling member 100 will be machined to 21 equal that of the expandable tubular I inside diameter to facilitate the transition of the 22 expansion tool through the expandable tubular I during the expansion operation.
1 Although the coupling member 100 shown in Figure 7 is shown as a double box member 2 coupling, one of skill in the art will appreciate that coupling member 100 is not limited to 3 such a configuration and could be any configuration that allows for threadably coupling 4 two expandable tubulars together with pin threads 12 and 14 and box threads 22 as disclosed herein.
6 Further, during the expansion operation, a solid cone of suitable material such as 7 hardened steel, machined to exact dimensions, is pulled through the expandable tubulars 8 and the threaded connections in the preferred embodiment. One of skill in the art will 9 appreciate, however, that this is not the only applicable expansion method that can be applied to expand the present invention. For example, the expansion cone could be 11 pushed through the expandable tubular rather than being pulled through, the expansion 12 operation could be performed using a rotary expansion method, or the expansion 13 operation could be performed using a combination of such methods in either a single or 14 multiple pass expansion operation.
Similarly, one of skill in the art will appreciate that the expansion cone or 16 expansion tool itself could be of different designs depending on the size and grade of the 17 material to be expanded and the desired results. For example, the expansion cone could 18 be a "bullet" shape, a sphere, or a combination of such shapes. Further, the expansion 19 cone or expansion tool could be either solid or a hollow "shell," or could be a "shell"
filled with a different material than that of the shell itself.
21 While the apparatus, compositions and methods of this invention have been 22 described in terms of preferred or illustrative embodiments, it will be apparent to those of 23 skill in the art that variations may be applied to the process described herein without DM_US\4562686.v2 15 I departing from the concept and scope of the invention. All such similar substitutes and 2 modifications apparent to those skilled in the art are deemed to be within the scope and 3 concept of the invention as it is set out in the following claims.
DM_US\4562686.v2 16
7 In the conventional drilling of an oil and gas well, a series of tubulars, typically 8 strings of casing, liner, and/or screen segments connected together, are sequentially 9 installed in the well bore until the depth of the producing zone of the formation is reached. Standard practice requires that each succeeding string of tubulars placed in the 11 well bore has an outside diameter smaller than the preceding string of tubulars and/or 12 bore hole such that the tubular segments can be passed through the preceding string of 13 tubulars and/or bore hole to their downhole location. The reduction in the diameter of 14 each successive string of tubular segments placed in the well bore results in a significant reduction in the diameter of the tubular through which hydrocarbons can be carried to the 16 surface. More importantly, to achieve the desired tubular diameter in the producing zone, 17 the initial bore hole size at the surface must be sufficiently large to allow for a large 18 diameter casing. The large initial bore hole size requires increased drilling time and 19 increased material costs, including increased use of materials such as drilling mud and casing cement.
21 The technology of expandable tubulars addresses these shortcomings in the 22 conventional casing/liner/screen hanging operations. Technology that allows the 23 permanent expansion of tubulars in oil and gas wells is rapidly developing.
Through DM_US\4562686.v2 2 I radial expansion of tubular segments until the outer wall of those segments contacts the 2 inner wall of the host pipe, it is possible to create a tight fit between the expandable 3 tubulars and the host pipe that holds the tubular segments in place and creates an annular 4 seal. Further, it is possible to achieve a well bore of virtually uniform diameter (i.e., a monobore well) by the radial expansion of successive strings of tubular segments. The 6 expandable tubulars are radially expanded by various means known in the art, including, 7 but not limited to, pulling or pushing fixed or variable diameter expansion cones through 8 the tubular, extruding the tubular off of a hydraulically-actuated expansion tool, or 9 rotating an expansion tool while pulling or pushing it through the tubular.
The tubular segments to be expanded are typically coupled together using I 1 threaded connections in which the male end, or pin member, of one tubular is threadably 12 connected to the female end, or box member, of an adjacent tubular.
Alternatively, the 13 ends of the adjacent tubulars may have a pin member at each end, with the box member 14 being formed by a short coupling threaded onto one of the pin members. When a conventional threaded connection is made up, the nose of the pin member is typically in 16 contact with or very close to the back of the box member. This threaded engagement 17 between properly secured pin and box members creates a conventional tubular joint that 18 effectively maintains a secure mechanical connection that holds the tubular segments 19 together and that effectively seals the internal tubular area from the formation and vice versa. Often, the sealing ability of the threaded engagement is augmented through the 21 use of Teflon rings or other deformable seal rings entrapped in the thread area as well 22 as the metal-to-metal seal formed by the contact between the pin and box members.
DM_US\4562686.v2 3 1 Problems have arisen, however, at the threaded connection point between tubular 2 segments during and after expansion when using conventional threaded tubular 3 connections and seals currently available in the industry. When the tubular string is 4 radially expanded, a conventional threaded connection changes dimensionally in a way that can prevent the pin and box members from maintaining proper engagement and 6 sealing. The radial expansion of a conventional threaded connection can cause the pin 7 and box members to radially separate. Essentially, because the radius of curvature of the 8 pin member is different than the radius of curvature of the box member during the 9 expansion process, the pin and box members experience different displacements that the threads of a typical threaded connection cannot accommodate. As a result, the radial 11 expansion weakens the coupling strength of the connections and degrades or lowers the 12 pressure holding integrity of the connections. The threaded connection point thus 13 becomes a source of potential weakness in the tubing string and of potential leaks during 14 and after expansion of the tubular string.
Additionally, the radial expansion of the tubular string causes the pin and box 16 members to undergo axial movement. The amount of axial movement experienced by the 17 pin and box members is dependent on numerous factors, including, but not limited to, the 18 amount of radial expansion of the tubular string, the geometry of the threaded connection 19 (e.g., whether the pin and box members have any thin wall sections), and the method of radial expansion employed.
21 As deeper wells and more difficult completions are attempted using expandable 22 tubulars, the threaded connections that hold the expandable tubulars together must 23 address these known problems and must be able to accommodate the higher pressures DM_US\4562686.v2 4 1 faced in such applications. What is needed is a threaded connection for expandable 2 tubulars that maintains the coupling strength and the pressure integrity of the connection 3 so that it will withstand high pressure during and after expansion. It is an object of the 4 present invention to provide an apparatus and method for creating a threaded connection between segments of expandable tubulars that maintains the coupling strength and the 6 pressure integrity of the expanded connection during and after expansion.
Those and 7 other objectives will become apparent to those of skill in the art from a review of the 8 specification below.
An expandable threaded connection between segments of expandable tubulars 11 that allows the threaded tubular connection to withstand the stresses and deformations 12 imposed on the connection by the tubular expansion process is disclosed.
The present 13 invention is a unique hybrid threaded connection that utilizes two complementary thread 14 segments to form the expandable threaded connection. The first segment of the threaded connection encompasses the area of the threaded connection between the back of the box 16 member and approximately the mid-point of the threaded connection. The first segment 17 of the threaded connection utilizes standard box and pin threads such that the threads on 18 the pin member in the area of the first segment fully engage the mating threads on the 19 box member in the area of the first segment. Additionally, the first segment of the threaded connection comprises a radial metal-to-metal seal, a resilient seal, and a thread 21 seal. All of these seals are fully activated upon make-up of the threaded connection.
22 The second segment of the threaded connection begins where the first segment 23 ends (i.e., at approximately the mid-point of the threaded connection) and extends to the DM_US\4562686.v2 5 l face of the box member. The second segment of the threaded connection has the threads 2 machined on the pin member in a manner such that the pin thread width is reduced. In 3 machining the threads of the pin member in the area of the second segment, material is 4 removed from the stab flank of the pin threads to reduce the standard width of the pin threads. In contrast to the pin threads of the second segment, the box threads of the 6 second segment are standard thread width and, thus, are the same thread width as the box 7 threads in the first segment.
8 The use of the reduced thread width in the pin threads of the second segment 9 allows for a loose fit between the pin threads of the second segment and the box threads of the second segment. As the threaded connection is expanded, the loose fit between the 11 pin and box threads of the second segment allows radial and axial movement between the 12 pin and box threads of the second segments of the threaded connection without causing 13 disengagement of the threaded connection. Thus, the disclosed hybrid threaded 14 connection utilizes multiple thread segments in which the second thread segment accommodates the stresses and deformations generated by the radial expansion process 16 while the threads of the first segment maintain pressure integrity where the metal to metal 17 seal, the resilient seal, and the thread seal are all fully engaged upon make-up of the 18 threaded connection.
19 Additionally, in the preferred embodiment the disclosed threaded connection utilizes a sleeve in the area of the back of the pin member that is placed onto a machined 21 land that is machined into the outer diameter of the pin member. When placed on this 22 land, the sleeve has an outer diameter substantially the same as the outer diameter of the 23 box member such that upon make-up of the threaded connection, the sleeve abuts the box DM_US\4562686.v2 6 1 member. The use of such a sleeve protects the face of the box member from being 2 damaged during running-in of the tubular string.
3 In another aspect, the invention provides an expandable threaded tubular 4 connection, comprising:
a first tubular segment with a box member, the box member comprising interengageable 6 threads that have load flanks and stab flanks of a constant pitch; and 7 a second tubular segment with a pin member, the pin member comprising 8 interengageable threads for engaging said box member, the interengageable threads of the 9 pin member having a first thread segment and a second thread segment, the first and second thread segments comprising multiple turns of threads;
11 wherein the first thread segment comprises load flanks and stab flanks of a first pitch, 12 the first pitch being constant across the first thread segment;
13 wherein the second thread segment comprises load flanks and stab flanks of a second 14 pitch, the second pitch being constant across the second thread segment, the threads of the second thread segment having a reduced axial thickness relative to the threads of the 16 first thread segment;
17 wherein the first and second pitch is equal to the pitch of the threads of the box member;
18 and 19 wherein the load flanks of the first and second thread segments are fully engaged with the load flanks of the box member upon makeup of the connection.
21 In another aspect, the invention provides an expandable threaded tubular 22 connection, comprising:
23 a first tubular segment with a box member, the box member comprising interengageable 24 threads that have load flanks and stab flanks of a constant pitch;
a second tubular segment with a pin member, the pin member comprising 26 interengageable threads for engaging said box member, the interengageable threads of the 27 pin member having a first thread segment and a second thread segment, the first and 28 second thread segments comprising multiple turns of threads;
1 wherein the threads of the first thread segment of the pin member fully engage 2 corresponding mating threads on the box member upon make-up of the threaded 3 connection;
4 wherein the threads of the second thread segment are formed such that material is removed from the stab flank of the pin threads of the second thread segment to reduce the 6 axial thickness of the threads relative to the axial thickness of the threads of the first 7 segment;
8 wherein the load flanks of the threads of the second thread segment is in full 9 engagement with the mating flanks of the threads of the box member upon makeup of the connection;
11 wherein the threads of the first thread segment comprises load flanks and stab flanks of 12 a first constant pitch and the second thread segment comprises load flanks and stab flanks 13 of a second constant pitch, the first constant pitch being equal to the pitch of the load 14 flanks and stab flanks of the threads of the box member; and wherein the reduced axial thickness of the threads of the second thread segment of the 16 pin member causes a gap to be formed between the stab flank of the pin threads and the 17 adjacent flank of the box threads when the threads of the second thread segment are 18 engaged with the corresponding mating threads of the box member upon make-up of the 19 threaded connection;
a machined land area in the outside diameter of the second tubular in the area adjacent 21 the external shoulder of the pin member; and 22 a sleeve secured around the second tubular on the machined land area.
23 In another aspect, the invention provides an expandable threaded tubular 24 connection, comprising:
a first tubular segment with a pin member, the pin member comprising interengageable 26 threads, the interengageable threads having a first thread segment and a second thread 27 segment;
28 a second tubular segment with a pin member, the pin member comprising 29 interengageable threads, the interengageable threads having a first thread segment and a second thread segment;
7a 1 wherein the first and second thread segments of the pin members each comprise 2 multiple turns of threads;
3 wherein the first thread segments of the pin members each comprise load flanks and 4 stab flanks of a first pitch, the first pitch being constant across the first thread segments of the pin members;
6 wherein the second thread segments of the pin members each comprise load flanks and 7 stab flanks of a second pitch, the second pitch being constant across the second thread 8 segments of the pin members;
9 wherein the threads of the second thread segments of each pin member are formed such that material is removed from the stab flank of the pin threads of the second thread 11 segments to reduce the axial thickness of the threads relative to the axial thickness of the 12 threads of the first segment;
13 a coupling member comprising box members on both ends of the coupling member, the 14 box members having interengageable threads designed to engage the pin threads of the pin members of the first tubular and the second tubular upon make-up of the threaded 16 connection;
17 wherein the threads of the box members have load flanks and stab flanks of a constant 18 pitch;
19 wherein the load flanks of the threads of the first and second thread segments are in contact with the mating flanks of the threads of the box members upon makeup of the 21 connection; and 22 wherein the reduced axial thickness of the threads of the second thread segments of each 23 pin member causes a gap to be formed between the stab flank of the pin threads and the 24 adjacent flanks of the box threads when the threads of the second thread segments of each pin member are fully engaged with the corresponding mating threads of the box 26 members of the coupling member upon make-up of the threaded connection.
27 In another aspect, the invention provides a method of forming a connection 28 between expandable tubulars, the method comprising:
7b 1 providing a box member in a first tubular segment, the box member including 2 interengageable threads;
3 providing a pin member on a second tubular segment, the pin member including 4 interengageable threads suitable for threadedly engaging the box member;
machining the threads of the pin member such that the pin member has a first thread 6 segment and a second thread segment, wherein the threads of the second thread segment 7 are machined such that material is removed from the stab flank of the pin threads to 8 reduce the width of the threads;
9 inserting the pin member of the second tubular into the box member of the first tubular;
causing the threads of the first thread segment of the pin member to fully engage 11 corresponding mating threads on the box member upon make-up of the threaded 12 connection; and 13 creating a gap between the stab flank of the pin threads and the adjacent flank of the box 14 threads when the pin threads of the second thread segment are engaged with the corresponding mating threads of the box member upon make-up of the threaded 16 connection.
17 In another aspect, the invention provides a method of forming a connection 18 between expandable tubulars, the method comprising:
19 providing a pin member on a first tubular segment, the pin member including interengageable threads;
21 providing a box member on a second tubular segment, the box member including 22 interengageable threads suitable for threadedly engaging the pin member;
23 machining the threads of the box member such that the box member has a first thread 24 segment and a second thread segment, wherein the threads of the second thread segment are machined such that material is removed from the flank of the box threads adjacent the 26 stab flank of the pin threads to reduce the width of the threads;
27 inserting the pin member of the first tubular into the box member of the second tubular;
7c 1 causing the threads of the first thread segment of the box member to fully engage 2 corresponding mating threads on the pin member upon make-up of the threaded 3 connection; and 4 creating a gap between the stab flank of the pin threads and the adjacent flank of the box threads when the threads of the second thread segment are engaged with the 6 corresponding mating threads of the pin member upon make-up of the threaded 7 connection.
8 In another aspect, the invention provides an expandable threaded tubular 9 connection, comprising:
a first tubular segment with a box member, the box member comprising interengageable 11 threads that have load flanks and stab flanks of a constant pitch;
12 a second tubular segment with a pin member, the pin member comprising 13 interengageable threads for engaging said box member, the interengageable threads of the 14 pin member having a plurality of thread segments, the plurality of thread segments comprising multiple turns of threads;
16 wherein one or more of the thread segments of the pin member comprise threads having 17 a reduced axial thickness relative to the axial thickness of the threads of the box member;
18 wherein the multiple turns of threads of the plurality of thread segments each have load 19 flanks and stab flanks of a constant pitch, the pitch being equal to the pitch of the load flanks and stab flanks of the threads of the box member; and 21 wherein the load flanks of the multiple turns of threads of the plurality of thread 22 segments are in full engagement with the mating flanks of the threads of the box member 23 upon makeup of the connection.
24 In another aspect, the invention provides an expandable threaded tubular connection, comprising:
26 a first tubular segment with a pin member, the pin member comprising interengageable 27 threads that have load flanks and stab flanks of a constant pitch;
7d 1 a second tubular segment with a box member, the box member comprising 2 interengageable threads for engaging said pin member, the interengageable threads of the 3 box member having a plurality of thread segments comprising multiple turns of thread;
4 wherein one or more of the thread segments of the box member comprises threads having a reduced axial thickness relative to the axial thickness of the threads of the pin 6 member;
7 wherein the multiple turns of threads of the plurality of thread segments each have load 8 flanks and stab flanks of a constant pitch, the pitch being equal to the pitch of the load 9 flanks and stab flanks of the threads of the pin member; and wherein the load flanks of the threads of the plurality of thread segments are in full 11 engagement with the mating flanks of the threads of the pin member upon makeup of the 12 connection.
13 In another aspect, the invention provides a method of forming a connection 14 between expandable tubulars, the method comprising:
providing a box member in a first tubular segment, the box member including 16 interengageable threads;
17 providing a pin member on a second tubular segment, the pin member including 18 interengageable threads suitable for threadedly engaging the box member;
19 machining the threads of the pin member such that the pin member has a plurality of thread segments, wherein the threads of one or more thread segments of the pin member 21 are machined such that material is removed from the stab flank of the pin threads to 22 reduce the width of the threads;
23 inserting the pin member of the second tubular into the box member of the first tubular;
24 causing the threads of one or more thread segments of the pin member to fully engage corresponding mating threads on the box member upon make-up of the threaded 26 connection; and 27 creating a gap between the stab flank of the reduced thread width pin threads and the 28 adjacent flank of the box threads when the reduced thread width pin threads are engaged 7e I with the corresponding mating threads of the box member upon make-up of the threaded 2 connection.
3 In another aspect, the invention provides a method of forming a connection 4 between expandable tubulars, the method comprising:
providing a pin member on a first tubular segment, the pin member including 6 interengageable threads;
7 providing a box member on a second tubular segment, the box member including 8 interengageable threads suitable for threadedly engaging the pin member;
9 machining the threads of the box member such that the box member has a plurality of thread segments, wherein the threads of one or more thread segments of the box member 11 are machined such that material is removed from the flank of the box threads adjacent the 12 stab flank of the pin threads to reduce the width of the threads;
13 inserting the pin member of the first tubular into the box member of the second tubular;
14 causing the threads of one or more thread segments of the box member to fully engage corresponding mating threads on the pin member upon make-up of the threaded 16 connection; and 17 creating a gap between the stab flank of the pin threads and the adjacent flank of the 18 reduced thread width box threads when the reduced thread width threads of the box 19 member are engaged with the corresponding mating threads of the pin member upon make-up of the threaded connection.
BRIEF DESCRIPTION OF THE DRAWINGS
The following figures form part of the present specification and are included to further demonstrate certain aspects of the present invention. The invention may be better 26 understood by reference to one or more of these figures in combination with the detailed 27 description of specific embodiments presented herein.
28 Figure 1 is a side view of an expandable tubular with pin and box threads 7f 1 machined into the expandable tubular.
2 Figure 2 is a side view of a hybrid threaded connection for expandable tubulars 3 showing the first and second thread segments according to one embodiment of the 4 present invention.
Figure 3 is a close up view of the pin and box threads of the second segment of 6 the hybrid threaded connection of Figure 2 according to one embodiment of the present 7 invention.
8 Figure 4 is a close up view of the pin and box threads of the first segment of the 9 hybrid threaded connection of Figure 2 according to one embodiment of the present invention.
11 Figure 5 is a side view of a hybrid threaded connection for expandable tubulars 12 showing the first and second thread segments according to an alternative embodiment of 13 the present invention in which the hybrid threaded connection is machined on pre-14 expanded tubular ends.
7g 1 Figure 6 is a side view of a hybrid threaded connection for expandable tubulars 2 showing the first and second thread segments according to an alternative embodiment of 3 the present invention in which the hybrid threaded connection is made up using a separate 4 coupling member.
7 The following examples are included to demonstrate preferred embodiments of 8 the invention. It should be appreciated by those of skill in the art that the techniques 9 disclosed in the examples that follow represent techniques discovered by the inventors to function well in the practice of the invention, and thus can be considered to constitute 11 preferred modes for its practice. However, those of skill in the art should, in light of the 12 present disclosure, appreciate that many changes can be made in the specific 13 embodiments that are disclosed and still obtain a like or similar result without departing 14 from the spirit and scope of the invention.
Referring to Figure 1, an expandable tubular 1 is shown. In the typical 16 application, multiple expandable tubulars I are connected together and sequentially 17 installed in the well bore until the depth of the producing zone of the formation is 18 reached. To accomplish this, expandable tubular 1 includes pin member 10 and box 19 member 20. Pin member 10 includes helical threads 12 and 14 extending along its length as discussed in more detail with reference to Figures 2 and 3. Box member 20 includes 21 helical mating threads 22 that are shaped and sized to mate with helical threads 12 and 14 22 on pin member 10 during make-up of a threaded connection between separate tubular 23 joints or segments. The interengaged threads of pin member 10 with the corresponding DM_US\4562686.v2 8 1 threads of box member 20 on an adjacent joint provide a threaded connection upon final 2 make-up. In this way, multiple segments of expandable tubulars can be threadably 3 connected.
4 The helical threads can be machined on plain end tubulars, tubulars with both ends upset, tubulars with one plain end and one upset end, or other connection types as 6 typically used in the oil and gas industry. Additionally, the helical threads can be 7 selected from a broad range of thread types used in the industry. One of skill in the art 8 can appreciate that the present invention is not limited in application to only certain kinds 9 of tubular ends or thread types.
Figure 2 is a side view of the hybrid threaded connection for expandable tubulars 11 of the present invention. As can be seen in Figure 2, the hybrid threaded connection 12 utilizes two complementary thread segments, Segment 1 and Segment 2, to form the 13 threaded connection. In Segment 1, the pin threads 14 are sized and shaped to fully 14 engage the box threads 22 upon make-up of the threaded connection. In contrast, in Segment 2, the pin threads 12 are specially machined to have a reduced thread width such 16 that when the connection is made-up, the pin threads 12 do not fully engage the box 17 threads 22. The result is the creation of a small gap 25 between the stab flank of the pin 18 threads 12 and the adjacent flank of the box threads 22. This small gap 25 allows radial 19 and axial movement between the pin and box threads of Segment 2 without causing disengagement of the threaded connection as the connection is expanded.
21 In the preferred embodiment of the present invention, the pin threads 12 of 22 Segment 2 are machined on the pin member 10 in a manner such that the pin thread width 23 is reduced by approximately one-third of the original, standard thread width. In DM_US\4562686.v2 9 I machining the pin threads 12 in the area of Segment 2, material is removed from the stab 2 flank of the pin threads 12 to reduce the standard width of the pin threads 12. In contrast 3 to the pin threads 12 of Segment 2, the box threads 22 of Segment 2 are standard thread 4 width and, thus, are the same thread width as the box threads 22 in Segment 1.
Although the width of the pin threads 12 of Segment 2 is reduced by 6 approximately one-third of standard width in the preferred embodiment, one of skill in 7 the art will appreciate that the pin thread width may be reduced by more than one-third or 8 less than one-third of the standard thread width depending on numerous factors, 9 including, but not limited to, the geometry of the expansion tool performing the tubular expansion, the amount of bending experienced by the threaded connection, the wall 11 thickness of the expandable tubulars, the grade of material used for the expandable 12 tubulars, and the percent expansion of the tubulars.
13 Additionally, one of skill in the art will appreciate that alternative embodiments 14 exists in which the pin threads may be of a uniform width across the entire length of the pin member 10 while the box threads of the box member 20 may be machined such that 16 the box member 20 has multiple thread segments, including a thread segment wherein the 17 box threads have a reduced thread width such that a gap is formed between the stabbing 18 flank of the pin threads and the adjacent flank on the box threads, for accomplishing the 19 objectives of the present invention.
Further, although the preferred embodiment utilizes a pin member 10 comprising 21 two thread segments, one of skill in the art will appreciate that alternative embodiments 22 exist in which a pin member (or box member) with more than two thread segments 23 having varying thread widths may be used to accomplish the objectives of the present DM_US\4562686.v2 10 1 invention. Moreover, although the preferred embodiment utilizes threads of a uniform 2 width reduction in Segment 2 of either the pin or box member, one of skill in the art will 3 appreciate that the threads of Segment 2 of either the pin member or the box member 4 could be cut such that the reduction in width of the threads progressively increases (i.e., the threads could be cut at an accelerating lead resulting in each "shaved"
thread having a 6 slightly smaller width than the preceding thread).
7 Figure 2 also shows the four-point seal that is created in the disclosed threaded 8 connection upon make-up of the connection. Specifically, upon make-up of the disclosed 9 threaded connection, radial metal-to-metal seals 30 and 40 will be created by the area of engagement between the pin member 10 and the box member 20 as shown in Figure 2, 11 while the engagement of pin threads 14 and box threads 22 in the area of Segment I will 12 also create a "thread seal." Additionally, a resilient seal ring 35, such as a Teflon ring, 13 may be placed in a groove between the pin and box threads in Segment 1. The use of a 14 resilient seal ring 35 augments the sealing capacity of the threaded connection. The resilient seal ring 35 can be selected from any suitable downhole sealing material known 16 in the industry, and can be shaped and sized to effect the greatest possible sealing 17 arrangement. Thus, as shown in Figure 2, the disclosed hybrid threaded connection 18 utilizes multiple thread segments, Segments 1 and 2, in which the threads of Segment 2 19 accommodate the stresses and deformations generated by the radial expansion process while the threads of Segment I maintain pressure integrity where the metal-to-metal seal 21 30, the resilient seal ring 35, and the seal between engaged threads 14 and 22 are all fully 22 activated upon make-up of the threaded connection.
DM US\4562686.v2 11 1 Figure 2 also discloses the use of a sleeve 55 that resides on a machined land 50 2 that is machined into the outer diameter of the expandable tubular 1 adjacent the pin 3 member 10. In the preferred embodiment, the sleeve 55 has an outer diameter 4 substantially identical to the outer diameter of the box member 20 and abuts up against, but does not cover, the end of box member 20. The benefits of utilizing sleeve 55 on 6 machined land 50 are discussed in more detail below with reference to Figure 3.
7 Figure 3 is a close up view of the pin threads 12 and the box threads 22 of 8 Segment 2 of the hybrid threaded connection of Figure 2. Figure 3 shows the gap 25 9 created by the engagement of the box threads 22 with the reduced width pin threads 12 in more detail.
11 Figure 3 also shows the use of sleeve 55 on machined land 50 in more detail. In 12 the preferred embodiment, box member 20 is machined on an area of the expandable 13 tubular 1 that has a slightly larger outer diameter than the remaining portion of the 14 expandable tubular 1. The outer diameter of the box member 20 is then "turned down" to the desired outside diameter - which is slightly larger than the outside diameter of the pin 16 member 10 in the preferred embodiment. This special turned down box member 20 will 17 allow for a better inspection of the box member 20 by different methods of non-18 destructive testing. The pin member 10 is machined on the other end of the expandable 19 tubular I such that the outside diameter of the pin member 10 is the same as that of the expandable tubular I outside diameter.
21 Machined land 50 is machined into the outer diameter of the expandable tubular 1 22 such that sleeve 55 can be secured on the pin end of the expandable tubular 1 on the 23 machined land 50 by a shrink fit method or any other suitable method such as the use of DM_US\4562686.v2 12 1 epoxy compounds. Machined land 50 extends from the external shoulder of pin member 2 10 to a point on the expandable tubular I that is approximately 2.0 inches from the 3 threaded connection. One of skill in the art will appreciate that the length of machined 4 land 50 can be greater than or less than 2.0 inches and still achieve the objectives of the present invention. In the preferred embodiment, sleeve 55 has an outside diameter equal 6 to that of box member 20. Sleeve 55 can be made of steel or other suitable material, 7 including resilient materials.
8 During the running in of the tubular string in a well, the pin member 10 will be 9 run in the "pin up" position, i.e., the position in which the pin nose is pointing towards the surface of the well. This is done to facilitate the movement of the expansion cone or 11 tool through the threaded connection as is customary with such applications. In this 12 position, box member 20 will be facing downward. Because the outside diameter of box 13 member 20 is slightly larger than the outside diameter of pin member 10, it is possible 14 that box member 20 may get "hung up" or damaged during the running in of the tubular string. Such damage can weaken the connection, as most expandable tubulars are thin-16 walled. Because the sleeve 55 outside diameter is machined to equal that of the box 17 member 20 outside diameter, the sleeve 55 serves to protect the exposed end of the box 18 member 20, thus reducing or eliminating the risk of damaging the face of the box 19 member 20 while running the string inside the host tubular or borehole.
Moreover, because sleeve 55 is not designed to cover box member 20, sleeve 55 21 does not increase the effective wall thickness of box member 20 and, thus, does not affect 22 the expansion capabilities of the tubular in the area of box member 20 and does not 23 interfere with the metal-to-metal contact between a host pipe and an expanded tubular.
DM_US\4562686.v2 13 I Although sleeve 55 is used in the preferred embodiment of the present invention, one of 2 skill in the art will appreciate that alternative embodiments of the present invention may 3 not use sleeve 55 or machined land 50.
4 Figure 4 is a close up view of the pin threads 14 and the box threads 22 of Segment I of the hybrid threaded connection of Figure 2. As Figure 4 shows, the pin 6 threads 14 of Segment 1 are standard width such that they fully engage the box threads 22 7 in the area of Segment 1. Figure 4 also shows the metal-to-metal seal 30 and resilient 8 seal 35 that are created or are functional when threads 14 and 22 are fully engaged upon 9 make-up of the threaded connection.
In an alternative embodiment of the present invention shown in Figure 5, pin 11 threads 12 and 14 and box threads 22 could be machined on pre-expanded ends of 12 expandable tubulars to reduce the amount of expansion of the connection versus the 13 amount of expansion of the tubular itself. The use of pre-expanded ends on expandable 14 tubulars is disclosed and claimed in United States Patent 7 125 053.
In another alternative embodiment of the present invention shown in Figure 6, pin 16 members 10 could be machined on both ends of the expandable tubulars I such that a 17 coupling member 100 is used to form a threaded and coupled connection. In such a 18 connection, coupling member 100 would serve as the box members 20 with box threads 19 22 that would engage pin threads 12 and 14 consistent with the teachings of the present,.
invention. Generally, the inside diameter of coupling member 100 will be machined to 21 equal that of the expandable tubular I inside diameter to facilitate the transition of the 22 expansion tool through the expandable tubular I during the expansion operation.
1 Although the coupling member 100 shown in Figure 7 is shown as a double box member 2 coupling, one of skill in the art will appreciate that coupling member 100 is not limited to 3 such a configuration and could be any configuration that allows for threadably coupling 4 two expandable tubulars together with pin threads 12 and 14 and box threads 22 as disclosed herein.
6 Further, during the expansion operation, a solid cone of suitable material such as 7 hardened steel, machined to exact dimensions, is pulled through the expandable tubulars 8 and the threaded connections in the preferred embodiment. One of skill in the art will 9 appreciate, however, that this is not the only applicable expansion method that can be applied to expand the present invention. For example, the expansion cone could be 11 pushed through the expandable tubular rather than being pulled through, the expansion 12 operation could be performed using a rotary expansion method, or the expansion 13 operation could be performed using a combination of such methods in either a single or 14 multiple pass expansion operation.
Similarly, one of skill in the art will appreciate that the expansion cone or 16 expansion tool itself could be of different designs depending on the size and grade of the 17 material to be expanded and the desired results. For example, the expansion cone could 18 be a "bullet" shape, a sphere, or a combination of such shapes. Further, the expansion 19 cone or expansion tool could be either solid or a hollow "shell," or could be a "shell"
filled with a different material than that of the shell itself.
21 While the apparatus, compositions and methods of this invention have been 22 described in terms of preferred or illustrative embodiments, it will be apparent to those of 23 skill in the art that variations may be applied to the process described herein without DM_US\4562686.v2 15 I departing from the concept and scope of the invention. All such similar substitutes and 2 modifications apparent to those skilled in the art are deemed to be within the scope and 3 concept of the invention as it is set out in the following claims.
DM_US\4562686.v2 16
Claims (114)
1. An expandable threaded tubular connection, comprising:
a first tubular segment with a box member, the box member comprising interengageable threads that have load flanks and stab flanks of a constant pitch; and a second tubular segment with a pin member, the pin member comprising interengageable threads for engaging said box member, the interengageable threads of the pin member having a first thread segment and a second thread segment, the first and second thread segments comprising multiple turns of threads;
wherein the first thread segment comprises load flanks and stab flanks of a first pitch, the first pitch being constant across the first thread segment;
wherein the second thread segment comprises load flanks and stab flanks of a second pitch, the second pitch being constant across the second thread segment, the threads of the second thread segment having a reduced axial thickness relative to the threads of the first thread segment;
wherein the first and second pitch is equal to the pitch of the threads of the box member;
and wherein the load flanks of the first and second thread segments are fully engaged with the load flanks of the box member upon makeup of the connection.
a first tubular segment with a box member, the box member comprising interengageable threads that have load flanks and stab flanks of a constant pitch; and a second tubular segment with a pin member, the pin member comprising interengageable threads for engaging said box member, the interengageable threads of the pin member having a first thread segment and a second thread segment, the first and second thread segments comprising multiple turns of threads;
wherein the first thread segment comprises load flanks and stab flanks of a first pitch, the first pitch being constant across the first thread segment;
wherein the second thread segment comprises load flanks and stab flanks of a second pitch, the second pitch being constant across the second thread segment, the threads of the second thread segment having a reduced axial thickness relative to the threads of the first thread segment;
wherein the first and second pitch is equal to the pitch of the threads of the box member;
and wherein the load flanks of the first and second thread segments are fully engaged with the load flanks of the box member upon makeup of the connection.
2. The expandable threaded tubular connection of claim 1, wherein the first thread segment comprises the portion of the pin member from the pin nose end to approximately the midpoint of the pin member.
3. The expandable threaded tubular connection of claim 2, wherein the second thread segment comprises the portion of the pin member from approximately the midpoint of the pin member to the external shoulder of the pin member.
4. The expandable threaded tubular connection of claim 3, wherein the reduced axial thickness of the threads of the second thread segment of the pin member causes a gap to be formed between the stab flank of the pin threads and the adjacent flank of the box threads when the threads of the second thread segment are engaged with the corresponding mating threads of the box member upon make-up of the threaded connection.
5. The expandable threaded tubular connection of claim 4, wherein the gap allows radial and axial movement between the pin threads of the second thread segment and the corresponding mating box threads during radial expansion of the threaded connection.
6. The expandable threaded tubular connection of claim 5, wherein the axial thickness of the pin threads of the second thread segment is reduced by one-third.
7. The expandable threaded tubular connection of claim 5, wherein the axial thickness of the pin threads of the second thread segment is reduced by less than one-third.
8. The expandable threaded tubular connection of claim 5, wherein the axial thickness of the pin threads of the second thread segment is reduced by more than one-third.
9. The expandable threaded tubular connection of any one of claims 1 to 8, wherein the outside diameter of the box member is greater than the outside diameter of the pin member.
10. The expandable threaded tubular connection of claim 9, further comprising a machined land area in the outside diameter of the second tubular extending from the external shoulder of the pin member to a point on the second tubular that is two inches from the threaded connection.
11. The expandable threaded tubular connection of claim 9, further comprising a machined land area in the outside diameter of the second tubular extending from the external shoulder of the pin member to a point on the second tubular that is less than two inches from the threaded connection.
12. The expandable threaded tubular connection of claim 9, further comprising a machined land area in the outside diameter of the second tubular extending from the external shoulder of the pin member to a point on the second tubular that is greater than two inches from the threaded connection.
13. The expandable threaded tubular connection of claim 10, further comprising a sleeve secured around the second tubular on the machined land area, the sleeve having an outside diameter substantially equal to the outside diameter of the box member.
14. The expandable threaded tubular connection of claim 13, wherein the sleeve is metal.
15. The expandable threaded tubular connection of claim 13, wherein the sleeve is a non-metallic material.
16. The expandable threaded tubular connection of claim 13, wherein the sleeve abuts the end of the box member upon make-up of the threaded connection.
17. The expandable threaded tubular connection of any one of claims 1 to 16, further comprising a radial metal-to-metal seal formed by the engagement of the box member with the pin member in the area of the first thread segment of the pin member upon make-up of the threaded connection.
18. The expandable threaded tubular connection of claim 17, further comprising a thread seal formed by the engagement of the box threads with the pin threads of the first thread segment upon make-up of the threaded connection.
19. The expandable threaded tubular connection of claim 18, further comprising a resilient sealing ring placed in a groove within the first thread segment, the resilient sealing ring forming a seal upon make-up of the threaded connection.
20. An expandable threaded tubular connection, comprising:
a first tubular segment with a box member, the box member comprising interengageable threads that have load flanks and stab flanks of a constant pitch;
a second tubular segment with a pin member, the pin member comprising interengageable threads for engaging said box member, the interengageable threads of the pin member having a first thread segment and a second thread segment, the first and second thread segments comprising multiple turns of threads;
wherein the threads of the first thread segment of the pin member fully engage corresponding mating threads on the box member upon make-up of the threaded connection;
wherein the threads of the second thread segment are formed such that material is removed from the stab flank of the pin threads of the second thread segment to reduce the axial thickness of the threads relative to the axial thickness of the threads of the first segment;
wherein the load flanks of the threads of the second thread segment is in full engagement with the mating flanks of the threads of the box member upon makeup of the connection;
wherein the threads of the first thread segment comprises load flanks and stab flanks of a first constant pitch and the second thread segment comprises load flanks and stab flanks of a second constant pitch, the first constant pitch being equal to the pitch of the load flanks and stab flanks of the threads of the box member; and wherein the reduced axial thickness of the threads of the second thread segment of the pin member causes a gap to be formed between the stab flank of the pin threads and the adjacent flank of the box threads when the threads of the second thread segment are engaged with the corresponding mating threads of the box member upon make-up of the threaded connection;
a machined land area in the outside diameter of the second tubular in the area adjacent the external shoulder of the pin member; and a sleeve secured around the second tubular on the machined land area.
a first tubular segment with a box member, the box member comprising interengageable threads that have load flanks and stab flanks of a constant pitch;
a second tubular segment with a pin member, the pin member comprising interengageable threads for engaging said box member, the interengageable threads of the pin member having a first thread segment and a second thread segment, the first and second thread segments comprising multiple turns of threads;
wherein the threads of the first thread segment of the pin member fully engage corresponding mating threads on the box member upon make-up of the threaded connection;
wherein the threads of the second thread segment are formed such that material is removed from the stab flank of the pin threads of the second thread segment to reduce the axial thickness of the threads relative to the axial thickness of the threads of the first segment;
wherein the load flanks of the threads of the second thread segment is in full engagement with the mating flanks of the threads of the box member upon makeup of the connection;
wherein the threads of the first thread segment comprises load flanks and stab flanks of a first constant pitch and the second thread segment comprises load flanks and stab flanks of a second constant pitch, the first constant pitch being equal to the pitch of the load flanks and stab flanks of the threads of the box member; and wherein the reduced axial thickness of the threads of the second thread segment of the pin member causes a gap to be formed between the stab flank of the pin threads and the adjacent flank of the box threads when the threads of the second thread segment are engaged with the corresponding mating threads of the box member upon make-up of the threaded connection;
a machined land area in the outside diameter of the second tubular in the area adjacent the external shoulder of the pin member; and a sleeve secured around the second tubular on the machined land area.
21. The expandable threaded tubular connection of claim 20, wherein the first thread segment comprises the portion of the pin member from the pin nose end to approximately the midpoint of the pin member.
22. The expandable threaded tubular connection of claim 21, wherein the second thread segment comprises the portion of the pin member from approximately the midpoint of the pin member to the external shoulder of the pin member.
23. The expandable threaded tubular connection of claim 22, wherein the gap allows radial and axial movement between the pin threads of the second thread segment and the corresponding mating box threads during radial expansion of the threaded connection.
24. The expandable threaded tubular connection of claim 23, wherein the axial thickness of the pin threads of the second thread segment is reduced by one-third.
25. The expandable threaded tubular connection of claim 23, wherein the axial thickness of the pin threads of the second thread segment is reduced by less than one-third.
26. The expandable threaded tubular connection of claim 23, wherein the axial thickness of the pin threads of the second thread segment is reduced by more than one-third.
27. The expandable threaded tubular connection of any one of claims 20 to 26, wherein the outside diameter of the box member is greater than the outside diameter of the pin member.
28. The expandable threaded tubular connection of claim 27, wherein the machined land area extends from the external shoulder of the pin member to a point on the second tubular that is two inches from the threaded connection.
29. The expandable threaded tubular connection of claim 27, wherein the machined land area extends from the external shoulder of the pin member to a point on the second tubular that is less than two inches from the threaded connection.
30. The expandable threaded tubular connection of claim 27, wherein the machined land area extends from the external shoulder of the pin member to a point on the second tubular that is greater than two inches from the threaded connection.
31. The expandable threaded tubular connection of any one of claims 20 to 30, wherein the sleeve is metal.
32. The expandable threaded tubular connection of any one of claims 20 to 30, wherein the sleeve is a non-metallic material.
33. The expandable threaded tubular connection of claim 32, wherein the sleeve abuts the end of the box member upon make-up of the threaded connection.
34. The expandable threaded tubular connection of any one of claims 20 to 33, further comprising a radial metal-to-metal seal formed by the engagement of the box member with the pin member in the area of the first thread segment of the pin member upon make-up of the threaded connection.
35. The expandable threaded tubular connection of claim 34, further comprising a thread seal formed by the engagement of the box threads with the pin threads of the first thread segment upon make-up of the threaded connection.
36. The expandable threaded tubular connection of claim 35, further comprising a resilient sealing ring placed in a groove within the first thread segment, the resilient sealing ring forming a seal upon make-up of the threaded connection.
37. The expandable threaded tubular connection of any one of claims 20 to 36, wherein the box member threads and the pin member threads are formed on pre-expanded ends of the first and second tubulars.
38. An expandable threaded tubular connection, comprising:
a first tubular segment with a pin member, the pin member comprising interengageable threads, the interengageable threads having a first thread segment and a second thread segment;
a second tubular segment with a pin member, the pin member comprising interengageable threads, the interengageable threads having a first thread segment and a second thread segment;
wherein the first and second thread segments of the pin members each comprise multiple turns of threads;
wherein the first thread segments of the pin members each comprise load flanks and stab flanks of a first pitch, the first pitch being constant across the first thread segments of the pin members;
wherein the second thread segments of the pin members each comprise load flanks and stab flanks of a second pitch, the second pitch being constant across the second thread segments of the pin members;
wherein the threads of the second thread segments of each pin member are formed such that material is removed from the stab flank of the pin threads of the second thread segments to reduce the axial thickness of the threads relative to the axial thickness of the threads of the first segment;
a coupling member comprising box members on both ends of the coupling member, the box members having interengageable threads designed to engage the pin threads of the pin members of the first tubular and the second tubular upon make-up of the threaded connection;
wherein the threads of the box members have load flanks and stab flanks of a constant pitch;
wherein the load flanks of the threads of the first and second thread segments are in contact with the mating flanks of the threads of the box members upon makeup of the connection; and wherein the reduced axial thickness of the threads of the second thread segments of each pin member causes a gap to be formed between the stab flank of the pin threads and the adjacent flanks of the box threads when the threads of the second thread segments of each pin member are fully engaged with the corresponding mating threads of the box members of the coupling member upon make-up of the threaded connection.
a first tubular segment with a pin member, the pin member comprising interengageable threads, the interengageable threads having a first thread segment and a second thread segment;
a second tubular segment with a pin member, the pin member comprising interengageable threads, the interengageable threads having a first thread segment and a second thread segment;
wherein the first and second thread segments of the pin members each comprise multiple turns of threads;
wherein the first thread segments of the pin members each comprise load flanks and stab flanks of a first pitch, the first pitch being constant across the first thread segments of the pin members;
wherein the second thread segments of the pin members each comprise load flanks and stab flanks of a second pitch, the second pitch being constant across the second thread segments of the pin members;
wherein the threads of the second thread segments of each pin member are formed such that material is removed from the stab flank of the pin threads of the second thread segments to reduce the axial thickness of the threads relative to the axial thickness of the threads of the first segment;
a coupling member comprising box members on both ends of the coupling member, the box members having interengageable threads designed to engage the pin threads of the pin members of the first tubular and the second tubular upon make-up of the threaded connection;
wherein the threads of the box members have load flanks and stab flanks of a constant pitch;
wherein the load flanks of the threads of the first and second thread segments are in contact with the mating flanks of the threads of the box members upon makeup of the connection; and wherein the reduced axial thickness of the threads of the second thread segments of each pin member causes a gap to be formed between the stab flank of the pin threads and the adjacent flanks of the box threads when the threads of the second thread segments of each pin member are fully engaged with the corresponding mating threads of the box members of the coupling member upon make-up of the threaded connection.
39. The expandable threaded tubular connection of claim 38, wherein the first thread segments of each pin member comprise the portion of each pin member from the pin nose end to approximately the midpoint of the pin member.
40. The expandable threaded tubular connection of claim 39, wherein the second thread segments of each pin member comprise the portion of each pin member from approximately the midpoint of each pin member to the external shoulder of each pin member.
41. The expandable threaded tubular connection of claim 40, wherein the gap allows radial and axial movement between the pin threads of the second thread segments and the corresponding mating box threads during radial expansion of the threaded connection.
42. The expandable threaded tubular connection of claim 41, wherein the axial thickness of the pin threads of the second thread segments of each pin member is reduced by one-third.
43. The expandable threaded tubular connection of claim 41, wherein the axial thickness of the pin threads of the second thread segments of each pin member is reduced by less than one-third.
44. The expandable threaded tubular connection of claim 41, wherein the axial thickness of the pin threads of the second thread segments of each pin member is reduced by more than one-third.
45. The expandable threaded tubular connection of any one of claims 38 to 44, further comprising a machined land area in the outside diameter of the first tubular in the area adjacent the external shoulder of the pin member of the first tubular.
46. The expandable threaded tubular connection of claim 45, wherein a sleeve is secured around the first tubular on the machined land area.
47. A method of forming a connection between expandable tubulars, the method comprising:
providing a box member in a first tubular segment, the box member including interengageable threads;
providing a pin member on a second tubular segment, the pin member including interengageable threads suitable for threadedly engaging the box member;
machining the threads of the pin member such that the pin member has a first thread segment and a second thread segment, wherein the threads of the second thread segment are machined such that material is removed from the stab flank of the pin threads to reduce the width of the threads;
inserting the pin member of the second tubular into the box member of the first tubular;
causing the threads of the first thread segment of the pin member to fully engage corresponding mating threads on the box member upon make-up of the threaded connection; and creating a gap between the stab flank of the pin threads and the adjacent flank of the box threads when the pin threads of the second thread segment are engaged with the corresponding mating threads of the box member upon make-up of the threaded connection.
providing a box member in a first tubular segment, the box member including interengageable threads;
providing a pin member on a second tubular segment, the pin member including interengageable threads suitable for threadedly engaging the box member;
machining the threads of the pin member such that the pin member has a first thread segment and a second thread segment, wherein the threads of the second thread segment are machined such that material is removed from the stab flank of the pin threads to reduce the width of the threads;
inserting the pin member of the second tubular into the box member of the first tubular;
causing the threads of the first thread segment of the pin member to fully engage corresponding mating threads on the box member upon make-up of the threaded connection; and creating a gap between the stab flank of the pin threads and the adjacent flank of the box threads when the pin threads of the second thread segment are engaged with the corresponding mating threads of the box member upon make-up of the threaded connection.
48. The method of claim 47, whereby the width of the pin threads of the second thread segment is reduced by one-third.
49. The method of claim 47, whereby the width of the pin threads of the second thread segment is reduced by less than one-third.
50. The method of claim 47, whereby the width of the pin threads of the second thread segment is reduced by more than one-third of the normal thread width.
51. The method of claim 47, further comprising forming the box member such that the outside diameter of the box member is greater than the outside diameter of the pin member.
52. The method of claim 51, further comprising forming a machined land area in the outside diameter of the second tubular in the area adjacent the external shoulder of the pin member.
53. The method of claim 52, further comprising securing a sleeve around the second tubular on the machined land area.
54. The method of claim 53, wherein the sleeve has an outside diameter substantially equal to the outside diameter of the box member.
55. The method of claim 54, whereby the sleeve is secured around the second tubular by shrink fitting the sleeve in place on the machined land.
56. The method of claim 54, whereby the sleeve is secured around the second tubular by an adhesive compound securing the sleeve to the machined land.
57. The method of claim 54, wherein the sleeve is metal.
58. The method of claim 54, wherein the sleeve is a non-metallic material.
59. The method of any one of claims 54 to 58, whereby the sleeve abuts the end of the box member upon make-up of the threaded connection.
60. The method of any one of claims 47 to 59, further comprising forming a radial metal-to-metal seal upon engagement of the box member with the pin member in the area of the first thread segment of the pin member upon make-up of the threaded connection.
61. The method of claim 60, further comprising forming a thread seal upon engagement of the box threads with the pin threads of the first thread segment upon make-up of the threaded connection.
62. The method of claim 61, further comprising placing a resilient sealing ring in a groove within the first thread segment such that the resilient sealing ring forms a seal upon make-up of the threaded connection.
63. A method of forming a connection between expandable tubulars, the method comprising:
providing a pin member on a first tubular segment, the pin member including interengageable threads;
providing a box member on a second tubular segment, the box member including interengageable threads suitable for threadedly engaging the pin member;
machining the threads of the box member such that the box member has a first thread segment and a second thread segment, wherein the threads of the second thread segment are machined such that material is removed from the flank of the box threads adjacent the stab flank of the pin threads to reduce the width of the threads;
inserting the pin member of the first tubular into the box member of the second tubular;
causing the threads of the first thread segment of the box member to fully engage corresponding mating threads on the pin member upon make-up of the threaded connection; and creating a gap between the stab flank of the pin threads and the adjacent flank of the box threads when the threads of the second thread segment are engaged with the corresponding mating threads of the pin member upon make-up of the threaded connection.
providing a pin member on a first tubular segment, the pin member including interengageable threads;
providing a box member on a second tubular segment, the box member including interengageable threads suitable for threadedly engaging the pin member;
machining the threads of the box member such that the box member has a first thread segment and a second thread segment, wherein the threads of the second thread segment are machined such that material is removed from the flank of the box threads adjacent the stab flank of the pin threads to reduce the width of the threads;
inserting the pin member of the first tubular into the box member of the second tubular;
causing the threads of the first thread segment of the box member to fully engage corresponding mating threads on the pin member upon make-up of the threaded connection; and creating a gap between the stab flank of the pin threads and the adjacent flank of the box threads when the threads of the second thread segment are engaged with the corresponding mating threads of the pin member upon make-up of the threaded connection.
64. The method of claim 63, whereby the width of the box threads of the second thread segment is reduced by one-third.
65. The method of claim 63, whereby the width of the box threads of the second thread segment is reduced by less than one-third.
66. The method of claim 63, whereby the width of the box threads of the second thread segment is reduced by more than one-third.
67. The method of any one of claims 63 to 66, further comprising forming the box member such that the outside diameter of the box member is greater than the outside diameter of the pin member.
68. The method of claim 67, further comprising forming a machined land area in the outside diameter of the first tubular in the area adjacent the external shoulder of the pin member.
69. The method of claim 68, further comprising securing a sleeve around the first tubular on the machined land area.
70. The method of claim 69, wherein the sleeve has an outside diameter substantially equal to the outside diameter of the box member.
71. The method of claim 70, whereby the sleeve is secured around the first tubular by shrink fitting the sleeve in place on the machined land.
72. The method of claim 70, whereby the sleeve is secured around the first tubular by an adhesive compound securing the sleeve to the machined land.
73. The method of claim 70, wherein the sleeve is metal.
74. The method of claim 70, wherein the sleeve is a non-metallic material.
75. The method of any one of claims 70 to 74, whereby the sleeve abuts the end of the box member upon make-up of the threaded connection.
76. The method of any one of claims 70 to 75, further comprising forming a radial metal-to-metal seal upon engagement of the box member with the pin member in the area of the first thread segment of the box member upon make-up of the threaded connection.
77. The method of claim 76, further comprising forming a thread seal upon engagement of the box threads of the first thread segment with the pin threads upon make-up of the threaded connection.
78. The method of claim 77, further comprising placing a resilient sealing ring in a groove within the first thread segment such that the resilient sealing ring forms a seal upon make-up of the threaded connection.
79. An expandable threaded tubular connection, comprising:
a first tubular segment with a box member, the box member comprising interengageable threads that have load flanks and stab flanks of a constant pitch;
a second tubular segment with a pin member, the pin member comprising interengageable threads for engaging said box member, the interengageable threads of the pin member having a plurality of thread segments, the plurality of thread segments comprising multiple turns of threads;
wherein one or more of the thread segments of the pin member comprise threads having a reduced axial thickness relative to the axial thickness of the threads of the box member;
wherein the multiple turns of threads of the plurality of thread segments each have load flanks and stab flanks of a constant pitch, the pitch being equal to the pitch of the load flanks and stab flanks of the threads of the box member; and wherein the load flanks of the multiple turns of threads of the plurality of thread segments are in full engagement with the mating flanks of the threads of the box member upon makeup of the connection.
a first tubular segment with a box member, the box member comprising interengageable threads that have load flanks and stab flanks of a constant pitch;
a second tubular segment with a pin member, the pin member comprising interengageable threads for engaging said box member, the interengageable threads of the pin member having a plurality of thread segments, the plurality of thread segments comprising multiple turns of threads;
wherein one or more of the thread segments of the pin member comprise threads having a reduced axial thickness relative to the axial thickness of the threads of the box member;
wherein the multiple turns of threads of the plurality of thread segments each have load flanks and stab flanks of a constant pitch, the pitch being equal to the pitch of the load flanks and stab flanks of the threads of the box member; and wherein the load flanks of the multiple turns of threads of the plurality of thread segments are in full engagement with the mating flanks of the threads of the box member upon makeup of the connection.
80. The expandable threaded tubular connection of claim 79, wherein the reduced axial thickness of the threads of the pin member causes a gap to be formed between the stab flank of the pin threads and the adjacent flank of the box threads when the reduced axial thickness threads of the pin member are engaged with the corresponding mating threads of the box member upon make-up of the threaded connection.
81. The expandable threaded tubular connection of claim 80, wherein the gap allows radial and axial movement between the reduced axial thickness pin threads and the corresponding mating box threads during radial expansion of the threaded connection.
82. The expandable threaded tubular connection of any one of claims 79 to 81, wherein the outside diameter of the box member is greater than the outside diameter of the pin member.
83. The expandable threaded tubular connection of claim 82, further comprising a machined land area in the outside diameter of the second tubular extending from the external shoulder of the pin member to a point on the second tubular that is approximately two inches from the threaded connection.
84. The expandable threaded tubular connection of claim 83, further comprising a sleeve secured around the second tubular on the machined land area, the sleeve having an outside diameter substantially equal to the outside diameter of the box member.
85. The expandable threaded tubular connection of claim 84, wherein the sleeve is metal.
86. The expandable threaded tubular connection of claim 84, wherein the sleeve is a non-metallic material.
87. An expandable threaded tubular connection, comprising:
a first tubular segment with a pin member, the pin member comprising interengageable threads that have load flanks and stab flanks of a constant pitch;
a second tubular segment with a box member, the box member comprising interengageable threads for engaging said pin member, the interengageable threads of the box member having a plurality of thread segments comprising multiple turns of thread;
wherein one or more of the thread segments of the box member comprises threads having a reduced axial thickness relative to the axial thickness of the threads of the pin member;
wherein the multiple turns of threads of the plurality of thread segments each have load flanks and stab flanks of a constant pitch, the pitch being equal to the pitch of the load flanks and stab flanks of the threads of the pin member; and wherein the load flanks of the threads of the plurality of thread segments are in full engagement with the mating flanks of the threads of the pin member upon makeup of the connection.
a first tubular segment with a pin member, the pin member comprising interengageable threads that have load flanks and stab flanks of a constant pitch;
a second tubular segment with a box member, the box member comprising interengageable threads for engaging said pin member, the interengageable threads of the box member having a plurality of thread segments comprising multiple turns of thread;
wherein one or more of the thread segments of the box member comprises threads having a reduced axial thickness relative to the axial thickness of the threads of the pin member;
wherein the multiple turns of threads of the plurality of thread segments each have load flanks and stab flanks of a constant pitch, the pitch being equal to the pitch of the load flanks and stab flanks of the threads of the pin member; and wherein the load flanks of the threads of the plurality of thread segments are in full engagement with the mating flanks of the threads of the pin member upon makeup of the connection.
88. The expandable threaded tubular connection of claim 87, wherein the reduced axial thickness threads of the box member cause a gap to be formed between the stab flank of the pin threads and the adjacent flank of the box threads when the reduced axial thickness threads of the box member are engaged with the corresponding mating threads of the pin member upon make-up of the threaded connection.
89. The expandable threaded tubular connection of claim 88, wherein the gap allows radial and axial movement between the reduced axial thickness box threads and the corresponding mating pin threads during radial expansion of the threaded connection.
90. The expandable threaded tubular connection of any one of claims 87 to 89, wherein the outside diameter of the box member is greater than the outside diameter of the pin member.
91. The expandable threaded tubular connection of claim 90, further comprising a machined land area in the outside diameter of the first tubular extending from the external shoulder of the pin member to a point on the first tubular that is approximately two inches from the threaded connection.
92. The expandable threaded tubular connection of claim 91, further comprising a sleeve secured around the first tubular on the machined land area, the sleeve having an outside diameter substantially equal to the outside diameter of the box member.
93. The expandable threaded tubular connection of claim 92, wherein the sleeve is metal.
94. The expandable threaded tubular connection of claim 92, wherein the sleeve is a non-metallic material.
95. A method of forming a connection between expandable tubulars, the method comprising:
providing a box member in a first tubular segment, the box member including interengageable threads;
providing a pin member on a second tubular segment, the pin member including interengageable threads suitable for threadedly engaging the box member;
machining the threads of the pin member such that the pin member has a plurality of thread segments, wherein the threads of one or more thread segments of the pin member are machined such that material is removed from the stab flank of the pin threads to reduce the width of the threads;
inserting the pin member of the second tubular into the box member of the first tubular;
causing the threads of one or more thread segments of the pin member to fully engage corresponding mating threads on the box member upon make-up of the threaded connection; and creating a gap between the stab flank of the reduced thread width pin threads and the adjacent flank of the box threads when the reduced thread width pin threads are engaged with the corresponding mating threads of the box member upon make-up of the threaded connection.
providing a box member in a first tubular segment, the box member including interengageable threads;
providing a pin member on a second tubular segment, the pin member including interengageable threads suitable for threadedly engaging the box member;
machining the threads of the pin member such that the pin member has a plurality of thread segments, wherein the threads of one or more thread segments of the pin member are machined such that material is removed from the stab flank of the pin threads to reduce the width of the threads;
inserting the pin member of the second tubular into the box member of the first tubular;
causing the threads of one or more thread segments of the pin member to fully engage corresponding mating threads on the box member upon make-up of the threaded connection; and creating a gap between the stab flank of the reduced thread width pin threads and the adjacent flank of the box threads when the reduced thread width pin threads are engaged with the corresponding mating threads of the box member upon make-up of the threaded connection.
96. The method of claim 95, wherein the amount of material removed from the stab flank of the pin threads varies between the thread segments of the pin member.
97. The method of claim 95, further comprising forming the box member such that the outside diameter of the box member is greater than the outside diameter of the pin member.
98. The method of claim 97, further comprising forming a machined land area in the outside diameter of the second tubular in the area adjacent the external shoulder of the pin member.
99. The method of claim 98, further comprising securing a sleeve around the second tubular on the machined land area.
100. The method of claim 99, wherein the sleeve has an outside diameter substantially equal to the outside diameter of the box member.
101. The method of claim 99, whereby the sleeve is secured around the second tubular by shrink fitting the sleeve in place on the machined land.
102. The method of any one of claims 99 to 101, whereby the sleeve is secured around the second tubular by an adhesive compound securing the sleeve to the machined land.
103. The method of any one of claims 99 to 102, wherein the sleeve is metal.
104. The method of any one of claims 99 to 102, wherein the sleeve is a non-metallic material.
105. A method of forming a connection between expandable tubulars, the method comprising:
providing a pin member on a first tubular segment, the pin member including interengageable threads;
providing a box member on a second tubular segment, the box member including interengageable threads suitable for threadedly engaging the pin member;
machining the threads of the box member such that the box member has a plurality of thread segments, wherein the threads of one or more thread segments of the box member are machined such that material is removed from the flank of the box threads adjacent the stab flank of the pin threads to reduce the width of the threads;
inserting the pin member of the first tubular into the box member of the second tubular;
causing the threads of one or more thread segments of the box member to fully engage corresponding mating threads on the pin member upon make-up of the threaded connection; and creating a gap between the stab flank of the pin threads and the adjacent flank of the reduced thread width box threads when the reduced thread width threads of the box member are engaged with the corresponding mating threads of the pin member upon make-up of the threaded connection.
providing a pin member on a first tubular segment, the pin member including interengageable threads;
providing a box member on a second tubular segment, the box member including interengageable threads suitable for threadedly engaging the pin member;
machining the threads of the box member such that the box member has a plurality of thread segments, wherein the threads of one or more thread segments of the box member are machined such that material is removed from the flank of the box threads adjacent the stab flank of the pin threads to reduce the width of the threads;
inserting the pin member of the first tubular into the box member of the second tubular;
causing the threads of one or more thread segments of the box member to fully engage corresponding mating threads on the pin member upon make-up of the threaded connection; and creating a gap between the stab flank of the pin threads and the adjacent flank of the reduced thread width box threads when the reduced thread width threads of the box member are engaged with the corresponding mating threads of the pin member upon make-up of the threaded connection.
106. The method of claim 105, wherein the amount of material removed from the flank of the box threads that is adjacent the stab flank of the pin threads varies between the thread segments of the box member.
107. The method of claim 105, further comprising forming the box member such that the outside diameter of the box member is greater than the outside diameter of the pin member.
108. The method of claim 107, further comprising forming a machined land area in the outside diameter of the first tubular in the area adjacent the external shoulder of the pin member.
109. The method of claim 108, further comprising securing a sleeve around the first tubular on the machined land area.
110. The method of claim 109, wherein the sleeve has an outside diameter substantially equal to the outside diameter of the box member.
111. The method of any one of claims 109 to 110, whereby the sleeve is secured around the first tubular by shrink fitting the sleeve in place on the machined land.
112. The method of any one of claims 109 to 110, whereby the sleeve is secured around the first tubular by an adhesive compound securing the sleeve to the machined land.
113. The method of any one of claims 109 to 112, wherein the sleeve is metal.
114. The method of anyone of claims 109 to 112, wherein the sleeve is a non-metallic material.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US10/885,824 US7452007B2 (en) | 2004-07-07 | 2004-07-07 | Hybrid threaded connection for expandable tubulars |
| US10/885,824 | 2004-07-07 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2510448A1 CA2510448A1 (en) | 2006-01-07 |
| CA2510448C true CA2510448C (en) | 2011-11-15 |
Family
ID=34839091
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2510448A Expired - Fee Related CA2510448C (en) | 2004-07-07 | 2005-06-21 | Hybrid threaded connection for expandable tubulars |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US7452007B2 (en) |
| CA (1) | CA2510448C (en) |
| GB (1) | GB2415974B (en) |
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-
2004
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-
2005
- 2005-06-01 GB GB0511043A patent/GB2415974B/en not_active Expired - Fee Related
- 2005-06-21 CA CA2510448A patent/CA2510448C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| GB2415974A (en) | 2006-01-11 |
| US7452007B2 (en) | 2008-11-18 |
| GB0511043D0 (en) | 2005-07-06 |
| GB2415974B (en) | 2009-04-08 |
| CA2510448A1 (en) | 2006-01-07 |
| US20060006647A1 (en) | 2006-01-12 |
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| EEER | Examination request | ||
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