Conduit liner for wellbore and method and apparatus for setting same

Claim 3

The method of claim 1 wherein said liner is disposed below both said swage means and said setting sleeve means and is connected with said setting sleeve means; said swage means engaging said force generating means for subjecting sad swage means to a force acting downwardly and said setting sleeve means being connected with said force generating means for subjecting said setting sleeve means to a reaction force acting upwardly; and wherein said force generating means is actuated to push said swage means downwardly completely out of the bottom of said liner, which is held by said setting sleeve means, while said reaction force is still acting upwardly on said liner.

Claim 4

The method of claim 2 wherein said setting sleeve means is connected with the top of said liner and is detachably connected with said force generating means; and wherein said setting sleeve means is detached during the operation of setting said liner and is left in said conduit with said liner expanded into tight frictional engagement with said conduit.

Claim 5

The method of claim 3 wherein a reduced outside diameter of saId swage means is effected to facilitate removal of said swage means upwardly through the expanded liner.

Claim 6

The method of claim 1 wherein said liner is disposed above both said swage means and said setting sleeve means and is connected with said setting sleeve means, said swage means being connected with said force generating means for subjecting said swage means to a force acting upwardly and said setting sleeve means engaging said force generating means for subjecting said setting sleeve means to a reaction force acting downwardly; and wherein said force generating means is actuated to pull said swage means completely through and out of the top of said liner, which is held by said setting sleeve means, while said reaction force is still acting downwardly on said liner.

Claim 7

The method of claim 5 wherein said setting sleeve means is connected with the bottom of said liner and has a portion that abuts a portion of a downwardly extending thrust member that is subjected to said reaction force from said force generating means, and said setting sleeve means is left in said conduit with said liner expanded into tight frictional engagement with said conduit.

Claim 8

The method of claim 6 wherein said setting sleeve means has connection means for connecting with a supplemental element emplaced therewithin.

Claim 9

The method of claim 7 wherein a seal unit is emplaced within said liner and said setting sleeve means, and has seal means engaging a longitudinally extending surface defining an internal bore in said liner, said longitudinally extending surface being effected by said swage means in expanding said liner outwardly into said tight frictional engagement with said conduit; said seal unit having a mating second connection means engaging said connection means.

Claim 10

The method of claim 1 wherein said liner is disposed above said swage means and below said setting sleeve means, said swage means being connected with said force generating means for subjecting said swage means to a force acting upwardly and said setting sleeve means engaging said force generating means for subjecting said setting sleeve means to a reaction force acting downwardly; and wherein said force generating means is actuated to pull said swage means completely through and out of the top of said liner, which bears against said setting sleeve means, and into a portion of said setting sleeve means while said reaction force is still acting downwardly on said liner.

Claim 11

The method of claim 9 wherein said swage means is pulled upwardly through said liner in a single stroke.

Claim 12

The method of claim 9 wherein said force generating means comprises a setting tool of a type wherein a piston assembly and a cylinder assembly are powered for relative movement by an ignitable charge.

Claim 13

The method of claim 11 wherein said setting sleeve means is connected with said setting tool, has flexible expander means and an expander support ring disposed concentrically within said expander means for support and wherein said swage means moves said expander support ring from within said expander means upon its passage therepast, said expander means expanding outwardly to allow passage of said swage means and springing inwardly to a position of normal repose thereafter, whereby a large upwardly acting force may be applied to said swage means without distorting said setting sleeve means, and said liner can be emplaced in said conduit with a single actuation of said force generating means and a single passage upwardly of said swage means.

Claim 14

The method of claim 9 wherein said liner positioned at said given depth in said conduit is connected with a second said liner via a connector means, which includes an elongate sleeve portion; said swage means is connected with a second swage means that has a slightly smaller diameter than said swage means and is arranged below said second liner; said swage means is pulled through said liner and said second swage means is pulled through said second liner to expand both liners outwardly iNto frictional and sealing engagement with said conduit; and both said swage means are removed in accordance with step (c) of claim 1.

Claim 15

The method of claim 13 wherein said swage means and said second swage means are drawn, respectively, through said liner and said second liner singly, whereby said force generating means does not have to generate a force great enough to pull both swaging means through both liners simultaneously.

Claim 16

A combination of liner and apparatus for setting the liner in conduit in a well penetrating subterranean formations comprising: a. a liner including an annular body portion having substantially cylindrical interior and exterior surfaces that are at least partially coextensive, having an outside diameter less than the diameter of said conduit, having sufficient malleability for and adapted for being expanded to conformingly engage said conduit, having a wall thickness sufficient to effect a wall after expansion capable of withstanding the pressure within or outside said conduit, and having a modulus of elasticity in compression sufficient to retain tight frictional engagement with said conduit after expansion thereagainst; b. swage means adjacent said liner for moving through and expanding said liner outwardly into tight frictional engagement with said conduit, the external dimensions of said swage means having been pre-selected in accordance with the internal dimensions of said conduit and the diameter and wall thickness of said liner to effect said tight frictional engagement with said conduit after expansion; c. an adapter rod means for connecting said swage means with a force generating means; said adapter rod means being connected at one end portion with said swage means and having, at the other end portion, means for engagement with a force generating means for subjecting said swage means to a force acting to move said swage means completely through said liner and expand said liner into said tight frictional engagement with said conduit; and d. setting sleeve means disposed radially of the central axis of said adapter rod means and adjacent said liner and having means for engagement with said force generating means for opposing movement of said liner by transmission of a reaction force that acts oppositely to said force from said force generating means; said setting sleeve means being constructed and disposed so as to allow movement of said swage means completely out of said annular body of said liner while said reaction force is still being applied to said liner.

Claim 17

A combination of liner and apparatus for setting the liner in conduit in a well penetrating subterranean formations comprising: a. a liner including an annular body portion having substantially cylindrical interior and exterior surfaces that are at least partially coextensive, having an outside diameter less than the diameter of said conduit, having sufficient malleability for and adapted for being expanded to conformingly engage said conduit, having a wall thickness sufficient to effect a wall after expansion capable of withstanding the pressure within or outside said conduit, and having a modulus of elasticity in compression sufficient to retain tight frictional engagement with said conduit after expansion thereagainst; b. swage means adjacent said liner for moving through and expanding said liner outwardly into tight frictional engagement with said conduit, the external dimensions of said swage means having been pre-selected in accordance with the internal dimensions of said conduit and the diameter and wall thickness of said liner to effect said tight frictional engagement with said conduit after expansion; c. an adapter rod means for connecting said swage means with a force generating means; said adapter rod means being connected at one end portion with said swage means and having, at the other end portion, means for engagement with a force generating means for subjecting said swage means to a force acting to move said swage means completely through said liner and expand said liner into said tight frictional engagement with said conduit; and d. setting sleeve means disposed radially of the central axis of said adapter rod means and adjacent said liner and having means for engagement with said force generating means for opposing movement of said liner by transmission of a reaction force that acts oppositely to said force from said force generating means; said setting sleeve means being constructed and disposed so as to allow movement of said swage means completely out of said annular body of said liner while said reaction force is still being applied to said liner.

Claim 18

The combination of claim 15 wherein said liner has a top portion integrally connected with said body portion and said top portion has an inner inverted frusto-conical section to form a stabbing section to facilitate entry of other elements into said liner once emplaced in said well.

Claim 19

The combination of claim 16 wherein said top portion has a plurality of notches in its top edge.

Claim 20

The combination of claim 15 wherein said swage means is disposed below said liner; said adapter rod means passes through said liner for pulling said swage means upwardly through and completely out of the top of said liner; said setting sleeve means is disposed below said liner with its upper end portion connected with said liner and has a portion that abuts a downwardly extending thrust member, said thrust member having means for engaging said force generating means and adapted for transmitting a downwardly acting reaction force for opposing movement of said liner when said swage means is pulled upwardly therethrough; and space is provided above the top of said annular body of said liner to allow said swage means to pass completely out of the top of said annular body while said reaction force is still being applied to said setting sleeve means.

Claim 21

The combination of claim 31 wherein said setting sleeve means has connection means for connection with a supplemental element emplaced therewithin; is sealingly connected with said liner, and removably abuts said thrust member such that said thrust member may be removed with said swage means and said setting sleeve means left in said conduit with said liner expanded into tight frictional engagement with said conduit.

Claim 22

The combination of claim 15 wherein said swage means is disposed above said liner; said adapter rod means is adapted for transmitting said force downwardly for pushing said swage means downwardly through said liner; said setting sleeve means is disposed above said liner with its lower end portion connected with said liner and is connected with a tensile means for transmitting a tensile force upwardly, said tensile means having means for engaging said force generating means and adapted for transmitting said reaction force upwardly for opposing movement of said liner when said swage means is pushed downwardly therethrough; and space is provided below the bottom of said annular body of said liner to allow said swage means to pass completely out of the bottom of said annular body while said reaction force is till being applied to said setting sleeve means.

Claim 23

The combination of claim 20 wherein said swage means has a frusto-conical section and a sectioned ring means for effecting said external dimensions of said swage means; said sectioned ring means being disposed peripherally of said frusto-conical section and freely movable longitudinally thereof, said sectioned ring means having a plurality of sections coupled together so as to effect an outside diameter when positioned at the largest portion of said frusto-conical section that effects said external dimensions of said swage means and is continuous for effecting a smooth bore in said liner; said sections being displacable sectionally vertically so as to effect a reduced outside diameter that can be readily withdrawn upwardly through said liner after emplacement.

Claim 24

The combination of claim 20 wherein said setting sleeve means is connected with the top of said liner and is connected with said tensile means via detachable connector means for being detached from said tensile means and left in place with said liner in said conduit.

Claim 25

The combination of claim 22 wherein said detachable connector means comprises a plurality of paired, mating, tension-sustaining connectors that are separable by lateral movement, one portion being carried by said setting sleeve means and one portion being carried by a biased portion of said tensile means that is biased for lateral movement so as to disengage from said setting sleeve means when not restrained, and a restraining means is disposed adjacent said biased portion for maintaining connection with said setting sleeve means until said swage means has passed completely out of said annular body of said liner.

Claim 26

The combination of claim 23 wherein said restraining means comprises a restraining ring and a shearable means for maintaining said restraining ring adjacent said biased portion; and said adapter rod means has a shoulder portion for shearing said shearable means and moving said restraining ring downwardly to release said biased portion after said swage means has passed downwardly through said liner and expanded it into tight frictional engagement with said conduit.

Claim 27

The combination of claim 23 wherein said paired connectors comprise respective mating apertures and protrusions.

Claim 28

The combination of claim 25 wherein said apertures are disposed in said setting sleeve means and said protrusions are carried by said biased portion, and said biased portion comprises inwardly biased collet fingers.

Claim 29

The combination of claim 15 wherein said swage means is disposed below said liner; said adapter rod means passes through said liner for pulling said swage means upwardly through and completely out of the top of said liner; said setting sleeve means is disposed above said liner with its lower end portion engaging the top of said liner and has means at its upper end portion for engagement with the force generating means and adapted for transmitting a downwardLy acting said reaction force for opposing upward movement of said liner when said swage means is pulled upwardly therethrough; and said setting sleeve means has means allowing movement of said swage means completely out of the top of said liner and within a portion of said setting sleeve means while said reaction force is still being applied to said setting sleeve means.

Claim 30

The combination of claim 27 wherein one of said adapter rod and said setting sleeve means are operatively connected with one of a piston assembly of a setting tool and a cylinder assembly of said setting tool for transmission respectively of said force acting upwardly and said downward acting reaction force; and said setting tool comprises a fluid actuated means means comprising a head assembly including igniter means, said cylinder assembly and said piston assembly within said cylinder assembly, with said piston assembly being slideable relative to said cylinder assembly; means including a combustion chamber adapted for receiving a combustible material power charge and disposed within said cylinder assembly for imparting relative motion to said cylinder assembly relative to said piston assembly to move said swage means upwardly through said liner, movement of which is opposed by said setting sleeve means.

Claim 31

The combination of claim 27 wherein said setting sleeve means expandably engages the top of said liner via flexible spring fingers for retaining said liner in place during setting, said spring fingers being adapted to flex outwardly to allow passage of said swage means therethrough and spring back into position after said swage means has passed therethrough.

Claim 32

The combination of claim 29 wherein an expander support ring is employed in said setting sleeve and is held in place adjacent said liner and within said flexible spring fingers with a shearable means for supporting said fingers during the interaction of the large force and reactive force pulling said swage means through said liner, said expander support ring having a shoulder for conformingly engaging a portion of said swage means after said swage means has passed through said liner and for moving said expander support ring upwardly as said swage means passes upwardly out of said liner.

Claim 33

The combination of claim 27 wherein the bottom of said body portion of said liner is sealingly connected with one end of a connector means and said connector means is sealingly connected at its other end with a terminal element.

Claim 34

The combination of claim 31 wherein said terminal element is at least a section of a production liner whereby said section of said production liner and any extensions thereof desired can be emplaced at a given location in said conduit by expansion of said body portion into frictional and sealing engagement with said conduit, and said production liner will resist being displaced upwardly by pressure or downwardly by its own weight.

Claim 35

The combination of claim 31 wherein said terminal element is a bull plug seal means and wherein said bull plug seal means can be emplaced at a given location in said conduit by expansion of said annular body portion into frictional and sealing engagement with said conduit and said bull plug seal means will resist being displaced upwardly or downwardly by force of a pressure acting thereon.

Claim 36

The combination of claim 31 wherein said terminal element is a second liner smaller than the diameter of said conduit, said second liner is sealingly connected at one end to said connector means via an expansible portion, and said connector means includes an elongate sleeve portion, to form a straddle patch for emplacing in said conduit for blocking a communicating passageway between the interior of said conduit and the exterior of said conduit; and wherein said swage means is connected with a second swage means below said second liner, said second swage means having a diameter slightly less than said swage means, said second swage means and said second liner cooperating to effect seaLing engagement of said second liner with said conduit when said second swage means is drawn upwardly through said second liner; whereby said second swage means can also pass through said liner after said swage means has expanded said liner into contact with said conduit.

Claim 37

The combination of claim 34 wherein said second swage means is immediately below and contiguous with said second liner and said swage means is spaced a distance below said liner sufficient to enable said second swage means to traverse through said second liner before said swage means starts its traverse of said liner.

Claim 38

The combination of claim 31 wherein said terminal element comprises a seal sub having a longitudinally extending internal sealing surface defining a bore for receiving in sealing relationship a large bore packer including single bore packers such as seal nipples; whereby said seal sub can be emplaced at a given location in said conduit by expansion of said annular body portion into frictional and sealing engagement with said conduit and said seal sub will resist being displaced upwardly or downwardly by a weight and the force of a pressure acting thereon.

Claim 39

The combination of claim 36 wherein there is included a large bore packer that conformingly and sealingly fits within said bore of said seal sub and has a portion that seals contiguous said sealing surface.

Claim 40

The combination of claim 37 wherein said large bore packer comprises a body having a longitudinally extending aperture penetrating therethrough.

Claim 41

The combination of claim 38 wherein said large bore packer body has a plurality of apertures extending longitudinally therethrough.