US20150047907A1

US20150047907A1 - Wrap-around band tool connector and method of forming

Info

Publication number: US20150047907A1
Application number: US14/461,292
Authority: US
Inventors: Jean Buytaert; Clayton Plucheck; Ira Eugene Hining
Original assignee: Antelope Oil Tool and Manufacturing Co LLC
Current assignee: Innovex Downhole Solutions Inc
Priority date: 2013-08-17
Filing date: 2014-08-15
Publication date: 2015-02-19
Also published as: WO2015026671A8; WO2015026668A1; US9765576B2; WO2015026670A1; WO2015026671A1; US20150047856A1

Abstract

A downhole tool including a body configured to be positioned on an outer surface of a tubular. A flexible member may extend circumferentially around the body more than once. The body may be positioned radially-between the outer surface of the tubular and the flexible member, and a tension force on the flexible member may cause the flexible member to apply a radially-inward gripping force on the body and the tubular.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application having Ser. No. 61/867,023, which was filed on Aug. 17, 2013. The entirety of this provisional application is incorporated herein by reference.

BACKGROUND

Oilfield tubulars, such as pipes, drill strings, casing, tubing, etc., may be used to transport fluids into or to produce water, oil, and/or gas from geologic formations through wellbores. In various applications, tools, such as centralizers, scrapers, cement baskets, etc. may be connected to the exterior of the tubular.
A variety of processes and structures are employed to connect the tools to the tubulars. One way to connect the tools to the tubular is to weld, fasten, adhere, or crimp the tool directly to the tubular. Similarly, an intermediate structure, often referred to as a stop collar, may be connected to the tubular using one or more of these processes, and the tool may connect with or otherwise engage the intermediate structure.
Each of these connection processes and/or structures is and used successfully in a variety of contexts. However, in some applications, welding may impact the metallurgical properties of the tubular, creating a heat-affected zone (HAZ) that may interfere with the desired characteristics of the tubular. Further, fasteners, such as set screws and/or teeth, may damage the exterior of the tubular or may not provide sufficient holding force. Adhesion also may not provide sufficient holding force, and/or the bonding may be affected by the downhole environment, e.g., in corrosive contexts. Additionally, crimping may damage the tubular, may not provide enough holding force, and/or may require a tool of reduced strength, so as to enable the crimping process.

SUMMARY

A downhole tool is disclosed. The downhole tool may include a body configured to be positioned on an outer surface of a tubular. The downhole tool may also include a flexible member configured to extend circumferentially around the body more than once. The body is configured to be positioned radially-between the outer surface of the tubular and the flexible member. When the tool is installed, a tension force on the flexible member causes the flexible member to apply a radially-inward gripping force on the body and the tubular.
In another embodiment, the downhole tool may include a body configured to be positioned on an outer surface of a tubular. The body may include first and second end rings and a middle portion positioned axially-between the first and second end rings. Outer surfaces of the first and second end rings may each have a recess formed therein, and the middle portion may extend radially-outward from the first and second end rings. Further, the tool may include first and second flexible members, which may each be configured to extend circumferentially-around the body more than once. When received around the body, the first and second flexible members may be at least partially positioned within the recesses of the first and second end rings, respectively. When the tool is installed, a tension force on the first and second flexible members may cause the first and second flexible members to apply a radially-inward gripping force on the first and second end rings and the tubular.
A method for installing a downhole tool on a tubular is also disclosed. The method may include positioning a body on an outer surface of the tubular. The body may have a first recess formed in an outer surface thereof. A first flexible member may be wrapped more than once around the body. The first flexible member may be positioned at least partially within the first recess. A first tension force may be applied to the first flexible member, and the first tension force may cause the first flexible member to apply a radially-inward gripping force on the body and the tubular.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may best be understood by referring to the following description and accompanying drawings that are used to illustrate embodiments of the invention. In the drawings:

FIG. 1A illustrates a perspective view of a stop collar installed on a tubular, according to an embodiment.

FIG. 1B illustrates a side, cross-sectional view of the stop collar installed on the tubular, according to an embodiment.

FIG. 1C illustrates an end view, taken along line 1C-1C in FIG. 1B, of the stop collar, according to an embodiment.

FIGS. 2A-E illustrate side views of an installation of the stop collar onto the tubular, according to an embodiment.

FIGS. 3A and 3B illustrate axial end, cross-sectional views of the flexible member of the stop collar, disposed around the tubular, according to an embodiment.

FIG. 4 illustrates an axial end, cross-sectional view of a multi-layered flexible member of the stop collar disposed around the tubular, according to several embodiments.

FIGS. 5-9 illustrate cross-sectional views of the flexible member, according to several embodiments

FIG. 10 illustrates a perspective view of a pre-coiled flexible member of the stop collar, according to an embodiment.

FIGS. 11A and 11B illustrate side views of a helical-spring embodiment of the flexible member in a contracted configuration and an expanded configuration, respectively, according to an embodiment.

FIG. 12A illustrates a side cross-sectional view of a stop collar including an insert disposed between the flexible member and the tubular, according to an embodiment.

FIG. 12B illustrates a side perspective view of the insert disposed around the tubular, according to an embodiment.

FIG. 13 illustrates a side perspective view of the flexible member and an engaging ring disposed adjacent thereto and around the tubular, according to an embodiment.

FIG. 14 illustrates a side perspective view of the flexible member and two profiled engaging rings disposed on opposite axial sides of the flexible member, according to an embodiment.

FIG. 15 illustrates a side, conceptual view of a stop collar and a centralizer disposed on the tubular, according to an embodiment.

FIGS. 16A and 16B illustrate a perspective view and an end view, respectively, of one or more inserts disposed around the tubular, according to an embodiment.

FIGS. 17A-C illustrate a perspective view, a side cross-sectional view, and an end view, respectively, of a scraper attached a tubular by flexible members, according to an embodiment.

FIGS. 18A-C illustrate a perspective view, a side cross-sectional view, and an end view, respectively, of a hole opener attached to a tubular by flexible members, according to an embodiment.

FIGS. 19A-C illustrate a perspective view, a side cross-sectional view, and an end view, respectively, of a cement basket attached to a tubular by a flexible member, according to an embodiment.

FIGS. 20A-C illustrate a perspective view, a side cross-sectional view, and an end view, respectively, of a packer and wiper attached to a tubular by flexible members, according to an embodiment.

FIGS. 21A-C illustrate a perspective view, a side cross-sectional view, and an end view, respectively, of a control line protector attached to a tubular by a flexible member, according to an embodiment.

FIGS. 22A-C illustrate a perspective view, a side cross-sectional view, and an end view, respectively, of a cylindrical housing attached to a tubular by flexible members, according to an embodiment.

FIGS. 23A-C illustrate a perspective view, a side cross-sectional view, and an end view, respectively, of a spiral blade attached to a tubular, according to an embodiment.

FIGS. 24A-C illustrate a perspective view, a side cross-sectional view, and an end view, respectively, of a passive flow turbulator attached to a tubular by flexible members, according to an embodiment.

FIG. 25 illustrates a flowchart of a method for installing downhole tool on a tubular, according to an embodiment.

DETAILED DESCRIPTION

The following disclosure describes several embodiments for implementing different features, structures, or functions of the invention. Embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference characters (e.g., numerals) and/or letters in the various embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed in the Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the embodiments presented below may be combined in any combination of ways, e.g., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.
Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. In addition, unless otherwise provided herein, “or” statements are intended to be non-exclusive; for example, the statement “A or B” should be considered to mean “A, B, or both A and B.”
FIGS. 1A and 1B illustrate a perspective view and a side, cross-sectional view, respectively, of a stop collar 100 installed on an oilfield tubular 102, according to an embodiment. As the term is used herein, an “oilfield tubular” includes a pipe, tubular, tubular member, casing, liner, tubing, drill pipe, drill string, a bar, a rod, a structural member and other like terms. Such oilfield tubulars may be or include one or more segments, which may be connected or “made-up” together to form a stand or string; accordingly, an “oilfield tubular” may refer to a joint or segment of a tubular member, or a stand or string of multiple tubular members joined together. As used herein, “axial” and “axially” refer to a direction that is parallel to a central or longitudinal axis of the tubular 102; “radial” and “radially” refer to a direction perpendicular to the axial direction.
In particular, FIG. 1A illustrates the exterior of the stop collar 100, which may include a coating 104. The coating 104 may be or include an adhesive, such as an epoxy, glue, resin, polyurethane, cyanoacrylate, acrylic polymer, hot melt adhesive, contact adhesive, reactive adhesive, light curing adhesive, low temperature metal spray, metal spray (such as WEARSOX® commercially available from Antelope Oil Tool & Mfg. Co., Houston, Tex.), combinations thereof, and/or the like. The coating 104 may be selected, for example, so as to exhibit material properties suitable for exposure to the downhole environment and running-in along with the tubular 102. Such material properties may include low friction, high strength, and/or the like. Further, the stop collar 100 may have two axial ends 106, 108, which may, in at least one embodiment, be defined by the coating 104, as shown. One or both of the axial ends 106, 108 may extend straight in a radial direction from the tubular 102 and/or may be tapered, beveled, rounded, or otherwise shaped.
Further, the coating 104 may extend entirely over the stop collar 100, as shown, may extend partially thereabout, and/or may or may not extend radially inward into contact with the tubular 102. In some embodiments, a plastic, elastomeric, composite, metallic, etc. sleeve may be positioned over the coating 104, e.g., with the coating 104 providing an adhesive coupling the sleeve to a remainder of the stop collar 100.
Referring now specifically to FIG. 1B, the stop collar 100 may include a flexible member 110, which may be disposed radially between the tubular 102 and at least a portion of the coating 104. For example, the flexible member 110 may be wrapped more than once (e.g., one 360 degree turn plus any fraction of a subsequent turn) around the tubular 102. The flexible member 110 may apply a radially-inward gripping force on the tubular 102. For example, the flexible member 110 may be wrapped helically around the tubular 102, with the gripping force being generated by applying a tension on the flexible member 110 during such helical wrapping. In another embodiment, the flexible member 110 may be heated after being wrapped around the tubular to or near to a red-hot transition temperature, which may cause the flexible member 110 to shrink, resulting in a tension force in the flexible member 110 that causes the flexible member 110 to apply a radially-inward gripping force on the tubular 102. Thereafter, the flexible member 110 may be cooled such that the flexible member 110 retains its shrunken length, thereby maintaining the radially-inward gripping force.
In such a helically-wrapped embodiment of the flexible member 110, the flexible member 110 may define turns 112 (e.g., 360 degree increments) around the tubular 102. Successive turns 112 may be adjacent to one another, generally in an axial direction along the tubular 102. In one, some, or all of the turns 112, the flexible member 110 may abut the flexible member 110 contained in at least one adjacent turn 112. As such, the flexible member 110 may form a generally continuous surface that is spaced radially apart from the tubular 102.
The coating 104 may be applied at least partially on the exterior (radial outside, facing away from the tubular 102) of the flexible member 110 by spraying, brushing, rolling, etc. In some embodiments, the coating 104 may be applied such that it extends axially past the first and last turns 112, so as to form the ends 106, 108, as noted above and shown in FIG. 1B. As such, the flexible member 110 may be at least partially embedded in the coating 104.
Furthermore, in at least one embodiment, an adhesive, which may or may not be formed from the same material as the coating 104, may be positioned radially between the flexible member 110 and the tubular 102, as will be described in greater detail below. In addition, the coating 104 may extend radially past (or through) the flexible member 110, between the ends 106, 108, and into engagement with the tubular 102. For example, the coating 104 may extend through spaces defined between the turns 112. Additionally or alternatively, holes may be formed in the flexible member 110, so as to allow traversal of the flexible member 110 by the coating 104.
The flexible member 110 may be an elongate member, which may be or include a monolithic or braided cable, wire, ribbon, string, cord, line, rope, band, tape, coil spring, multi-strand wire, wire rope and any member having the flexibility and strength to be wrapped about the outer surface of the tubular 102. For example, the flexible member 110 may constructed from a metal, plastic, composite, or any combination thereof. In one embodiment, the flexible member 110 includes a steel cable, e.g., a stainless steel cable. Further, the flexible member 110 may be one unitary length of material, e.g., a length providing a desired holding force once it is wrapped (and/or adhered) on the oilfield tubular. In other embodiments, the flexible member 110 may include multiple segments that are attached together (e.g., end-on-end).
FIG. 1C illustrates an axial end view of the flexible member 110 disposed around the tubular 102, according to an embodiment, e.g., as taken along lines 1C-1C of FIG. 1B. As shown, the flexible member 110 may include ends 114, e.g., one at the beginning of the first turn 112 proximal the first end 106. It will be appreciated that an axial view of the flexible member 110 proximal the second end 108 may be substantially similar, also providing a circumferential end where the flexible member 110 terminates. The ends 114 may be cut at angles, such that the ends 114 taper, and thereby provide a generally flush or gradual change in the end surface for the flexible member 110.
FIGS. 2A-2E illustrate an installation sequence for the stop collar 100, according to an embodiment. Beginning with FIG. 2A, installation collars 200, 202 may be positioned on the tubular 102 and spaced axially apart, e.g., such that the inboard sides 204, 206, respectively, of the collars 200, 202 are positioned generally where the ends 106, 108 (FIGS. 1A and 1B) of the stop collar 100 will be positioned. In some embodiments, such installation collars 200, 202 may be omitted from use during installation. In an embodiment, the installation collars 200, 202 may be each be provided by a unitary ring that may be slid over an end of the tubular 102. In another embodiment, the installation collars 200, 202 may be provided by a unitary ring that is flexible and includes an axially-extending gap, such that two circumferential ends are defined. In such an embodiment, the installation collars 200, 202 may be flexed so as to receive the tubular 102 laterally. In another embodiment, the installation collars 200, 202 may be provided by two or more arcuate sections that are connected together (e.g., hinged, clamped, fastened, etc.). It will be appreciated that in some embodiments, one of the installation collars 200 may be provided by one of the embodiments just described, while the other one of the installation collars 202 may be provided according to another embodiment.
Further, a layer 208 may be applied to the tubular 102, e.g., at least partially between the inboard sides 204, 206 of the collars 200, 202. The layer 208 may be or include an adhesive, such as an epoxy, glue, resin, polyurethane, cyanoacrylate, acrylic polymer, hot melt adhesive, contact adhesive, reactive adhesive, light curing adhesive, low temperature metal spray, metal spray (such as WEARSOX®), combinations thereof, and/or the like. The layer 208 may be employed to increase the holding force provided by the stop collar 100, avoid the flexible member 110 biting into the tubular 102, and/or the like. The layer 208 may coat the tubular 102 entirely between the installation collars 200, 202 or, in other embodiments, may include axially and/or circumferentially-extending gaps.
Before or after the layer 208 is cured (e.g., when using an adhesive for the layer 208), a first turn 112 of the flexible member 110 may be disposed around the tubular 102, between the installation collars 200, 202, e.g., proximal to the installation collar 200, and on the layer 208. The first turn 112 may include the end 114-1 of the flexible member 110. Further, the end 114-1 may be secured in place, such that it is generally stationary relative to the tubular 102 during installation. For example, the end 114-1 may be held in place, with tension applied to the flexible member 110, and the end 114-1 welded to a second turn 112 of the flexible member 110. In other embodiments, the flexible member 110 may be adhered to itself near the end 114-1, clamped or fastened to itself, or the like. In other embodiments, the end 114-1 of the flexible member 110 may be secured to the installation collar 200, which may be secured against rotation. In other embodiments, a section of the flexible member 110 proximal to the end 114-1 may be turned, e.g., toward an axial direction, and held temporarily in place while one or more additional turns 112 of the flexible member 110 are received over the end 114-1.
Referring now to FIG. 2B, the flexible member 110 may be helically wrapped around the tubular 102, e.g., as successive turns 112 are provided. In an embodiment, the tubular 102 may be turned while the flexible member 110 is fed laterally onto the tubular 102, e.g., from a spool. A friction or resistance (e.g., as applied by the spool of the flexible member 110 resisting the extension of the flexible member 110) may apply tension to the flexible member 110, causing the flexible member 110 to apply a radially-inwardly directed gripping force on the tubular 102. Thus, the gripping force supplied by the flexible member 110 may provide the holding force for the stop collar 100, once installed. In another embodiment, the tubular 102 may remain stationary while the flexible member 110 is wrapped therearound. In yet another embodiment, the tubular 102 may rotate and the flexible member 110 may be moved around the tubular 102, e.g., such that both components are in motion during the installation process. As shown, the successive turns 112 may abut against one another; however, in other embodiments, two or more of the adjacent turns 112 may be spaced apart, such that they do not abut.
In some embodiments, applying the layer 208 and wrapping the flexible member 110 may be an iterative process. For example, a certain width, e.g., less than the distance between the installation collars 200, 202, of the layer 208 may be applied onto the tubular 102, and then the flexible member 110 may be wrapped over that width of the layer 208. Then, another width of the layer 208 may be applied, and then flexible member 110 wrapped over that width. This process may repeat one or more times. In other embodiments, the layer 208 may be applied to the extent needed (e.g., all or a portion of the width between the installation collars 200, 202), and then the flexible member 110 may be wrapped around the tubular 102 continuously.
As shown in FIG. 2C, the helical wrapping of the flexible member 110 around the tubular 102 may continue, e.g., until the flexible member 110 abuts both of the installation collars 200, 202. In some embodiments, the wrapping of the flexible member 110 end prior to the flexible member 110 spanning the entire distance between the installation collars 200, 202.
In addition, in at least some embodiments, two or more adjacent turns 112 may be welded, adhered, or otherwise secured together. For example, as shown, several welds 210 may be created, attaching together the turns 112. Such welding (and/or otherwise attaching) together the turns 112 may further serve to retain the position of the flexible member 110.
Referring to FIG. 2D, with the flexible member 110 in place, the coating 104 may be applied. As noted above with reference to FIGS. 1A-1C, the coating 104 may be an adhesive, spray metal, and/or the like. The coating 104 may be deposited between the installation collars 200, 202. The radial height of the installation collars 200, 202 may be approximately equal to, or greater than, the thickness of the flexible member 110. Accordingly, the installation collars 200, 202 may act similar to the sides of a mold, keeping the coating 104 on the flexible member 110, and forming the ends 106, 108.
In some embodiments, e.g., due to the helical shape of the flexible member 110, a space may be defined between the ends of the flexible member 110 and the inboard sides 204, 206 of the installation collars 200, 202. This space may be filled with the coating 104, so as to provide the axial ends 106, 108 with a generally annular shape. Further, in some cases, the ends of the flexible member 110 may not contact the collars 200, 202, and thus the coating 104 may extend past the flexible member 110 and define the ends 106, 108, e.g., as shown in FIG. 1B.
In at least one embodiment, a shell may be placed around the flexible member 110 and/or the coating 104. The shell may have an outer surface that is planar or outwardly-curved (e.g., convex), and the inner surface of the shell may include a plurality of projections, curved ridges, a fish scale pattern, or the like. The shell may be structurally reinforced with a strut, a brace, a rib, or the like that extends between two opposite sides of the shell. The shell may be formed from a composite material (e.g., a fiber-reinforced resin material), which may be surface-treated before molding of the shell. The shell may have at least one inlet configured to receive a liquid material such as a bonding agent. The bonding agent may be used to couple the shell to the outer surface of the tubular and the flexible members. The flexible member may provide support to the shell. Additional details of the shell may be found in PCT Application No. PCT/EP2013/057416, filed Apr. 9, 2013, which is hereby incorporated by reference in its entirety.
Referring to FIG. 2E, once the coating 104 is applied, the installation collars 200, 202 may be removed from the tubular 102, e.g., by sliding the installation collars 200, 202 over opposite ends of the tubular 102 or by removing one or more of the installation collars 200, 202 laterally, e.g., by opening a hinge. The remaining structure may generally provide the stop collar 100, according to an embodiment. In some cases, further forming, e.g., to taper, round, smooth, roughen, or otherwise shape the ends 106, 108 and/or the outer diameter of the coating 104, may be conducted. Further, a sleeve or any other structure may be coupled with the coating 104 and/or to the flexible member 110.
Although described above with reference to a relatively thin (in axial dimension and relative to the total axial width of the stop collar 100) flexible member 110, it will be appreciated that the flexible member 110 may have a larger axial width, up to a width that equals the axial dimension, from end 106 to end 108, of the stop collar 100. For example, rather than helically wrapping the flexible member 110 around the tubular 102, each turn of the tubular 102 with respect to the flexible member 110 (either the tubular 102 or the flexible member 110 may be moving, as described above) may result in a complete layer of the flexible member 110 being deposited. Thus, as will be described below, multiple layers of the flexible member 110 may be wrapped around the tubular 102, e.g., in concentric layers.
FIGS. 3A and 3B illustrate two axial, cross-sectional views of the flexible member 110, similar to the view shown in FIG. 1C, according to two embodiments. As depicted in FIG. 3A, in some instances, the tubular 102 may be generally elliptical, rather than circular. The flexible member 110 may, however, be configured to wrap around such a non-circular geometry. Similarly, as shown in FIG. 3B, the tubular 102 may be polygonal, e.g., rectangular, in shape, and the flexible member 110 may be disposed along the perimeter of the tubular 102. Accordingly, embodiments of the stop collar 100 may be configured to be disposed around any shape.
FIG. 4 illustrates an axial end-view of a multi-layered flexible member 400, according to an embodiment. The multi-layered flexible member 400 may include at least two layers 401, 402. In an embodiment, the flexible member 110 may provide the first layer 401, which may, as discussed above, be disposed against the tubular 102. In addition, the second layer 402 may be disposed radially outward from the first layer 401, e.g., provided as a second flexible member that is wrapped around the flexible member 110. The second layer 402 may be wrapped around at least a portion of the flexible member 110, e.g., using an embodiment of the wrapping process discussed above with respect to FIGS. 2A-2E. Any number of layers 401, 402 may be provided, e.g., so as to achieve a desired positive outer diameter (e.g., the radial distance added by the provision of the stop collar 100 extending from the tubular 102), which may be larger than a thickness of the flexible member 110.
Further, in some embodiments, the first and second layers 401, 402 may have differently-shaped cross-sections. For example, the first layer 401 may have a circular cross-section, while the second layer 402 may have a braided cross-section. Any other combination of cross-sections may be provided for the first and second layers 401, 402, whether the same or different.
In another embodiment, the flexible member 110 may provide both of the first and second layers 401, 402. For example, in an embodiment in which the flexible member 110 is a relatively thin (relative to the axial length of the stop collar 100), helically-wrapped member, the first layer 401 may be constructed by wrapping the flexible member 110 around the tubular 102, and then the wrapping direction may be reversed, with the second layer 402 of the flexible member 110 being wrapped around the first layer 401 thereof. In another embodiment, the flexible member 110 may have the same width as the stop collar, and thus each turn of the tubular 102 may provide an additional layer.
FIGS. 5-9 illustrate five example cross-sections for the flexible member 110. As shown in FIG. 5, the cross-section of the flexible member 110 may be generally circular, e.g., as with a solid wire or other flexible cylindrical structure. FIG. 6 illustrates a square-shaped cross-section, and FIG. 7 similarly illustrates a rectangular-shaped cross-section, which may be provided in an embodiment in which the flexible member 110 is formed as a band. FIG. 8 illustrates a more complex cross-section for the flexible member 110, which may be made of a plurality of filaments 800. The filaments 800 may be braided or otherwise combined into strands 802, which may in turn be braided or otherwise combined to form the cross-section of the flexible member 110. Although seven strands 802 are illustrated, any number of strands 802 may be employed, each of which may be constructed using any number of filaments 800.
Moreover, as depicted in FIG. 9, the flexible member 110 may be constructed from two or more bodies. For example, the flexible member 110 may include a mandrel 900 and a sheath 902, which may be generally concentric. The mandrel 900 may have any shape cross-section and may be solid, hollow, or formed from a combination of filaments, strands, etc. The sheath 902 may fit over and/or around the mandrel 900. The mandrel 900 may be attached to the sheath 902, but in other embodiments may be movable therein.
Still referring to FIG. 9, FIG. 10 illustrates a perspective view of a pre-wound or pre-coiled flexible member 110 that includes the mandrel 900 and the sheath 902, according to an embodiment. The flexible member 110 may be pro-wound in that it is formed into the illustrated helix prior to installation around a tubular (e.g., the tubular 102 shown in FIG. 1A).
Further, ends 1002, 1004 of the mandrel 900 may extend from the sheath 902. In a pre-coiled embodiment, the coil of flexible member 110 may initially have an inner diameter that is larger than the outer diameter of the tubular (e.g., tubular 102), and may thus slide onto the tubular. Upon reaching an installation point, which may or may not include a layer of adhesive, such as the layer 208, a tension force may be applied to the ends 1002, 1004, thereby reducing the diameter of the mandrel 900. In some cases, at least initially, the sheath 902 may move with the mandrel 900, but may become engaged between the mandrel 900 and the tubular. Continued application of force on the ends 1002, 1004 may cause the mandrel 900 to move relative to the sheath 902, and the sheath 902 may be compressed between the tubular and the mandrel 900. In some embodiments, the sheath 902 may be made from a relatively soft material, such as a plastic, elastomer, or relatively soft metal, which may prevent the mandrel 900, which may be made of a harder material, from damaging the tubular during constriction of the mandrel 900.
In other embodiments, the flexible member 110 including the mandrel 900 and the sheath 902 may be wound as it is installed onto the tubular 102, for example, similar to the way in which the flexible member 110 is installed as shown in and described above with reference to FIGS. 2A-2E. In an embodiment, the flexible member 110 may be wrapped loosely around the tubular 102, and then the tension applied to the ends 1002, 1004, so as to contract the mandrel 900 and cause the flexible member 110 to grip the tubular.
FIGS. 11A and 11B illustrate side views of another pre-wound, helical-spring embodiment of the flexible member 1100 for use in the stop collar 100. In particular, FIG. 11A shows the flexible member 1100 in a first or “natural” configuration, and FIG. 11B shows the flexible member 1100 in an expanded configuration. In an embodiment, the flexible member 1100 may be formed with a first or “natural” length L₁and a first or “natural” diameter D₁, as shown in FIG. 11A. The natural length L₁and natural diameter D₁may be the length and diameter, respectively, that the helical spring of the flexible member 110 has when no external force is applied. The flexible member 1100 may also define a certain number of turns 112 in the natural configuration.
Prior to installing the flexible member 1100 onto the tubular, a torque force may be applied to the flexible member 1100, e.g., to the ends 1102, 1104 thereof. The torque force may serve to expand the flexible member 1100 at least to a second diameter D₂, e.g., by reducing the number of turns 112. Such torque may also create spaces between the turns 112, which may cause the length of the flexible member 1100 to increase to a second length L₂. The flexible member 1100 in the expanded configuration may be received over a tubular having a diameter that is between the first and second diameters D₁, D₂of the flexible member 1100. Upon reaching a desired installation location, the torque force may be removed, causing the flexible member 1100 to contract. In another embodiment, a temporary adhesive may be employed to retain the flexible member 1100 in the expanded configuration for a duration, before breaking down and allowing the flexible member 1100 to contract. Full contraction to the first, natural diameter D₁may be prevented by the flexible member 1100 bearing on the tubular, and thus the flexible member 1100 may apply a spring force on the tubular, which may provide the gripping/holding force.
FIG. 12A illustrates a side, cross-sectional view of the stop collar 100 including an insert 1200, according to an embodiment. FIG. 12B illustrates a side view of the insert 1200, with the remainder of the stop collar 100 omitted for purposes of illustration. The insert 1200 (which may also be referred to as a “spline”) may be formed from a plurality of segments 1202. Each segment 1202 may include a head 1204 and an elongate body 1206. The segments 1202 may be disposed in an alternating orientation, such that the head 1204 of one segment 1202 is disposed at an axially opposite side to the head 1204 of an adjacent segment 1202, as shown. Thus, the elongate body 1206 of each segment 1202 may serve as a spacer between circumferentially-adjacent segments 1202. In other embodiments, each segment 1202 may include two heads 1204, e.g., one on each axial side thereof.
Further, the heads 1204 may extend radially outwards from the tubular 102, farther than the elongate bodies 1206. The heads 1204 may thus collectively define end rings on either side of the insert 1200, which may be engaged by a tool or another device disposed around the tubular 102, e.g., in the wellbore. For example, the combination of the elongate bodies 1206 and the flexible member 120 may extend to approximately the same radial position as the radial-outside of the heads 1204; however, in other embodiments, the heads 1204 may extend farther outwards than, or not as far outwards as, the flexible member 110 disposed on the elongate bodies 1206.
The segments 1202 may be connected together, e.g., using an elastic band received around the tubular 102. In another embodiment, the segments 1202 may be unitary, glued, snapped, hooked, or otherwise held together circumferentially, so as to facilitate installation around the tubular 102.
In operation, the insert 1200 may, as shown, be sandwiched between the flexible member 110 and the tubular 102. The insert 1200 may be fabricated at least partially from a material that is relatively soft compared to the tubular 102 and the flexible member 110. For example, the insert 1200 may be made from a molded plastic, an elastomer, another plastic, a composite, a relatively soft metal, etc. Thus, the insert 1200 may be compressed when the flexible member 110 is received around the tubular 102, and may provide a buffer between the flexible member 110 and the tubular 102, e.g., to reduce the risk of damaging the tubular 102, to increase holding forces (e.g., by providing a high-friction insert 1200 and/or by including teeth or other marking structures on an inner surface and/or outer surface of the insert 1200), and/or the like.
In at least one embodiment, the insert 1200 may contain an adhesive, which may be released upon compression of the insert 1200 by the flexible member 110. For example, the insert 1200 may include encapsulated pockets of adhesive therein, and may include holes or predetermined rupture locations. When the flexible member 110 provides a radially-inward gripping force, the adhesive may migrate out of the pockets and into contact with the flexible member 110, forming a bond between the flexible member 110 and the tubular 102 and/or the insert 1200.
FIG. 13 illustrates a side view of the flexible member 110 and an engaging ring 1300 of the stop collar 100, according to an embodiment. The engaging ring 1300 may be made from an annular band of material, such as metal, plastic, elastomer, composite, etc. The engaging ring 1300 may be secured at least in an axial position by fixing the engaging ring 1300 to either or both of the tubular 102 and/or the flexible member 110, e.g., using adhesives, welding, set screws, etc. In other embodiments, the engaging ring 1300 may be free to move about and/or along the tubular 102, except as constrained by axial engagement with the flexible member 110 and any other collars or protrusions disposed on the tubular 102. Further, the engaging ring 1300 may be configured to bear upon, and thus transmit a generally axially-directed force against a side 1302 of the flexible member 110.
Accordingly, the engaging ring 1300 may provide a generally uniform, radially-extending surface against which tools, etc., may engage and push toward the flexible member 110. The engaging ring 1300 may thus be sandwiched between the flexible member 110 and the force-applying member (e.g., tool, component, etc.). As such, the flexible member 110 may continue providing the holding force, while the engaging ring 1300 may prevent the force-applying member from damage caused by engaging the end 114-1 of the helical, flexible member 110.
It will be appreciated that a second engaging ring may be provided, e.g., adjacent to the opposite axial side 1304 of the flexible member 110, e.g., to provide for engagement with a force-applying member in an opposite direction.
FIG. 14 illustrates a side view of two engaging rings 1400, 1402 on either axial side 1302, 1304 of a flexible member 110, according to an embodiment. The engaging rings 1400, 1402 may be generally similar in form and/or function to the engaging ring 1300 of FIG. 13; however, the engaging rings 1400, 1402 may include profiled inner surfaces 1404, 1406 that face in the axial direction. For example, the inner surface 1404, may begin at a certain thickness at a starting point, and decrease in thickness as proceeding circumferentially around the engaging ring 1400, until reaching the stating point, at which point the thickness may abruptly (or smoothly) return to the original thickness. The opposing engaging ring 1402 may be similarly constructed, but the profiled inner surface 1406 thereof may be a mirror image of the profiled inner surface 1404. That is, for example, the profiled inner surface 1406 may smoothly reduce in thickness from the starting point as proceeding clockwise, while the profiled inner surface 1404 may smoothly reduce in thickness from the starting point in a counterclockwise direction.
The profiled inner surfaces 1404, 1406 may thus define a shoulder 1408, 1410 at the starting points thereof. The shoulders 1408, 1410 may be configured to receive the ends 114-1, 114-2, respectively, of the flexible member 110, and the profiled inner surfaces 1404, 1406 may be configured to engage a maximum surface area of the flexible member 110 along the proximal turn 112.
FIG. 15 illustrates a side view of the stop collar 100 installed on the tubular 102 and straddled by a centralizer 1500, according to an embodiment. The centralizer 1500 may include two end collars 1502, 1504, which are received around the tubular 102 and separated axially apart. A plurality of ribs 1506, which may be rigid, semi-rigid, or flexible, bow-springs extend between the end collars 1502, 1504 and are disposed at circumferential intervals around the tubular 102. The ribs 1506 may extend radially outward from the tubular 102 and may be configured to engage a surrounding tubular (e.g., a casing, liner, or wellbore wall), so as to maintain a generally annular stand-offbetween the tubular 102 and the surrounding tubular 102.
As shown, the end collars 1502, 1504 may be disposed on opposite axial sides of the stop collar 100, i.e., in a “straddled” configuration. In this embodiment, the ribs 1506 extend over the stop collar 100. In addition, engaging members may be coupled with one or both of the end collars 1502, 1504 and the stop collar 100. In other embodiments, one or more stop collars 100 may be disposed on the outboard axial ends of the end collars 1502, 1504.
The end collars 1502, 1504 may bear on the stop collar 100, e.g., when passing through a wellbore restriction or otherwise experiencing axially-directed (e.g., drag) forces. The stop collar 100 may provide a holding force, which may retain the axial position of the centralizer 1500 with respect to the tubular 102.
FIGS. 16A and 16B illustrate a perspective view and a cross-sectional view, respectively, of one or more helical inserts (three are shown: 1630A-C) disposed around the tubular 1600, according to an embodiment. The inserts 1630A-C may be positioned radially between the outer surface of the tubular 1600 and the flexible member 1604. The inserts 1630A-C may be at least partially disposed within adhesive. For example, the adhesive may be positioned within the void caused by the inserts 1630A-C between the outer surface of the tubular 1600 and the flexible member 1604.
As shown, the inserts 1630A-C may be wrapped helically around the tubular 1600 with a greater lead and/or pitch than the flexible member 1604. However, in other embodiments, the inserts 1630A-C may be substantially parallel to the longitudinal axis of the tubular 1600. The inserts 1630A-C may be longitudinal rods that provide structural support to the tubular 1600. In another embodiment, the inserts 1630A-C may be conduits and/or cables for transmitting power, communication signals, fluids, and the like.
In at least one embodiment, a shell may be placed around the flexible member 1604. The shell may have an outer surface that is planar or outwardly-curved (e.g., convex), and the inner surface of the shell may include a plurality of projections, curved ridges, a fish scale pattern, or the like. The shell may be structurally reinforced with a strut, a brace, a rib, or the like that extends between two opposite sides of the shell. The shell may be formed from a composite material (e.g., a fiber-reinforced resin material), which may be surface-treated before molding of the shell. The shell may have at least one inlet configured to receive a liquid material such as a bonding agent. The bonding agent may be used to couple the shell to the outer surface of the tubular and the flexible members. The flexible member may provide support to the shell. Additional details of the shell may be found in PCT Application No. PCT/EP2013/057416, filed Apr. 9, 2013, which is hereby incorporated by reference in its entirety.
FIG. 17A illustrates a perspective view of a scraper 1701 attached to a tubular 1700 by flexible members 1704A, B, according to an embodiment. The scraper 1701 may include a hollow, substantially cylindrical body having one or more blades (four are shown: 1732A-D) extending radially-outward therefrom. Each blade 1732A-D may include one or more angled notches 1733 extending radially-inward from the outer surface thereof. As shown, each blade 1732A-D includes three angled notches 1733 that are axially-offset from one another with respect to the longitudinal axis of the tubular 1700. The blades 1732A-D may be positioned axially-between opposing end rings 1716, 1718.
FIG. 17B illustrates a cross-sectional side view of the scraper 1701 attached to the tubular 1700, according to an embodiment. The scraper 1701 may include attachment portions 1720A, B. The attachment portions 1720A, B may be configured to move radially-inward to grip the tubular 1700 when a radial force is applied. In at least one embodiment, the attachment portions 1720A, B may be splines, metal mesh, collapsible metal with holes, etc. The attachment portions 1720A, B may be positioned axially between the end rings 1716, 1718 and the blades 1732A-D. The attachment portions 1720A, B may be unitary, segmented, cut along an axial line, etc. The attachment portions 1720A, B may define recesses that extend radially inward from the outer surface of the scraper 1701 with respect to the longitudinal axis of the tubular 1700. The flexible members 1704A, B may be wrapped around the scraper 1701 to secure the scraper 1701 to the tubular 1700. More particularly, the flexible members 1704A, B may be wrapped (e.g., helically) around the attachment portions 1720A, B, respectively, to provide a radially-inward gripping force against the tubular 1700. An adhesive 1702A, B may be disposed within the recesses formed by the attachment portions 1720A, B, respectively. The adhesive 1702A, B may at least partially surround the wraps of the flexible members 1704A, B. In at least one embodiment, a shell, as described above with respect to PCT Application No. PCT/EP2013/057416, may be placed around the flexible members 1704A, B.
FIG. 17C illustrates a cross-sectional side view of the scraper 1701 attached to the tubular 1700, according to an embodiment. The blades 1732A-D may be circumferentially-offset from one another around the longitudinal axis of the tubular 1700 (e.g., by about 900). As shown, the outer surface of the blades 1732A-D may be positioned radially-outward from the end rings 1716, 1718 (FIG. 17B).
FIG. 18A illustrates a perspective view of a hole opener 1801 attached to a tubular 1800 using flexible members 1804A, B, according to an embodiment. The hole opener 1801 may include a hollow, substantially cylindrical body having one or more blades (four are shown: 1832A-D) extending radially-outward therefrom. The blades 1832A-D may be positioned axially-between opposing end rings 1816, 1818.
FIG. 18B illustrates a cross-sectional side view of the hole opener 1801 attached to the tubular 1800, according to an embodiment. The blades 1832A-D may include a first axial side 1833 and a second axial side 1834. A distance between an outer surface of the first axial side 1833 and the longitudinal axis of the tubular 1800 may increase moving in a first axial direction (e.g., to the right, as shown in FIG. 18B). As shown, the outer surface of the first axial side 1833 may be curved (e.g., convex); however, in other embodiments the outer surface may be concave or straight. A distance between an outer surface of the second axial side 1834 and the longitudinal axis of the tubular 1800 may decrease moving in the first axial direction (e.g., to the right, as shown in FIG. 18B). As shown, the outer surface of the second axial side 1834 may be stepped to form a plurality of ridges or teeth.
The hole opener 1801 may include attachment portions 1820A, B. The attachment portions 1820A, B may be configured to move radially-inward to grip the tubular 1800 when a radial force is applied. In at least one embodiment, the attachment portions 1820A, B may be splines, metal mesh, collapsible metal with holes, etc. The attachment portions 1820A, B may be unitary, segmented, cut along an axial line, etc. The first attachment portion 1820A may be positioned axially-between the end ring 1816 and the blades 1832A-D, and the second attachment portion 1820B may be positioned axially-between the blades 1832A-D and the end ring 1818. The attachment portions 1820A, B may define recesses that extend radially-inward from the outer surface of the hole opener 1801 with respect to the longitudinal axis of the tubular 1800. The flexible members 1804A, B may be wrapped around the hole opener 1801 to secure the hole opener 1801 to the tubular 1800. More particularly, the flexible members 1804A, B may be wrapped (e.g., helically) around the attachment portions 1820A, B, respectively, to provide a radially-inward gripping force against the tubular 1800. An adhesive 1802A, B may be disposed within the recesses formed by the attachment portions 1820A, B, respectively. The adhesive 1802A, B may at least partially surround the wraps of the flexible members 1804A, B. In at least one embodiment, a shell, as described above with respect to PCT Application No. PCT/EP2013/057416, may be placed around the flexible members 1804A, B.
FIG. 18C illustrates a cross-sectional side view of the hole opener 1801 attached to the tubular 1800, according to an embodiment. The blades 1832A-D may be circumferentially-offset from one another around the longitudinal axis of the tubular 1800 (e.g., by about 90°). As shown, the outer surface of the blades 1832A-D may be positioned radially outward from the end ring 1816.
FIG. 19A illustrates a perspective view of a cement basket 1901 attached to a tubular 1900 using a flexible member 1904, according to an embodiment. The cement basket 1901 may include a hollow, frustoconical body made up of a plurality of bows 1934A, B. The bows 1934A, B may form a basket, which may define a void 1936 between the outer surface of the tubular 1900 and the inner surface of the bows 1934A, B. A plurality of axial recesses 1935 may be formed in the outer surface of the cement basket 1901. Each recess 1935 may be positioned circumferentially between adjacent bows 1934A, B. First and second end rings 1916, 1918 may be positioned on a same axial side of the basket 1936, as described in more detail below with reference to FIG. 19B.
FIG. 19B illustrates a side cross-sectional view of the cement basket 1901 attached to the tubular 1900, according to an embodiment. A distance between the bows 1934A, B and the inner surface of the tubular 1900 may decrease moving in a first axial direction (e.g., to the right, as shown in FIG. 19B). This may form the frustoconical cement basket 1901. The axial end of each bow 1934A, B that is closest to the outer surface of the tubular 1900 (e.g., the right end, as shown in FIG. 19B) may be coupled to or integral with a first end ring 1918.
The cement basket 1901 may include an attachment portion 1920. The attachment portion 1920 may be configured to move radially-inward to grip the tubular 1900 when a radial force is applied. In at least one embodiment, the attachment portion 1900 may be a spline, a metal mesh, collapsible metal with holes, etc. The attachment portion 1920 may be positioned axially between the end rings 1916, 1918. The attachment portion 1920 may be unitary, segmented, cut along an axial line, etc. The attachment portion 1920 may define a recess that extends radially inward from the outer surface of the end rings 1916, 1918 with respect to the longitudinal axis of the tubular 1900. The flexible member 1904 may be wrapped around the cement basket 1901 to secure the cement basket 1901 to the tubular 1900. More particularly, the flexible member 1904 may be wrapped (e.g., helically) around the attachment portion 1920 to provide a radially-inward gripping force against the tubular 1900. An adhesive 1902 may be disposed within the recess formed by the attachment portion 1920. The adhesive 1902 may at least partially surround the wraps of the flexible member 1904. In at least one embodiment, a shell, as described above with respect to PCT Application No. PCT/EP2013/057416, may be placed around the flexible members 1904.
FIG. 19C illustrates a cross-sectional side view of the cement basket 1901 attached to the tubular 1900, according to an embodiment. The bows 1934A, B may be circumferentially-offset from one another around the longitudinal axis of the tubular 1900. Although 18 bows 1934A, B are shown, it will be appreciated that more or fewer bows 1934A, B may be implemented.
FIG. 20A illustrates a perspective view of a packer and wiper 2001 attached to a tubular 2000 using flexible members 2004A, B, according to an embodiment. The packer and wiper 2001 may include a frustoconical body made up of a plurality of packer and wiper members 2032A, B. The packer and wiper members 2032A, B may define a void 2033 between the outer surface of the tubular 2000 and the inner surface of the packer and wiper members 2032A, B. First and second end rings 2016, 2018 may be positioned on opposing axial sides of the packer and wiper 2001, as described in more detail below with reference to FIG. 20B.
FIG. 20B illustrates a side cross-sectional view of the packer and wiper 2001 attached to the tubular 2000, according to an embodiment. The packer and wiper members 2032A, B may include a first axial side 2034 and a second axial side 2035. A distance between an outer surface of the first axial side 2034 and the longitudinal axis of the tubular 2000 may increase moving in a first axial direction (e.g., to the right, as shown in FIG. 20B). As shown, the outer surface of the first axial side 2034 may be substantially straight; however, in other embodiments the outer surface may be curved (e.g., concave or convex). A distance between an outer surface of the second axial side 2035 and the longitudinal axis of the tubular 2000 may also increase moving in the first axial direction (e.g., to the right, as shown in FIG. 20B). As such, the outer surface of the second axial side 2035 may be frustoconical and define the void 2033.
The packer and wiper 2001 may include attachment portions 2020A, B. The attachment portions 2020A, B may be configured to move radially-inward to grip the tubular 2000 when a radial force is applied. In at least one embodiment, the attachment portions 2020A, B may be splines, metal mesh, collapsible metal with holes, etc. The attachment portions 2020A, B may be unitary, segmented, cut along an axial line, etc. As shown, a first attachment portion 2020A may be positioned axially-between the first end ring 2016 and the packer and wiper members 2032A, B, and a second attachment portion 2020B may be positioned axially-between the packer and wiper members 2032A, B and the second end ring 2018. The attachment portions 2020A, B may define recesses that extend radially-inward from the outer surface of the packer and wiper 2001 with respect to the longitudinal axis of the tubular 2000. The flexible members 2004A, B may be wrapped around the packer and wiper 2001 to secure the packer and wiper 2001 to the tubular 2000. More particularly, the flexible members 2004A, B may be wrapped (e.g., helically) around the attachment portions 2020A, B, respectively, to provide a radially-inward gripping force against the tubular 2000. An adhesive 2002A, B may be disposed within the recesses formed by the attachment portions 2020A, B, respectively. The adhesive 2002A, B may at least partially surround the wraps of the flexible members 2004A, B. In at least one embodiment, a shell, as described above with respect to PCT Application No. PCT/EP2013/057416, may be placed around the flexible members 2004A, B.
FIG. 20C illustrates a side cross-sectional view of the packer and wiper 2001 attached to the tubular 2000, according to an embodiment. The packer and wiper members 2032A, B may be circumferentially-offset from one another around the longitudinal axis of the tubular 2000. Although 24 packer and wiper members 2032A, B are shown, it will be appreciated that more or fewer packer and wiper members 2032A, B may be implemented. As shown, the outer surface of the packer and wiper members 2032A, B may be positioned radially-outward from the end ring 2016.
FIG. 21A illustrates a perspective view of a control line protector 2101 attached to a tubular 2100 using a flexible member 2104, according to an embodiment. The control line protector 2101 may include first and second end rings 2116, 2118 that are axially-offset from one another along the tubular 2100. Each end ring 2116, 2118 may include one or more slots 2146, 2148 formed axially therethrough. In addition, each end ring 2116, 2118 may include a void 2142 that provides a lateral path into the corresponding slot 2146, 2148 (e.g., in a radially-inward direction).
A protected pathway or conduit 2138A, B may be disposed within the slots 2146, 2148. As shown, the conduit 2138A may extend through the slot 2148 in the first end ring 2116 and through the slot 2146 in the second end ring 2118. The conduits 2138A, B may be parallel to the longitudinal axis of the tubular 2100. In other embodiments, the conduits 2138A, B may be in a helical formation around the tubular 2100. The conduits 2138A, B may include a slit or opening 2144 formed axially therethrough, and one or more cables or lines may extend through the opening 2144. The cables may be or include control lines for transmitting power, communication signals, fluids, and the like.
FIG. 21B illustrates a side cross-sectional view of the control line protector 2101 attached to the tubular 2100, according to an embodiment. The control line protector 2101 may include one or more attachment portions (one is shown: 2120). The attachment portion 2120 may be configured to move radially-inward to grip the tubular 2100 when a radial force is applied. In at least one embodiment, the attachment portion 2120 may be splines, metal mesh, collapsible metal with holes, etc. The attachment portion 2120 may be unitary, segmented, cut along an axial line, etc. The attachment portion 2120 may be positioned axially-between the end rings 2116, 2118. The attachment portion 2120 may define a recess that extends radially-inward from the outer surface of the control line protector 2101 with respect to the longitudinal axis of the tubular 2100. The flexible member 2104 may be wrapped around the control line protector 2101 to secure the control line protector 2101 to the tubular 2100. More particularly, the flexible member 2104 may be wrapped (e.g., helically) around the attachment portion 2120 to provide a radially-inward gripping force against the tubular 2100. An adhesive 2102 may be disposed within the recess formed by the attachment portion 2120. The adhesive 2102 may at least partially surround the wraps of the flexible member 2104. The conduits 2138A, B may be positioned radially outward from the flexible member 2104 and/or the adhesive 2102. In at least one embodiment, a shell, as described above with respect to PCT Application No. PCT/EP2013/057416, may be placed around the flexible members 2104.
FIG. 21C illustrates an end view of the control line protector 2101 attached to the tubular 2100, according to an embodiment. The conduits 2138A, B may be circumferentially-offset from one another around the longitudinal axis of the tubular 2100. Although two conduits 2138A, B are shown, it will be appreciated that more or fewer conduits 2138A, B may be used.
FIG. 22A illustrates a perspective view of a cylindrical housing 2201 attached to a tubular 2200 using flexible members 2204A, B, according to an embodiment. The cylindrical housing 2201 may include a plurality of segments 2232A, B that are circumferentially-offset from one another. The cylindrical housing 2201 may be positioned axially-between opposing end rings 2216, 2218.
FIG. 22B illustrates a side cross-sectional view of the cylindrical housing 2201 attached to the tubular 2200, according to an embodiment. The cylindrical housing 2201 may define an annular chamber 2250 therein. The chamber 2250 may be sealed to prevent fluids from flowing into the chamber 2250 from an exterior of the cylindrical housing 2201, or vice versa. In at least one embodiment, the chamber 2250 may have one or more sensors, actuators, or other devices disposed therein.
The cylindrical housing 2201 may include one or more attachment portions 2220A, B. The attachment portions 2220A, B may be configured to move radially-inward to grip the tubular 2200 when a radial force is applied. In at least one embodiment, the attachment portions 2220A, B may be splines, metal mesh, collapsible metal with holes, etc. The attachment portions 2220A, B may be unitary, segmented, cut along an axial line, etc. For example, a first attachment portion 2220A may be positioned axially-between the first end ring 2216 and the chamber 2250, and a second attachment portion 2220B may be positioned axially-between the chamber 2250 and the second end ring 2218. The attachment portion 2220A, B may define recesses that extend radially-inward from the outer surface of the cylindrical housing 2201 with respect to the longitudinal axis of the tubular 2200. The flexible members 2204A, B may be wrapped around the cylindrical housing 2201 to secure the cylindrical housing 2201 to the tubular 2200. More particularly, the flexible members 2204A, B may be wrapped (e.g., helically) around the attachment portions 2220A, B, respectively, to provide a radially-inward gripping force against the tubular 2200. An adhesive 2202A, B may be disposed within the recesses formed by the attachment portions 2220A, B, respectively. The adhesive 2202A, B may at least partially surround the wraps of the flexible members 2204A, B. In at least one embodiment, a shell, as described above with respect to PCT Application No. PCT/EP2013/057416, may be placed around the flexible members 2204A, B.
FIG. 22C illustrates an end view of the cylindrical housing 2201 attached to the tubular 2200, according to an embodiment. The segments 2232A, B may be circumferentially-offset from one another around the longitudinal axis of the tubular 2000. Although 24 segments 2232A, B are shown, it will be appreciated that more or fewer segments 2232A, B may be implemented. As shown, the outer surface of the segments 2232A, B may be positioned radially-outward from the end ring 2216.
FIG. 23A illustrates a perspective view of a spiral blade 2301 attached to a tubular 2300, according to an embodiment. A flexible member 2304 may be wrapped (e.g., helically) around the tubular 2300 to form the spiral blade 2301 on the tubular 2300. An adhesive 2302 may be disposed at least partially around the outer surface of the tubular 2300 and/or the flexible member 2304.
FIGS. 23B and 23C illustrate a side cross-sectional view, and an end view, respectively, of the spiral blade 2301 attached to the tubular 2300, according to an embodiment. The cross-sectional profile of the adhesive 2302 may be substantially arcuate, and the outermost radial surface of the flexible member 2304 may be positioned radially-inward from or flush with the outer surface of the adhesive 2302. As shown, the flexible member 2304 may be surrounded by the adhesive 2302.
FIG. 24A illustrates a perspective view of a passive flow turbulator 2401 attached to a tubular 2400 using flexible members 2404A, B, according to an embodiment. A first flexible member 2452 may be wrapped (e.g., helically) around the tubular 2400. The first flexible member 2452 may have one or more blades 2454A-D coupled thereto and spaced axially-apart along the first flexible member 2452. The blades 2454A-D may extend radially-outward from the first flexible member 2452 and the tubular 2400 with respect to the longitudinal axis of the tubular 2400 when the first flexible member 2452 is wrapped around the tubular 2400. The first flexible member 2452 and the blades 2454A-D may be positioned axially-between opposing end rings 2416, 2418.
FIG. 24B illustrates a side cross-sectional view of the passive flow turbulator 2401 attached to the tubular 2400, according to an embodiment. The passive flow turbulator 2401 may include attachment portions 2420A, B. The attachment portions 2420A, B may be configured to move radially-inward to grip the tubular 2400 when a radial force is applied. In at least one embodiment, the attachment portions 2420A, B may be splines, metal mesh, collapsible metal with holes, etc. The attachment portions 2420A, B may be positioned on opposing axial sides of the first flexible member 2452 and/or the blades 2454A-D. The attachment portions 2420A,B may be unitary, segmented, cut along an axial line, etc. The attachment portions 2420A, B may define recesses that extend radially inward with respect to the longitudinal axis of the tubular 2400. Second and third flexible members 2404A, B may be wrapped around the passive flow turbulator 2401 to secure the passive flow turbulator 2401 to the tubular 2400. More particularly, the second and third flexible members 2404A, B may be wrapped (e.g., helically) around the attachment portions 2420A, B, respectively, to provide a radially-inward gripping force against the tubular 2400. An adhesive 2402A, B may be disposed within the recesses formed by the attachment portions 2420A, B, respectively. The adhesive 2402A, B may at least partially surround the wraps of the second and third flexible members 2404A, B. In at least one embodiment, a shell, as described above with respect to PCT Application No. PCT/EP2013/057416, may be placed around the flexible members 2404A, B.
FIG. 24C illustrates an end view of the passive flow turbulator 2401 attached to the tubular 2400, according to an embodiment. The blades 2454A-D may be circumferentially-offset from one another around the longitudinal axis of the tubular 2400. Although 4 blades 2454A-D are shown, it will be appreciated that more or fewer blades 2454A-D may be implemented.
FIG. 25 illustrates a flowchart of a method 2500 for installing a downhole tool on a tubular, according to an embodiment. The method 2500 may be best understood with reference to FIGS. 1-24 and, more particularly, FIGS. 16-24; however, it will be appreciated that the method 2500 is not limited to any particular structure, unless otherwise specifically stated herein.
The method 2500 may include positioning a body on an outer surface of a tubular, as at 2502. The body may be or include, for example, the insert 1630A (FIG. 16), the scraper 1701 (FIG. 17), the hole opener 1801 (FIG. 18), the cement basket 1901 (FIG. 19), the packer and wiper 2001 (FIG. 20), the control line protector 2101 (FIG. 21), the cylindrical housing 2201 (FIG. 22), or the like. An outer surface of the body may include a recess formed therein. The recess may be formed in an end ring that is coupled to or integral with the body. In at least one embodiment, the body may include two end rings that are axially offset from one another, and each end ring may include a recess.
A flexible member may be wrapped more than once around the body, as at 2504. For example, the flexible member may be helically wrapped around the tubular such that the flexible member defines a plurality of axially-adjacent turns. In another example, the flexible member may be heated, such that it shrinks, during or after the winding process. In an embodiment, the flexible member may be concentrically wrapped around the tubular. Such helical and concentric embodiments may provide one or more radially-adjacent layers of the flexible member. In addition, in some embodiments, the flexible member may be pre-coiled (or pre-wound), expanded, and slid over the tubular. The flexible member may be positioned at least partially within the recess. When the body includes two end rings, a first flexible member may be positioned at least partially within the recess of the first end ring, and a second flexible member may be positioned at least partially within the recess of the second end ring.
A tension force may be applied to the flexible member(s), as at 2506. For example, the tension force may be applied to the flexible member while wrapping the flexible member around the tubular. In another example, the tension force may be applied to ends of a mandrel of the flexible member disposed within a sheath of the flexible member, such that the mandrel moves relative to the sheath. In another example, the flexible member may be radially-contracting to apply the tension force, such as by allowing a helical spring of the flexible member to contract. The tension force may cause the flexible member to apply a radially-inward gripping force on the body and/or the tubular.
In at least one embodiment, an adhesive may be applied to the flexible member, as at 2508. The adhesive may at least partially surround and/or cover the flexible member in the recess.
The foregoing has outlined features of several embodiments so that those skilled in the art may better understand the present disclosure. Those skilled in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and/or achieving the same advantages of the embodiments introduced herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure.

Claims

What is claimed is:

1. A downhole tool, comprising:

a body configured to be positioned on an outer surface of a tubular; and

a flexible member configured to extend circumferentially around the body more than once, wherein the body is configured to be positioned radially-between the outer surface of the tubular and the flexible member, and wherein, when the tool is installed, a tension force on the flexible member causes the flexible member to apply a radially-inward gripping force on the body and the tubular.

2. The downhole tool of claim 1, wherein the body comprises a longitudinal conduit or cable for transmitting power, communication signals, fluids, or a combination thereof.

3. The downhole tool of claim 2, wherein the body is wrapped helically around the outer surface of the tubular, and wherein a lead of the body is less than a corresponding lead of the flexible member, a pitch of the body is less than a corresponding pitch of the flexible member, or both.

4. The downhole tool of claim 3, wherein the body comprises two or more bodies that are circumferentially-offset from one another around the tubular.

5. The downhole tool of claim 1, wherein the body has a recess formed in an outer surface thereof, and wherein the flexible member is at least partially disposed within the recess.

6. The downhole tool of claim 5, further comprising an adhesive disposed within the recess, wherein the adhesive is in contact with the flexible member.

7. The downhole tool of claim 5, wherein the body further comprises a plurality of blades extending radially-outward therefrom that are circumferentially-offset from one another, wherein each blade has a plurality of angled notches formed in an outer surface thereof that are axially-offset from one another, and wherein the blades are axially-offset from the flexible member.

8. The downhole tool of claim 5, wherein the body further comprises a plurality of blades extending radially-outward therefrom that are circumferentially-offset from one another, wherein each blade comprises first and second axial sides, wherein a distance between an outer surface of the first axial side and the outer surface of the tubular increases moving in a first axial direction, wherein a distance between an outer surface of the second axial side and the outer surface of the tubular decreases moving in the first axial direction, and wherein the outer surface of the second axial side comprises a plurality of teeth.

9. The downhole tool of claim 5, wherein the body further comprises a plurality of bows extending radially-outward therefrom, the plurality of bows being circumferentially-offset from one another and forming a frustoconical basket, and wherein a void is defined between the outer surface of the tubular and the inner surface of the basket.

10. The downhole tool of claim 5, wherein the body further comprises a plurality of members extending radially-outward therefrom that are circumferentially-offset from one another, wherein each member comprises first and second axial sides, wherein a distance between an outer surface of the first axial side and the outer surface of the tubular increases moving in a first axial direction, and wherein a distance between an outer surface of the second axial side and the outer surface of the tubular also increases moving in the first axial direction.

11. The downhole tool of claim 5, wherein the body further defines an axial slot extending at least partially therethrough, wherein a conduit is disposed within the slot, and wherein the conduit is positioned radially-outward from the flexible member.

12. The downhole tool of claim 5, wherein the body defines an annular chamber therein.

13. A downhole tool, comprising:

a body configured to be positioned on an outer surface of a tubular, wherein the body comprises first and second end rings and a middle portion positioned axially-between the first and second end rings, wherein outer surfaces of the first and second end rings each have a recess formed therein, and wherein the middle portion extends radially-outward from the first and second end rings; and

first and second flexible members each configured to extend circumferentially-around the body more than once, wherein, when received around the body, the first and second flexible members are at least partially positioned within the recesses of the first and second end rings, respectively, and wherein, when the tool is installed, a tension force on the first and second flexible members causes the first and second flexible members to apply a radially-inward gripping force on the first and second end rings and the tubular.

14. The downhole tool of claim 13, wherein the middle portion comprises a plurality of blades that are circumferentially-offset from one another, wherein each blade has a plurality of angled notches formed in an outer surface thereof that are axially-offset from one another, and wherein the blades are axially-between the first and second end rings.

15. The downhole tool of claim 13, wherein the body further comprises a plurality of blades extending that are circumferentially-offset from one another, wherein each blade comprises first and second axial sides, wherein a distance between an outer surface of the first axial side and the outer surface of the tubular increases moving in a first axial direction, wherein a distance between an outer surface of the second axial side and the outer surface of the tubular decreases moving in the first axial direction, and wherein the outer surface of the second axial side comprises a plurality of teeth.

16. The downhole tool of claim 13, wherein the body further comprises a plurality of members that are circumferentially-offset from one another, wherein each member comprises first and second axial sides, wherein a distance between an outer surface of the first axial side and the outer surface of the tubular increases moving in a first axial direction, and wherein a distance between an outer surface of the second axial side and the outer surface of the tubular also increases moving in the first axial direction.

17. The downhole tool of claim 13, wherein the body defines an annular chamber therein.

18. A method for installing a downhole tool on a tubular, comprising:

positioning a body on an outer surface of the tubular, wherein the body has a first recess formed in an outer surface thereof;

wrapping a first flexible member more than once around the body, wherein the first flexible member is positioned at least partially within the first recess; and

causing a first tension force to be applied to the first flexible member, wherein the first tension force causes the first flexible member to apply a radially-inward gripping force on the body and the tubular.

19. The method of claim 18, further comprising placing an adhesive within the first recess, wherein the adhesive is in contact with the first flexible member.

20. The method of claim 19, wherein the body has a second recess formed in the outer surface thereof, wherein the second recess is axially-offset from the first recess, and further comprising:

wrapping a second flexible member more than once around the body, wherein the second flexible is positioned at least partially within the second recess; and

causing a second tension force to be applied to the second flexible member, wherein the second tension force causes the second flexible member to apply a radially-inward gripping force on the body and the tubular.