Note: Descriptions are shown in the official language in which they were submitted.
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
PROTECTIVE SLEEVE FOR THREADED CONNECTIONS FOR EXPANDABLE LINER
HANGER
Cross Reference To Related Applications
[001] The present application claims the benefit of the filing dates of (1)
U.S. provisional patent
application serial no. 60/397,284, attorney docket no 25791.106, filed on
7119/2002, which is a
continuation-in-part of U.S. provisional patent application serial no.
60/372,632, attorney docket no.
25791.101, filed on 4/15/2002, which was a continuation-in-part of U.S.
provisional patent application
serial no. 60/372,048, attorney docket no. 25791.93, filed on April 12, 2002,
which was a continuation-in-
part of U.S. provisional patent application serial no. 60/346,309, attorney
docket no. 25791.92, filed on
1/7/2002, the disclosures of which are incorporated herein by reference. '.
[002] The present application is related to the following: (1) U.S. patent
application serial no.
09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, (2) U.S.
patent application serial no.
09/510,913, attorney docket no. 25791.7.02, filed on 2/23/2000, (3) U.S.
patent application serial no.
09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, (4) U.S.
patent application serial no.
09/440,338, attorney docket no. 25791.9.02, filed on 11/15/1999, (5) U.S.
patent application serial no.
09/523,460, attorney docket no. 25791.11.02, filed on 3/10/2000, (6) U.S.
patent application serial no.
09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, (7) U.S.
patent application serial no.
09/511,941, attorney docket no. 25791.16.02, filed on 2/24/2000, (8) U.S.
patent application serial no.
09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000,(9) U.S. patent
application serial no.
09/559,122, attorney docket no. 25791.23.02, filed on 4/26/2000, (10) PCT
patent application serial no.
PCT/LTS00/18635, attorney docket no. 25791.25.02, filed on 7/9/2000, (11) U.S.
provisional patent
application serial no. 60/162,671, attorney docket no. 25791.27, filed on
11/1/1999, (12) U.S. provisional
patent application serial no. 60/154,047, attorney docket no. 25791.29, filed
on 9/16/1999, (13) U.S.
provisional patent application serial no. 60/159,082, attorney docket no.
25791.34, filed on 10/12/1999,
(14) U.S. provisional patent application serial no. 60/159,039, attorney
docket no. 25791.36, filed on
10/12/1999, (15) U.S. provisional patent application serial no. 60/159,033,
attorney docket no. 25791.37,
filed on 10/12/1999, (16) U.S. provisional patent application serial no.
60/212,359, attorney docket no.
25791.38, filed on 6/19/2000, (17) U.S. provisional patent application serial
no. 60/165,228, attorney
docket no. 25791.39, filed on 11/12/1999, (18) U.S. provisional patent
application serial no. 60/221,443,
attorney docket no. 25791.45, filed on 7/28/2000, (19) U.S. provisional patent
application serial no.
60/221,645, attorney docket no. 25791.46, filed on 7/28/2000, (20) U.S.
provisional patent application
serial no. 60/233,638, attorney docket no. 25791.47, filed on 9/18/2000, (21)
U.S. provisional patent
application serial no. 60/237,334, attorney docket no. 25791.48, filed on
10/2/2000, (22) U.S. provisional
patent application serial no. 60/270,007, attorney docket no. 25791.50, filed
on 2/20/2001, (23) U.S.
provisional patent application serial no. 60/262,434, attorney docket no.
25791.51, filed on 1/17/2001, (24)
1
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
U.S, provisional patent application serial no. 60/259,486, attorney docket no.
25791.52, filed on 1/3/2001,
(25) U.S. provisional patent application serial no. 60/303,740, attorney
docket no. 25791.61, filed on
7/6/2001, (26) U.S~. provisional patent application serial no. 60/313,453,
attorney docket no. 25791.59,
filed on 8/20/2001, (27) U.S. provisional patent application serial no.
60/317,985, attorney docket no.
25791.67, filed on 9/6/2001, (28) U.S. provisional patent application serial
no. 60/3318,386, attorney
docket no. 25791.67.02, filed on 9/10/2001, (29) U.S. utility patent
application serial no. 09/969,922,
attorney docket no. 25791.69, filed on 10/3/2001, (30) U.S. utility patent
application serial no. 10/016,467,
attorney docket no. 25791.70, filed on 12/1012001; (31) U.S. provisional
patent application serial no.
60/343,674, attorney docket no. 25791.68, filed on 12/27/2001; (32) U.S.
provisional patent application
serial no. 60/346,309, attorney docket no 25791.92, filed on 1/7/2002; (33)
U.S. provisional patent
application serial no. 60/372,048, attorney docket no. 25791.93, filed on
4/12/2002; (34) U.S. provisional
patent application serial no. 60/380,147, attorney docket no. 25791.104, filed
on 5/6/2002; (35) U.S.
provisional patent application serial no. 60/387,486, attorney docket no.
25791.107, filed on 6/10/2002;
(36) U.S. provisional patent application serial no. 60/387,961, attorney
docket no. 25791.108, filed on
6/12/2002; and (37) U.S. provisional patent application serial no. 60/391,703,
attorney docket no.
25791.90, filed on 6/26/2002, the disclosures of which are incorporated herein
by reference.
Background of the Invention
[003] This invention relates generally to oil and gas exploration, and in
particular to forming and
repairing wellbore casings to facilitate oil and gas exploration.
[004] During oil exploration, a wellbore typically traverses a number of zones
within a
subterranean formation. Wellbore casings are then formed in the wellbore by
radially expanding and
plastically deforming tubular members that are coupled to one another by
threaded connections.
Existing methods for radially expanding and plastically deforming tubular
members coupled to one
another by threaded connections are not always reliable or produce
satisfactory results. In particular,
the.threaded connections can be damaged during the radial expansion process.
Furthermore, the
threaded connections between adjacent tubular members, whether radially
expanded or not, are
typically not sufficiently coupled to permit the transmission of energy
through the tubular members
from the surface to a downhole location.
[005] The present invention is directed to overcoming one or more of the
limitations of the
existing processes for radially expanding and plastically deforming tubular
members coupled to one
another by threaded connections.
Summary of the Invention
[006] According to one aspect of the present invention, a method is provided
that includes coupling
an end of a first tubular member to an end of a tubular sleeve, coupling an
end of a second tubular member
to another end of the tubular sleeve, coupling the ends of the first and
second tubular members, and radially
expanding and plastically deforming the first tubular member and the second
tubular member.
2
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
[00"7] According to another aspect of the present invention, an apparatus is
provided that includes a
tubular sleeve, a first tubular member coupled to an end of the tubular
sleeve, and a second tubular member
coupled to another end of the tubular sleeve and the first tubular member.
[00~] According to another aspect of the present invention, a method of
extracting geothermal
energy from a subterranean source of geothermal energy is provided that
includes drilling a borehole that
traverses the subterranean source of geothermal energy, positioning a first
casing string within the
borehole; radially expanding and plastically deforming the first casing string
within the borehole,
positioning a second casing string within the borehole that traverses the
subterranean source of geothermal
energy, overlapping a portion of the second casing string with a portion of
the first casing string, radially
expanding and plastically deforming the second casing string within the
borehole, and extracting
geothermal energy from the subterranean source of geothermal energy using the
first and second casing
strings.
[009] According to another aspect of the present invention, an apparatus for
extracting geothermal
energy from a subterranean source of geothermal energy is provided that
includes a borehole that traverses
the subterranean source of geothermal energy, a first casing string positioned
within the borehole, and a
second casing positioned within the borehole that overlaps with the first
casing string that traverses the
subterranean source of geothermal energy. The first casing string and the
second casing string are radially
expanded and plastically deformed within the borehole.
[0010] According to another aspect of the present invention, a method is
provided that includes
coupling an end of a first tubular member to an end of a tubular sleeve,
coupling an end of a second tubular
member to another end of the tubular sleeve, coupling the ends of the first
and second tubular members,
injecting a pressurized fluid through the first and second tubular members,
determining if any of the
pressurized fluid leaks through the coupled ends of the frst and second
tubular members, and if a
predetermined amount of the pressurized fluid leaks through the coupled ends
of the first and second
tubular members, then coupling a tubular sleeve to the ends of the first and
second tubular members and
radially expanding and plastically deforming only the portions of the first
and second tubular members
proximate the tubular sleeve.
[0011] According to another aspect of the present invention, a method is
provided that includes
coupling an end of a first tubular member to an end of a tubulax sleeve,
coupling an end of a second tubular
member to another end of the tubular sleeve, coupling the ends of the first
and second tubular members,
radially expanding and plastically deforming the first tubular member and the
second tubular member, and
transmitting energy through the first and second tubular members.
[0012] According to another aspect of the present invention, a system is
provided that includes a
source of energy, a borehole formed in the earth, a first tubular member
positioned within the borehole
operably coupled to the source of energy, a second tubular member positioned
within the borehole coupled
to the first tubular member, and a tubular sleeve positioned within the
borehole coupled to the first and
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
second tubular members. The first tubular member, second tubular member, and
the tubular sleeve are
plastically deformed into engagement with one another.
[0013] According to another aspect of the present invention, a method of
operating a well for
extracting hydrocarbons from a subterranean formation is provided that
includes drilling a borehole into the
earth that traverses the subterranean formation, positioning a wellbore casing
in the borehole, transmitting
energy through the wellbore casing, and extracting hydrocarbons from the
subterranean formation.
Brief Description of the Drawings
[0014] FIG. la is a fragmentary cross-sectional illustration of a first
tubular member having an
internally threaded connection at an end portion.
[0015] Fig. lb is a fragmentary cross-sectional illustration of the placement
of a tubular sleeve onto
the end portion of the first tubular member of Fig. 1 a.
[0016] Fig. 1 c is a fragmentary cross-sectional illustration of the coupling
of an externally threaded
connection at an end portion of a second tubular member to the internally
threaded connection at the end
portion of the first tubular member of Fig. lb.
[0017] Fig. ld is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of the first tubular member of Fig. 1 c.
[0018] Fig. le is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded connection between the first and second tubular
members and the tubular
sleeve ofFig. ld.
[0019] Fig. 2a is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of a first tubular member having an internally
threaded connection at an end
portion, an alternative embodiment of a tubular sleeve supported by the end
portion of the first tubular
member, and a second tubular member having an externally threaded portion
coupled to the internally
threaded portion of the first tubular member.
[0020] Fig. 2b is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded connection between the first and second tubular
members and the tubular
sleeve of Fig. 2a.
[0021] Fig. 3a is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of a first tubular member having an internally
threaded connection at an end
portion, an alternative embodiment of a tubular sleeve supported by the end
portion of the first tubular
member, and a second tubular member having an externally threaded portion
coupled to the internally
threaded portion of the first tubular member.
[0022] Fig. 3b is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded connection between the first and second tubular
members and the tubular
sleeve of Fig. 3 a.
4
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
[0023] Fig. 4a is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of a first tubular member having an internally
threaded connection at an end
portion, an alternative embodiment of a tubular sleeve having an external
sealing element supported bythe
end portion of the first tubular member, and a second tubular member having an
externally threaded
portion coupled to the internally threaded portion of the first tubular
member.
[0024] Fig. 4b is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded connection between the first and second tubular
members and the tubular
sleeve of Fig. 4a.
[0025] Fig. Sa is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of a first tubular member having an internally
threaded connection at an end
portion, an alternative embodiment of a tubular sleeve supported by the end
portion of the first tubular
member, and a second tubular member having an externally threaded portion
coupled to the internally
threaded portion of the first tubular member.
[0026] Fig. Sb is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded connection between the first and second tubular
members and the tubular
sleeve of Fig. Sa.
[0027] Fig. 6a is a fragmentary cross sectional illustration of an alternative
embodiment of a tubular
sleeve.
[0028] Fig. 6b is a fragmentary cross sectional illustration of an alternative
embodiment of a tubular
sleeve.
[0029] Fig. 6c is a fragmentary cross sectional illustration of an alternative
embodiment of a tubular
sleeve.
[0030] Fig. 6d is a fragmentary cross sectional illustration of an alternative
embodiment of a tubular
sleeve.
[0031] FIG. 7a is a fragmentary cross-sectional illustration of a first
tubular member having an
internally threaded connection at an end portion.
[0032] Fig. 7b is a fragmentary cross-sectional illustration of the placement
of an alternative
embodiment of a tubular sleeve onto the end portion of the first tubular
member of Fig. 7a.
[0033] Fig. 7c is a fragmentary cross-sectional illustration of the coupling
of an externally threaded
connection at an end portion of a second tubular member to the internally
threaded connection at the end
portion of the first tubular member of Fig. 7b.
[0034] Fig. 7d is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of the first tubular member of Fig. 1 c.
[0035] Fig. 7e is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded connection between the first and second tubular
members and the tubular
sleeve of Fig. 7d.
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
[0036] FIG. 8a is a fragmentary cross-sectional illustration of a first
tubular member having an
internally threaded connection at an end portion.
[0037] Fig. 8b is a fragmentary cross-sectional illustration of the placement
of an alternative
embodiment of a tubular sleeve onto the end portion of the first tubular
member of Fig. 8a.
(0038] Fig. 8c is a fragmentary cross-sectional illustration of the coupling
of the tubular sleeve of Fig.
8b to the end portion of the first tubular member.
[0039] Fig. 8d is a fragmeptary cross-sectional illustration of the coupling
of an externally threaded
connection at an end portion of a second tubular member to the internally
threaded connection at the end
portion of the first tubular member of Fig. 8b.
[0040] Fig. 8e is a fragmentary cross-sectional illustration of the coupling
of the tubular sleeve ofFig.
8d to the end portion of the second tubular member.
[0041] Fig. 8f is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of the first tubular member of Fig. 8e.
[0042] Fig. 8g is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded connection between the first and second tubular
members and the tubular
sleeve of Fig. 8f.
[0043] FIG. 9a is a fragmentary cross-sectional illustration of a first
tubular member having an
internally threaded connection at an end portion.
[0044] Fig. 9b is a fragmentary cross-sectional illustration of the placement
of an alternative
embodiment of a tubular sleeve onto the end portion of the first tubular
member of Fig. 9a.
[0045] Fig. 9c is a fragmentary cross-sectional illustration of the coupling
of an externally threaded
connection at an end portion of a second tubular member to the internally
threaded connection at the end
portion of the first tubular member-of Fig. 9b.
[0046] Fig. 9d is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of the first tubular member of Fig. 9c.
[0047] Fig. 9e is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded connection between the first and second tubular
members and the tubular
sleeve of Fig. 9d.
[0048] FIG. l0a is a fragmentary cross-sectional illustration of a first
tubular member having an
internally threaded connection at an end portion.
[0049] Fig. lOb is a fragmentary cross-sectional illustration of the placement
of an alternative
embodiment of a tubular sleeve onto the end portion of the first tubular
member of Fig. 10a.
(0050] Fig. 1 Oc is a fragmentary cross-sectional illustration of the coupling
of an externally threaded
connection at an end portion of a second tubular member to the internally
threaded connection at the end
portion of the first tubular member of Fig. l Ob.
6
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
[0051] Fig. lOd is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of the first tubular member of Fig. l Oc.
(0052] Fig. l0e is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded connection between the first and second tubular
members and the tubular
sleeve of Fig. 1 Od.
[0053) FIG. l la is a fragmentary cross-sectional illustration of a first
tubular member having an
internally threaded connection at an end portion.
[0054] Fig. llb is a fragmentary cross-sectional illustration of the placement
of an alternative
embodiment of a tubular sleeve onto the end portion of the first tubular
member of Fig. 11 a.
[0055] Fig. 11 c is a fragmentary cross-sectional illustration of the coupling
of an externally threaded
connection at an end portion of a second tubular member to the internally
threaded connection at the end
portion of the first tubular member of Fig. l lb.
[0056] Fig. l ld is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of the first tubular member of Fig. 11 c.
[0057] Fig. 11 a is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded connection between the first and second tubular
members and the tubular
sleeve of Pig. 11 d.
[0058] FIG. 12a is a fragmentary cross-sectional illustration of a first
tubular member having an
internally threaded connection at an end portion.
[0059] Fig. 12b is a fragmentary cross-sectional illustration of the placement
of an alternative
embodiment of a tubular sleeve onto the end portion of the first tubular
member of Fig. 12a.
[0060] Fig. 12c is a fragmentary cross-sectional illustration of the coupling
of an externally threaded
connection at an end portion of a second tubular member to the internally
threaded connection at the end
portion of the first tubular member of Fig. 12b.
[0061] Fig. 12d is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of the first tubular member of Fig. 12c.
[0062] Fig. 12e is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded connection between the first and second tubular
members and the tubular
sleeve of Fig. 12d.
[0063] Fig. 13a is a fragmentary cross-sectional illustration of the coupling
of an end portion of an
alternative embodiment of a tubular sleeve onto the end portion of a first
tubular member.
[0064] Fig. 13b is a fragmentary cross-sectional illustration of the coupling
of an end portion of a
second tubular member to the other end portion of the tubular sleeve of Fig.
13 a.
[0065] Fig. 13c is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of the first tubular member of Fig. 13b.
7
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
[0066] Fig. 13d is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded coimection between the first and second tubular
members and the tubular
sleeve of Fig. 13c.
[0067] FIG. 14a is a fragmentary cross-sectional illustration of an end
portion of a first tubular
member.
[0068] Fig. 14b is a fragmentary cross-sectional illustration of the coupling
of an end portion of an
alternative embodiment of a tubular sleeve onto the end portion of the first
tubular member of Fig. 14a.
[0069] Fig. 14c is a fragmentary cross-sectional illustration of the coupling
of an end portion of a
second tubulax member to the other end portion of the tubular sleeve of Fig.
14b.
[0070] Fig. 14d is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of the first tubular member of Fig. 14c.
[0071] Fig. 14e is a fragmentary cross sectional of the continued radial
expansion and plastic
deformation of the threaded connection between the first and second tubular
members and the tubular
sleeve of Fig. 14d.
[0072] Fig. 1 Sa is a fragmentary cross-sectional illustration of the coupling
of an internally threaded
end portion of a first tubular member to an externally threaded end portion of
a second tubular member
including a protective sleeve coupled to the end portions of the first and
second tubular member.
[0073] Fig. 15b is a cross-sectional illustration of the first and second
tubular members and the
protective sleeve following the radial expansion of the first and second
tubulars and the protective sleeve.
[0074] Fig. 15c is a fragmentary cross-sectional illustration of an
alternative embodiment that includes
a metallic foil for amorphously bonding the first and second tubular members
of Figs. 1 Sa and 1 Sb during
the radial expansion and plastic deformation of the tubular members.
[0075] Fig. 16 is a cross-sectional illustration of a borehole including a
plurality of overlapping
radially expanded wellbore casings that traverses a subterranean source of
geothermal energy.
[0076] Fig. 17a is a fragmentary cross-sectional illustration of the coupling
of an internally threaded
end portion of a first tubular member to an externally threaded end portion of
a second tubular member
including a protective sleeve coupled to the end portions of the first and
second tubular member.
[0077] Fig. 17b is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of the threaded portions of the first and second tubular members
using an adjustable expansion
cone.
[0078] Fig. 17c is an enlarged fragmentary cross-sectional illustration of the
threaded portions of the
first and second tubular members and the protective sleeve prior to the radial
expansion and plastic
deformation of the threaded portions.
[0079] Fig. 17d is an enlarged fragmentary cross-sectional illustration of the
threaded portions of the
first and second tubular members and the protective sleeve after the xadial
expansion and plastic
deformation of the threaded portions.
8
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
(0080] Fig. 18a is a fragmentary cross-sectional illustration of the coupling
of an internally threaded
end portion of a first tubular member to an externally threaded end portion of
a second tubular member
including a protective sleeve coupled to the end portions of the first and
second tubular member.
[0081] Fig. 18b is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of the threaded portions of the first and second tubular members
using a rotary expansion tool.
[0082] Fig. 19 is an exemplary embodiment of a method of providing a fluid
tight seal in the junction
between a pair of adjacent tubular members.
[0083] Fig. 20 is an exemplary embodiment of a method of transmitting energy
through a pair of
radially expanded adjacent tubular members including a protecting sleeve.
Detailed Description of the Illustrative Embodiments
[0084] Referring to Fig. 1 a, a first tubular member 10 includes an internally
threaded connection
12 at an end portion 14. As illustrated in Fig. lb, a first end of a tubular
sleeve 16 that includes an
internal flange 18 and tapered portions, 20 and 22, at opposite ends is then
mounted upon and receives
the end portion 14 of the first tubular member 10. In an exemplary embodiment,
the end portion 14 of
the first tubular member 10 abuts one side of the iliternal flange 18 of the
tubular sleeve 16, and the
internal diameter of the internal flange of the tubular sleeve is
substantially equal to or greater than the
maximum internal diameter of the internally threaded connection 12 of the end
portion of the first
tubular member. As illustrated in Fig. 1 c, an externally threaded connection
24 of an end portion 26 of
a second tubular member 28 having an annular recess 30 is then positioned
within the tubular sleeve 16
and threadably coupled to the internally threaded connection 12 of the end
portion 14 of the first
tubular member 10. In an exemplary embodiment, the internal flange 18 of the
tubular sleeve 16 mates
with and is received within the annular recess 30 of the end portion 26 of the
second tubular member
28. Thus, the tubular sleeve 16 is coupled to and surrounds the external
surfaces of the first and
second tubular members, 10 and 28.
[0085] In an exemplary embodiment, the internally threaded connection 12 of
the end portion 14
of the first tubular member 10 is a box connection, and the externally
threaded connection 24 of the
end portion 26 of the second tubular member 28 is a pin connection. In an
exemplary embodiment, the
internal diameter of the tubular sleeve 16 is at least approximately .020"
greater than the outside
diameters of the first and second tubular members, 10 and 28. In this manner,
during the threaded
coupling of the first and second tubular members, 10 and 28, fluidic materials
within the first and
second tubular members may be vented from the tubular members.
[0086] In an exemplary embodiment, as illustrated in Figs. ld and le, the
first and second tubular
members, 10 and 28, and the tubular sleeve 16 may then be positioned within
another structure 32
such as, for example, a wellbore, and radially expanded and plastically
deformed, for example, by
moving an expansion cone 34 through the interiors of the first and second
tubular members. The
tapered portions, 20 and 22, of the tubular sleeve 16 facilitate the insertion
and movement of the first
9
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
and second tubular members within and through the structure 32, and the
movement of the expansion
cone 34 through the interiors of the first and second tubular members, 10 and
28, may be from top to
bottom or from bottom to top.
[0087] In an exemplary embodiment, during the radial expansion and plastic
deformation of the
first and second tubular members, 10 and 28, the tubular sleeve 16 is also
radially expanded and
plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 16 may be
maintained in circumferential tension and the end portions, 14 and 26, of the
first and second tubular
members, 10 and 28, may be maintained in circumferential compression.
[0088] In several exemplary embodiments, the first and second tubular members,
10 and 28, are
radially expanded and plastically deformed using the expansion cone 34 in a
conventional manner
and/or using one or more of the methods and apparatus disclosed in one or more
of the following: ( 1 )
U.S. patent application serial no. 09/454,139, attorney docket no.
25791.03.02, filed on 12/3/1999, (2)
U.S. patent application serial no. 091510,913, attorney docket no. 25791.7.02,
filed on 2/23/2000, (3)
U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02,
filed on 2/10/2000, (4)
U.S. patent application serial no. 09/440,338, attorney docket no. 25791.9.02,
filed on 11/15/1999, (5)
U.S. patent application serial no. 091523,460, attorney docket no.
25791.11.02, filed on 311012000, (6)
U.S. patent application serial no. 091512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, (7)
U.S. patent application serial no. 09/511,941, attorney docket no.
25791.16.02, filed on 2/24/2000, (8)
U.S. patent application serial no. 09/588,946, attorney docket no.
25791.17.02, filed on 6/7/2000, (9)
U.S. patent application serial no. 09/559,122, attorney docket no.
25791.23.02, filed on 4/2612000,
(10) PCT patent application serial no. PCT/LTS00/18635, attorney docket no.
25791.25.02, filed on
7/9/2000, (11) U.S. provisional patent application serial no. 60/162,671,
attorney docket no. 25791.27,
filed."on 11/1/1999, (12) U.S. provisional patent application serial no.
60/154,047, attorney docket no.
25791.29, filed on 9/16/1999, (13) U.S. provisional patent application serial
no. 601159,082, attorney
docket no. 25791.34, filed on 10/12/1999, (14) U.S. provisional patent
application serial no.
60/159,039, attorney docket no. 25791.36, filed on 10/12/1999, (15) U.S.
provisional patent
application serial no. 60/159,033, attorney docket no. 25791.37, filed on
10/12/1999, (16) U.S.
provisional patent application serial no. 60/212,359, attorney docket no.
25791.38, filed on 6/19/2000,
(17) U.S. provisional patent application serial no. 601165,228, attorney
docket no. 25791.39, filed on
11/12/1999, (18) U.S. provisional patent application serial no. 60/221,443,
attorney docket no.
25791.45, filed on 7/28/2000, (19) U.S. provisional patent application serial
no. 60/221,645, attorney
docket no. 25791.46, filed on 7/28/2000, (20) U.S. provisional patent
application serial no.
60/233,638, attorney docket no. 25791.47, filed on 9/18/2000, (21) U.S.
provisional patent application
serial no. 601237,334, attorney docket no. 25791.48, filed on 10/2/2000, (22)
U.S. provisional patent
application serial no. 60/270,007, attorney docket no. 25791.50, filed on
2/2012001, (23) U.S.
provisional patent application serial no. 60/262,434, attorney docket no.
25791.51, filed on 1117/2001,
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
(24) U.S, provisional patent application serial no. 60/259,486, attorney
docket no. 25791.52, filed on
1/3/2001, (25) U.S. provisional patent application serial no. 60/303,740,
attorney docket no. 25791.61,
filed on 7/6/2001, (26) U.S. provisional patent application serial no.
60/313,453, attorney docket no.
25791.59, filed on 8/20/2001, (27) U.S. provisional patent application serial
no. 60/317,985, attorney
docket no. 25791.67, filed on 9/6/2001, (28) U.S. provisional patent
application serial no.
60/3318,386, attorney docket no. 25791.67.02, filed on 9/10/2001, (29) U.S.
utility patent application
serial no. 09/969,922, attorney docket no. 25791.69, filed on 10/3/2001, (30)
U.S. utility patent
application serial no. 10/016,467, attorney docket no. 25791.70, filed on
12/10/2001; (31) U.S.
provisional patent application serial no. 60/343,674, attorney docket no.
25791.68, filed on
12/27/2001; (32) U.S. provisional patent application serial no. 60/346,309,
attorney docket no
25791.92, filed on 1/7/2002; (33) U.S. provisional patent application serial
no. 601372,048, attorney
docket no. 25791.93, filed on 4/12/2002; (34) U.S. provisional patent
application serial no.
60/380,147, attorney docket no. 25791.104, filed on 5/6/2002; (35) U.S.
provisional patent application
serial no. 60/387,486, attorney docket no. 25791.107, filed on 6/10/2002; (36)
U.S. provisional patent
application serial no. 60/387,961, attorney docket no. 25791.108, filed on
6/12/2002; and (37) U.S.
provisional patent application serial no. 60/391,703, attorney docket no.
25791.90, filed on 6/26/2002,
the disclosures of which are incorporated herein by reference.
[0089] In several alternative embodiments, the first and second tubular
members, 10 and 28, are
radially expanded and plastically deformed using other conventional methods
for radially expanding
and plastically deforming tubular members such as, for example, internal
pressurization and/or roller
expansion devices such as, for example, that disclosed iii U.S. patent
application publication no. US
2001/0045284 A1, the disclosure of which is incorporated herein by reference.
,;. [0090] The use of the tubular sleeve 16 during (a) the coupling of the
first tubular member 10 to
the second tubular member 28, (b) the placement of the first and second
tubular members in the
structure 32, and (c) the radial expansion and plastic deformation of the
first and second tubular
members provides a number of significant benefits. For example, the tubular
sleeve 16 protects the
exterior surfaces of the end portions, 14 and 26, of the first and second
tubular members, 10 and 28,
during handling and insertion of the tubular members within the structure 32.
In this manner, damage
to the exterior surfaces of the end portions, 14 and 26, of the first and
second tubular member, 10 and
28, are prevented that could result in stress concentrations that could result
in a catastrophic failure
during subsequent radial expansion operations. Furthermore, the tubular sleeve
16 provides an
alignment guide that facilitates the insertion and threaded coupling of the
second tubular member 28 to
the first tubular member 10. In this manner, misalignment that could result in
damage to the threaded
connections, 12 and 24, of the first and second tubular members, 10 and 28,
may be avoided. In
addition, during the relative rotation of the second tubular member with
respect to the first tubular
member, required during the threaded coupling of the first and second tubular
members, the tubular
11
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
sleeve 16 provides an indication of to what degree the first and second
tubular members are threadably
coupled. For example, if the tubular sleeve 16 can be easily rotated, that
would indicate that the first
and second tubular members, 10 and 28, are not fully threadably coupled and in
intimate contact with
the internal flange 18 of the tubular sleeve. Furthermore, the tubular sleeve
16 may prevent crack
propagation during the radial expansion and plastic deformation of the first
and second tubular
members, 10 and 28. In this manner, failure modes such as, for example,
longitudinal cracks in the
end portions, 14 and 26, of the first and second tubular members may be
limited in severity or
eliminated all together. In addition, after completing the radial expansion
and plastic deformation of
the first and second tubular members, 10 and 28, the tubular sleeve 16 may
provide a fluid tight metal-
to-metal seal between interior surface of the tubular sleeve and the exterior
surfaces of the end
portions, 14 and 26, of the first and second tubular members. In this manner,
fluidic materials are
prevented from passing through the threaded connections, 12 and 24, of the
first and second tubular
members, 10 and 28, into the annulus between the first and second tubular
members and the structure
32. Furthermore, because, following the radial expansion and plastic
deformation of the first and
second tubular members, 10 and 28, the tubular sleeve 16 may be maintained in
circumferential
tension and the end portions, 14 and 26, of the first and second tubular
members, 10 and 28, may be
maintained in circumferential compression, axial loads and/or torque loads may
be transmitted through
the tubular sleeve. In addition, the tubular sleeve 16 may also increase the
collapse strength of the end
portions, 14 and 26, of the first and second tubular members, 10 and 28.
[0091] Referring to Figs. 2a and 2b, in an alternative embodiment, a tubular
sleeve 110 having an
internal flange 112 and a tapered portion 114 is coupled to the first and
second tubular members, 10
and 28. In particular, the tubular sleeve 110 receives and mates with the end
portion 14 of the first
tubular member 10, and the internal flange 112 of the tubular sleeve is.
received within the annular
recess 3 0 of the second tubular member 28 proximate the end of the first
tubular member. In this
manner, the tubular sleeve 110 is coupled to the end portions, 14 and 26,
ofthe first and second tubular
members, 10 and 28, and the tubular sleeve covers the end portion 14 of the
first tubular member 10.
(0092] In an exemplary embodiment, the first and second tubular members, 10
and 28, and the
tubular sleeve 110 may then be positioned within the siructure 32 and radially
expanded and plastically
deformed, for example, by moving an expansion cone 34 through the interiors of
the first and second
tubular members. In an exemplary embodiment, following the radial expansion
and plastic
deformation of the first and second tubular members, 10 and 28, the tubular
sleeve 110 may be
maintained in circumferential tension and the end portions, 14 and 26, of the
first and second tubular
members, 10 and 28, may be maintained in circumferential compression.
[0093] The use of the tubular sleeve 110 during (a) the coupling of the first
tubular member 10 to
the second tubular member 28, (b) the placement of the first and second
tubular members in the
structure 32, and (c) the radial expansion and plastic deformation of the
first and second tubular
12
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
members provides a number of significant benefits. For example, the tubular
sleeve 110 protects the
exterior surface of the end portion 14 of the first tubular member 10 during
handling and insertion of
the tubular members within the structure 32. In this manner, damage to the
exterior surfaces of the end
portion 14 of the first tubular member 10 is prevented that could result in
stress concentrations that
could result in a catastrophic failure during subsequent radial expansion
operations. In addition, during
the relative rotation of the second tubular member with respect to the first
tubular member, required
during the threaded coupling of the first and second tubular members, the
tubular sleeve 110 provides
an indication of to what degree the first and second tubular members are
threadably coupled. For
example, if the tubular sleeve 110 can be easily rotated, that would indicate
that the first and second
tubular members, 10 and 28, are not fully threadably coupled and in intimate
contact with the internal
flange 112 of the tubular sleeve. Furthermore, the tubular sleeve 110 may
prevent crack propagation
during the radial expansion and plastic deformation of the first and second
tubular members, 10 and
28. In this manner, failure modes such as, for example, longitudinal cracks in
the end portions, 14 and
26, of the first and second tubular members may be limited in severity or
eliminated all together. In
addition, after completing the radial expansion and plastic deformation of the
first and second tubular
members, 10 and 28, the tubular sleeve 110 may provide a fluid tight metal-to-
metal seal between
interior surface of the tubular sleeve and the exterior surface of the end
portionl4 of the first tubular
member. In this manner, fluidic materials are prevented from passing through
the threaded
connections, 12 and 24, of the first and second tubular members, 10 and 28,
into the annulus between
the first and second tubular members and the structure 32. Furthermore,
because, following the radial
expansion and plastic deformation of the first and second tubular members, 10
and 28, the tubular
sleeve 110 may be maintained in circumferential tension and the end portions,
14 and 26, of the first
and second tubular members, 10 and 28, may be maintained in circumferential
compression, axial
loads and/or torque loads may be transmitted through the tubular sleeve.
[0094] Referring to Figs. 3a and 3b, in an alternative embodiment, a tubular
sleeve 210 having an
internal flange 212, tapered portions, 214 and 216, at opposite ends, and
annular sealing members, 218
and 220, positioned on opposite sides of the internal flange, is coupled to
the first and second tubular
members, 10 and 28. In particular, the tubular sleeve 210 receives and mates
with the end portions, 14
and 26, of the first and second tubular members, 10 and 28, and the internal
flange 212 of the tubular
sleeve is received within the annular recess 30 of the second tubular member
28 proximate the end of
the first tubular member. Furthermore, the sealing members, 218 and 220, of
the tubular sleeve 210
engage and fluidicly seal the interface between the tubular sleeve and the end
portions, 14 and 26, of
the first and second tubular members, 10 and 28. In this manner, the tubular
sleeve 210 is coupled to
the end portions, 14 and 26, of the first and second tubular members, 10 and
28, and the tubular sleeve
covers the end portions, 14 and 26, of the first and second tubular members,
10 and 28.
[0095] In an exemplary embodiment, the first and second tubular members, 10
and 28, and the
13
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
tubular sleeve 210 may then be positioned within the structure 32 and radially
expanded and plastically
deformed, for example, by moving an expansion cone 34 through the interiors of
the first and second
tubular members. In an exemplary embodiment, following the radial expansion
and plastic
deformation of the first and second tubular members, 10 and 28, the tubular
sleeve 210 may be
maintained in circumferential tension and the end portions, 14 and 26, of the
first and second tubular
members, 10 and 28, may be maintained in circumferential compression.
[0096] The use of the tubular sleeve 210 during (a) the coupling of the first
tubular member 10 to
the second tubular member 28, (b) the placement of the first and second
tubular members in the
structure 32, and (c) the radial expansion and plastic deformation of the
first and second tubular
members provides a number of significant benefits. For example, the tubular
sleeve 210 protects the
exterior surfaces of the end portions, 14 and 26, of the first and second
tubular members, 10 and 28,
during handling and insertion of the tubular members within the structure 32.
In this manner, damage
to the exterior surfaces of the end portions, 14 and 26, of the first and
second tubular members, 10 and
28, is prevented that could result in stress concentrations that could result
in a catastrophic failure
during subsequent radial expansion operations. In addition, during the
relative rotation of the second
tubular member with respect to the first tubular member, required during the
threaded coupling of the
first and second tubular members, the tubular sleeve 210 provides an
indication of to what degree the
first and second tubular members are threadably coupled. For example, if the
tubular sleeve 210 can
be easily rotated, that would indicate that the first and second tubular
members, 10 and 28, are not fully
threadably coupled and in intimate contact with the internal flange 212 of the
tubular sleeve.
Furthermore, the tubular sleeve 210 may prevent crack propagation during the
radial expansion and
plastic deformation of the first and second tubular members, 10 and 28. In
this manner, failure modes
such as, for example, longitudinal cracks in the end portions, 14 and 26, of
the first and second tubular
members, 10 and 28, may be limited in severity or eliminated all together. In
addition, after
completing the radial expansion and plastic deformation of the first and
second tubular members, 10
and 28, the tubular sleeve 210 may provide a fluid tight metal-to-metal seal
between interior surface of
the tubular sleeve and the exterior surfaces of the end portions,14 and 26, of
the first and second
tubular members. In this manner, fluidic materials are prevented from passing
through the threaded
connections, 12 and 24, of the first and second tubular members, 10 and 28,
into the annulus between
the first and second tubular members and the structure 32. Furthermore,
because, following the radial
expansion and plastic deformation of the first and second tubular members, 10
and 28, the tubular
sleeve 210 may be maintained in circumferential tension and the end portions,
14 and 26, of the first
and second tubular members, 10 and 28, may be maintained in circumferential
compression, axial
loads andlor torque loads may be transmitted through the tubular sleeve. In
addition, the tubular sleeve
210 may also increase the collapse strength of the end portions, 14 and 26, of
the first and second
tubular members, 10 and 28.
14
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
(0097] Referring to Figs. 4a and 4b, in an alternative embodiment, a tubular
sleeve 310 having an
internal flange 312, tapered portions, 314 and 316, at opposite ends, and an
annular sealing member
318 positioned on the exterior surface of the tubular sleeve, is coupled to
the first and second tubular
members, 10 and 28. In particular, the tubular sleeve 310 receives and mates
with the end portions, 14
and 26, of the first and second tubular members, 10 and 28, and the internal
flange 312 of the tubular
sleeve is received within the annular recess 30 of the second tubular member
28 proximate the end of
the first tubular member. In this manner, the tubular sleeve 310 is coupled to
the end portions, 14 and
26, of the first and second tubular members, 10 and 28, and the tubular sleeve
covers the end portions,
14 and 26, of the first and second tubular members, 10 and 28.
[0098] In an exemplary embodiment, the first and second tubular members, 10
and 28, and the
tubular sleeve 310 may then be positioned within the structure 32 and radially
expanded and plastically
deformed, for example, by moving an expansion cone 34 through the interiors of
the first and second
tubular members. In an exemplary embodiment, following the radial expansion
and plastic
deformation of the first and second tubular members, 10 and 28, the tubular
sleeve 310 may be
maintained in circumferential tension and the end portions, 14 and 26, of the
first and second tubular
members, 10 and 28, may be maintained in circumferential compression.
Furthermore, in an
exemplary embodiment, following the radial expansion and plastic deformation
of the first and second
tubular members, 10 and 28, the annular sealing member 318 circumferentially
engages the interior
surface of the structure 32 thereby preventing the passage of fluidic
materials through the annulus
between the tubular sleeve 310 and the structure. In this manner, the tubular
sleeve 310 may provide
an expandable packer element.
[0099] The use of the tubular sleeve 310 during (a) the coupling of the first
tubular member 10 to
the second tubular member 28, (b) the placement of the first and second
tubular members in the
structure 32, and (c) the radial expansion and plastic deformation of the
first and second tubular
members provides a number of significant benefits. For example, the tubular
sleeve 310 protects the
exterior surfaces of the end portions, 14 and 26, of the first and second
tubular members, 10 and 28,
during handling and insertion of the tubular members within the structure 32.
In this manner, damage
to the exterior surfaces of the end portions, 14 and 26, of the first and
second tubular members, 10 and
28, is prevented that could result in stress concentrations that could result
in a catastrophic failure
during subsequent radial expansion operations. In addition, during the
relative rotation of the second
tubular member with respect to the first tubular member, required during the
threaded coupling of the
first and second tubular members, the tubular sleeve 310 provides an
indication of to what degree the
first and second tubular members are threadably coupled. For example, if the
tubular sleeve 310 can
be easily rotated, that would indicate that the first and second tubular
members, 10 and 28, are not fully
threadably coupled and in intimate contact with the internal flange 312 of the
tubular sleeve.
Furthermore, the tubular sleeve 310 may prevent crack propagation during the
radial expansion and
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
plastic deformation of the first and second tubular members, 10 and 28. In
this manner, failure modes
such as, for example, longitudinal cracks in the end portions, 14 and 26, of
the first and second tubular
members, 10 and 28, may be limited in severity or eliminated all together. In
addition, after
completing the radial expansion and plastic deformation of the first and
second tubular members, 10
and 28, the tubular sleeve 310 may provide a fluid tight metal-to-metal seal
between interior surface of
the tubular sleeve and the exterior surfaces of the end portions,14 and 26, of
the first and second
tubular members. In this manner, fluidic materials are prevented from passing
through the threaded
connections, 12 and 24, of the first and second tubular members, 10 and 28,
into the annulus between
the first and second tubular members and the structure 32. Furthermore,
because, following the radial
expansion and plastic deformation of the first and second tubular members, 10
and 28, the tubular
sleeve 310 may be maintained in circumferential tension and the end portions,
14 and 26, of the first
and second tubular members, 10 and 28, may be maintained in circumferential
compression, axial
loads and/or torque loads may be transmitted through the tubular sleeve. In
addition, because,
following the radial expansion and plastic deformation of the first and second
tubular members, 10 and
28, the annular sealing member 318 may circumferentially engage the interior
surface of the structure
32, the tubular sleeve 310 may provide an expandable packer element. In
addition, the tubular sleeve
318 may also increase the collapse strength of the end portions, 14 and 26, of
the first and second
tubular members, 10 and 28.
[00100] Referring to Figs. Sa and Sb, in an alternative embodiment, a non-
metallic tubular sleeve
410 having an internal flange 412, and tapered portions, 414 and 416, at
opposite ends, is coupled to
the first and second tubular members, 10 and 28. In particular, the tubular
sleeve 410 receives and
mates with the end portions, 14 and 26, of the first and second tubular
members, 10 and 28, and the
internal flange 412 of the tubular sleeve is received within the annular
recess 30 of the second tubular
member 28 proximate the end of the first tubular member. In this manner, the
tubular sleeve 410 is
coupled to the end portions, 14 and 26, of the first and second tubular
members, 10 and 28, and the
tubular sleeve covers the end portions, 14 and 26, of the first and second
tubular members, 10 and 28.
[00101] In several exemplary embodiments, the tubular sleeve 410 may be
plastic, ceramic,
elastomeric, composite and/or a frangible material.
[00102] In an exemplary embodiment, the first and second tubular members, 10
and 28, and the
tubular sleeve 410 may then be positioned within the structure 32 and radially
expanded and plastically
deformed, for example, by moving an expansion cone 34 through the interiors of
the first and second
tubular members. In an exemplary embodiment, following the radial expansion
and plastic
deformation of the first and second tubular members, 10 and 28, the tubular
sleeve 410 may be
maintained in circumferential tension and the end portions, 14 and 26, of the
first and second tubular
members, 10 and 28, may be maintained in circumferential compression.
Furthermore, in an
exemplary embodiment, during the radial expansion and plastic deformation of
the first and second
16
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
tubular members, 10 and 28, the tubular sleeve 310 may be broken ofF of the
first and second tubular
members.
[00103] The use of the tubular sleeve 410 during (a) the coupling of the first
tubular member 10 to
the second tubular member 28, (b) the placement of the first and second
tubular members in the
structure 32, and (c) the radial expansion and plastic deformation of the
first and second tubular
members provides a number of significant benefits. For example, the tubular
sleeve 410 protects the
exterior surfaces of the end portions, 14 and 26, of the first and second
tubular members, 10 and 28,
during handling and insertion of the tubular members within the structure 32.
In this manner, damage
to the exterior surfaces of the end portions, 14 and 26, of the first and
second tubular members, 10 and
28, is prevented that could result in stress concentrations that could result
in a catastrophic failure
during subsequent radial expansion operations. In addition, during the
relative rotation of the second
tubular member with respect to the first tubular member, required during the
threaded coupling of the
first and second tubular members, the tubular sleeve 410 provides an
indication of to what degree the
first and second tubular members are threadably coupled. For example, if the
tubular sleeve 410 can
be easily rotated, that would indicate that the first and second tubular
members, 10 and 28, are not fully
threadably coupled and in intimate contact with the internal flange 412 of the
tubular sleeve.
Furthermore, the tubular sleeve 410 may prevent crack propagation during the
radial expansion and
plastic deformation of the first and second tubular members, 10 and 28. In
this manner, failure modes
such as, for example, longitudinal cracks in the end portions, 14 and 26, of
the first and second tubular
members, 10 and 28, may be limited in severity or eliminated all together. In
addition, after
completing the radial expansion and plastic deformation of the first and
second tubular members, 10
and 28, the tubular sleeve 410 may provide a fluid tight metal-to-metal seal
between interior surface of
the tubular sleeve and the exterior surfaces of the end portions,14 and 26, of
the first and second
tubular members. In this manner, fluidic materials are prevented from passing
through the threaded
connections, 12 and 24, of the first and second tubular members, 10 and 28,
into the annulus between
the first and second tubular members and the structure 32. Furthermore,
because, following the radial
expansion and plastic deformation of the first and second tubular members, 10
and 28, the tubular
sleeve 410 may be maintained in circumferential tension and the end portions,
14 and 26, of the first
and second tubular members, 10 and 28, may be maintained in circumferential
compression, axial
loads and/or torque loads may be trmsmitted through the tubular sleeve. In
addition, because, during
the radial expansion and plastic deformation of the first and second tubular
members, 10 and 28, the
tubular sleeve 410 may be broken off of the first and second tubular members,
the final outside
diameter of the first and second tubular members may more closely match the
inside diameter of the
structure 32. In addition, the tubular sleeve 410 may also increase the
collapse strength of the end
portions, 14 and 26, of the first and second tubular members, 10 and 28.
[00104] Referring to Fig. 6a, in an exemplary embodiment, a tubular sleeve 510
includes an
17
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
internal flange 512, tapered portions, 514 and 516, at opposite ends, and
defines one or more axial slots
518. In an exemplary embodiment, during the radial expansion and plastic
deformation of the first and
second tubular members, 10 and 28, the axial slots 518 reduce the required
radial expansion forces.
[00105] Referring to Fig. 6b, in an exemplary embodiment, a tubular sleeve 610
includes an
internal flange 612, tapered portions, 614 and 616, at opposite ends, and
defines one or more offset
axial slots 618. In an exemplary embodiment, during the radial expansion and
plastic deformation of
the first and second tubular members, 10 and 28, the axial slots 618 reduce
the required radial
expansion forces.
[00106] Referring to Fig. 6c, in an exemplary embodiment, a tubular sleeve 710
includes an
internal flange 712, tapered portions, 714 and 716, at opposite ends, and
defines one or more radial
openings 718. In an exemplary embodiment, during the radial expansion and
plastic deformation of
the first and second tubular members, 10 and 28, the radial openings 718
reduce the required radial
expansion forces.
[00107] Referring to Fig. 6d, in an exemplary embodiment, a tubular sleeve 810
includes an
internal flange 812, tapered portions, 814 and 816, at opposite ends, and
defines one or more axial slots
818 that extend from the ends of the tubular sleeve. In an exemplary
embodiment, during the radial
expansion and plastic deformation of the first and second tubular members, 10
and 28, the axial slots
818 reduce the required radial expansion forces.
[00108] Referring to Fig. 7a, a first tubular member 910 includes an
internally threaded connection
912 at an end portion 914 and a recessed portion 916 having a reduced outside
diameter. As illustrated
in Fig. 7b, a first end of a tubular sleeve 918 that includes annular sealing
members, 920 and 922, at
opposite ends, tapered portions, 924 and 926, at one end, and tapered
portions, 928 and 930, at another
end is then mounted upon and receives the end portion 914 of the first tubular
member 910. In an
exemplary embodiment, a resilient retaining ring 930 is positioned between the
lower end of the
tubular sleeve 918 and the recessed portion 916 of the first tubular member
910 in order to couple the
tubular sleeve to the first tubular member. In an exemplary embodiment, the
resilient retaining ring
930 is a split ring having a toothed surface in order to lock the tubular
sleeve 918 in place.
[00109] As illustrated in Fig. 7c, an externally threaded connection 934 of an
end portion 936 of a
second tubular member 938 having a recessed portion 940 having a reduced
outside diameter is then
positioned within the tubular sleeve 918 and threadably coupled to the
internally threaded connection
912 of the end portion 914 of the first tubular member 910. In an exemplary
embodiment, a resilient
retaining ring 942 is positioned between the upper end of the tubular sleeve
918 and the recessed
portion 940 of the second tubular member 938 in order to couple the tubular
sleeve to the second
tubular member. In an exemplary embodiment, the resilient retaining ring 942
is a split ring having a
toothed surface in order to lock the tubular sleeve 918 in place.
[00110] In an exemplary embodiment, the internally threaded connection 912 of
the end portion
18
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
914 of the first tubular member 910 is a box connection, and the externally
threaded connection 934 of
the end portion 936 of the second tubular member 938 is a pin connection. In
an exemplary
embodiment, the internal diameter of the tubular sleeve 918 is at least
approximately .020" greater than
the outside diameters of the end portions, 914 and 936, of the first and
second tubular members, 910
and 938. In this manner, during the threaded coupling of the first and second
tubular members, 910
and 938, fluidic materials within the first and second tubular members may be
vented from the tubular
members.
[00111] In an exemplary embodiment, as illustrated in Figs. 7d and 7e, the
first and second tubular
members, 910 and 938, and the tubular sleeve 918 may then be positioned within
another structure 32
such as, for example, a wellbore, and radially expanded and plastically
deformed, for example, by
moving an expansion cone 34 through the interiors of the first and second
tubular members. The
tapered portions, 924 and 928, of the tubular sleeve 918 facilitate the
insertion and movement of the
first and second tubular members within and through the structure 32, and the
movement of the
expansion cone 34 through the interiors of the first and second tubular
members, 910 and 93 8, may be
from top to bottom or from bottom to top.
[00112] In an exemplary embodiment, during the radial expansion and plastic
deformation of the
first and second tubular members, 910 and 938, the tubular sleeve 918 is also
radially expanded and
plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 918 may be
maintained in circumferential tension and the end portions, 914 and 936, of
the first and second tubular
members, 910 and 938, may be maintained in circumferential compression.
[00113] The use of the tubular sleeve 918 during (a) the coupling of the first
tubular member 910
to the second tubular member 938, (b) the placement of the first and second
tubular members in the
structure 32, and (c) the radial expansion and plastic deformation of the
first and second tubular."
members provides a number of significant benefits. For example, the tubular
sleeve 918 protects the
exterior surfaces of the end portions, 914 and 936, of the first and second
tubular members, 910 and
938, during handling and insertion of the tubular members within the structure
32. In this manner,
damage to the exterior surfaces of the end portions, 914 and 936, of the first
and second tubular
member, 910 and 938, are prevented that could result in stress concentrations
that could result in a
catastrophic failure during subsequent radial expansion operations.
Furthermore, the tubular sleeve
918 provides an alignment guide that facilitates the insertion and threaded
coupling of the second
tubular member 938 to the first tubular member 910. In this manner,
misalignment that could result in
damage to the threaded connections, 912 and 934, of the first and second
tubular members, 910 and
938, may be avoided. Furthermore, the tubular sleeve 918 may prevent crack
propagation during the
radial expansion and plastic deformation of the first and second tubular
members, 910 and 938. In this
manner, failure modes such as, for example, longitudinal cracks in the end
portions, 914 and 936, of
the first and second tubular members may be limited in severity or eliminated
all together. In addition,
19
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
after completing the radial expansion and plastic deformation of the first and
second tubular members,
910 and 938, the tubular sleeve 918 may provide a fluid tight metal-to-metal
seal between interior
surface of the tubular sleeve and the exterior surfaces of the end portions,
914 and 936, of the first and
second tubular members. In this manner, fluidic materials are prevented from
passing through the
threaded connections, 912 and 934, of the first and second tubular members,
910 and 938, into the
annulus between the first and second tubular members and the structure 32.
Furthermore, because,
following the radial expansion and plastic deformation of the first and second
tubular members, 910
and 938, the tubular sleeve 918 may be maintained in circumferential tension
and the end portions,
914 and 93 6, of the first and second tubular members, 910 and 93 8, may be
maintained in
circumferential compression, axial loads and/or torque loads may be
transmitted through the tubular
sleeve. In addition, the annular sealing members, 920 and 922, of the tubular
sleeve 918 may provide a
fluid tight seal between the tubular sleeve and the end portions, 914 and 936,
of the first and second
tubular members, 910 and 938. Furthermore, the tubular sleeve 918 may also
increase the collapse
strength of the end portions, 914 and 936, of the first and second tubular
members, 910 and 938.
[00114] Referring to Fig. 8a, a first tubular member 1010 includes an
internally threaded
connection 1012 at an end portion 1014 and a recessed portion 1016 having a
reduced outside
diameter. As illustrated in Fig. 8b, a first end of a tubular sleeve 1018 that
includes annular sealing
members, 1020 and 1022, at opposite ends, tapered portions, 1024 and 1026, at
one end, and tapered
portions, 1028 and 1030, at another end is then mounted upon and receives the
end portion 1014 of the
first tubular member 1010. In an exemplary embodiment, as illustrated in Fig.
8c, the end of the
tubular sleeve I 018 is then crimped onto the recessed portion 1016 of the
first tubular member 1 O 10 in
order to couple the tubular sleeve to the first tubular member.
[00115] As illustrated in Fig. 8d, an externally threaded connection 1032 of
an end portion 1034 of
a second tubular member 1036 having a recessed portion 1038 having a reduced
external diameter is
then positioned within the tubular sleeve 1018 and threadably coupled to the
internally threaded
connection 1012 of the end portion 1014 of the first tubular member 1010. In
an exemplary
embodiment, as illustrated in Fig. 8e, the other end of the tubular sleeve
1018 is then crimped into the
recessed portion 1038 of the second tubular member 1036 in order to couple the
tubular sleeve to the
second tubular member.
[00116] In an exemplary embodiment, the internally threaded connection 1012 of
the end portion
1014 of the first tubular member 1010 is a box connection, and the externally
threaded connection
1032 of the end portion 1034 of the second tubular member 1036 is a pin
connection. In an exemplary
embodiment, the internal diameter of the tubular sleeve 1018 is at least
approximately .020" greater
than the outside diameters of the end portions, 1014 and 1034, of the first
and second tubular members,
1010 and 1036. In this manner, during the threaded coupling of the first and
second tubular members,
1010 and 1036, fluidic materials within the first and second tubular members
may be vented from the
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
tubular members.
[00117] In an exemplary embodiment, as illustrated in Figs. 8f and 8g, the
first and second tubular
members, 1010 and 1036, and the tubular sleeve 1018 may then be positioned
within another structure
32 such as, for example, a wellbore, and radially expanded and plastically
deformed, for example, by
moving an expansion cone 34 through the interiors of the first and second
tubular members. The
movement of the expansion cone 34 through the interiors of the first and
second tubular members,
1010 and 1036, may be from top to bottom or from bottom to top.
[00118] In an exemplary embodiment, during the radial expansion and plastic
deformation of the
first and second tubular members, 1010 and 1036, the tubular sleeve 1018 is
also radially expanded
and plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 1018 may be
maintained in circumferential tension and the end portions, 1014 and 1034, of
the first and second
tubular members, 1010 and 1036, may be maintained in circumferential
compression.
[00119] The use of the tubular sleeve 1018 during (a) the coupling of the
first tubular member
1010 to the second tubular member 1036, (b) the placement of the first and
second tubular members in
the structure 32, and (c) the radial expansion and plastic deformation of the
first and second tubular
members provides a number of significant benefits. For example, the tubular
sleeve 1018 protects the
exterior surfaces of the end portions, 1014 and 1034, of the first and second
tubular members, 1010
and 1036, during handling and insertion of the tubular members within the
structure 32. In this
manner, damage to the exterior surfaces of the end portions, 1014 and 1034, of
the first and second
tubular members, 1010 and 1036, are prevented that could result in stress
concentrations that could
result in a catastrophic failure during subsequent radial expansion
operations. Furthermore, the tubular
sleeve 1018 provides an alignment guide that facilitates the insertion and
threaded coupling of the
__ second tubular member 1036 to the first tubular member 1010. In this
manner,. misalignment that
could result in damage to the threaded connections, 1012 and 1032, of the
first and second tubular
members, 1010 and 1036, may be avoided. Furthermore, the tubular sleeve 1018
may prevent crack
propagation during the radial expansion and plastic deformation of the first
and second tubular
members, 1010 and 1036. In this manner, failure modes such as, for example,
longitudinal cracks in
the end portions, 1014 and 1034, of the first and second tubular members may
be limited in severity or
eliminated all together. In addition, after completing the radial expansion
and plastic deformation of
the first and second tubular members, 1010 and 1036, the tubular sleeve 1018
may provide a fluid tight
metal-to-metal seal between interior surface of the tubular sleeve and the
exterior surfaces of the end
portions, 1014 and 1034, of the first and second tubular members. In this
manner, fluidic materials are
prevented from passing through the threaded connections, 1012 and 1032, of the
first and second
tubular members, 1010 and 1036, into the annulus between the first and second
tubular members and
the structure 32. Furthermore, because, following the radial expansion and
plastic deformation of the
first and second tubular members, 1010 and 1036, the tubular sleeve 1018 may
be maintained in
21
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
circumferential tension and the end portions, 1014 and 1034, of the first and
second tubular members,
1010 and 1036, may be maintained in circumferential compression, axial loads
and/or torque loads
may be transmitted through the tubular sleeve. In addition, the annular
sealing members, 1020 and
1022, of the tubular sleeve 1018 may provide a fluid tight seal between the
tubular sleeve and the end
portions, 1014 and 1034, of the first and second tubular members, 1010 and
1036. Furthermore, the
tubular sleeve 1 O 18 may also increase the collapse strength of the end
portions, 1014 and 1034, of the
first and second tubular members, 1010 and 1036.
[00120] Referring to Fig. 9a, a first tubular member 1110 includes an
internally threaded
connection 1112 at an end portion 1114. As illustrated in Fig. 9b, a first end
of a tubular sleeve 1116
having tapered portions, 1118 and 1120, at opposite ends, is then mounted upon
and receives the end
portion 1114 of the first tubular member 1110. In an exemplary embodiment, a
toothed resilient
retaining ring 1122 is then attached to first tubular member 1010 below the
end of the tubular sleeve
1116 in order to couple the tubular sleeve to the first tubular member.
[00121] As illustrated in Fig. 9c, an externally threaded connection 1124 of
an end.portion 1126 of
a second tubular member 1128 is then positioned within the tubular sleeve 1116
and threadably
coupled to the internally threaded connection 1112 of the end portion 1114 of
the first tubular member
1110. In an exemplary embodiment, a toothed resilient retaining ring 1130 is
then attached to second
tubular member 1128 above the end of the tubular sleeve 1116 in order to
couple the tubular sleeve to
the second tubular member.
[00122] In an exemplary embodiment, the internally threaded connection 1112 of
the end portion
1114 of the first tubular member 1110 is a box connection, and the externally
threaded connection
1124 of the end portion 1126 of the second tubular member 1128 is a pin
connection. In an exemplary
embodiment, the internal diameter of the tubular sleeve 1116 is at least
approximately .020" greater
than the outside diameters of the end portions, 1114 and 1126, of the first
and second tubular members,
1110 and 1128. In this manner, during the threaded coupling of the first and
second tubular members,
1110 and 1128, fluidic materials within the first and second tubular members
may be vented from the
tubular members.
(00123] In an exemplary embodiment, as illustrated in Figs. 9d and 9e, the
first and second tubular
members, 1110 and 1128, and the tubular sleeve 1116 may then be positioned
within another structure
32 such as, for example, a wellbore, and radially expanded and plastically
deformed, for example, by
moving an expansion cone 34 through the interiors of the first and second
tubular members. The
movement of the expansion cone 34 through the interiors of the first and
second tubular members,
1110 and 1128, may be from top to bottom or from bottom to top.
[00124] In an exemplary embodiment, during the radial expansion and plastic
deformation of the
first and second tubular members, 1110 and 1128, the tubular sleeve 1116 is
also radially expanded
and plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 1116 may be
22
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
maintained in circumferential tension and the end portions, 1114 and 1126, of
the first and second
tubular members, 1110 and 1128, may be maintained in circumferential
compression.
[00125] The use of the tubular sleeve 1116 during (a) the coupling of the
first tubular member
1110 to the second tubular member 1128, (b) the placement of the first and
second tubular members in
the structure 32, and (c) the radial expansion and plastic deformation of the
first and second tubular
members provides a number of significant benefits. For example, the tubular
sleeve 1116 protects the
exterior surfaces of the end portions, 1114 and 1126, of the first and second
tubular members, 1110
and 1128, during handling and insertion of the tubular members within the
structure 32. In this
manner, damage to the exterior surfaces of the end portions, 1114 and 1126, of
the first and second
tubular members, 1110 and 1128, are prevented that could result in stress
concentrations that could
result in a catastrophic failure during subsequent radial expansion
operations. Furthermore, the tubular
sleeve 1116 provides an alignment guide that facilitates the insertion and
threaded coupling of the
second tubular member 1128 to the first tubular member 1110. In this manner,
misalignment that
could result in damage to the threaded connections, 1112 and 1124, of the
first and second tubular
members, 1110 and 1128, may be avoided. Furthermore, the tubular sleeve 1116
may prevent crack
propagation during the radial expansion and plastic deformation of the first
and second tubular
members, 1110 and 1128. In this manner, failure modes such as, for example,
longitudinal cracks in
the end portions, 1114 and 1126, of the first and second tubular members may
be limited in severity or
eliminated all together. In addition, after completing the radial expansion
and plastic deformation of
the first and second tubular members, 1110 and 1128, the tubular sleeve 1116
may provide a fluid tight
metal-to-metal seal between interior surface of the tubular sleeve and the
exterior surfaces of the end
portions, 1114 and 1128, of the first and second tubular members. In this
manner, fluidic materials are
prevented from passing through the threaded connections, 1112 and 1124, of the
first and second
tubular members, 1110 and 1128, into the annulus between the first and second
tubular members and
the structure 32. Furthermore, because, following the radial expansion and
plastic deformation of the
first and second tubular members, 1110 and 1128, the tubular sleeve 1116 may
be maintained in
circumferential tension and the end portions, 1114 and 1126, of the first and
second tubular members,
1110 and 1128, may be maintained in circumferential compression, axial loads
and/or torque loads
may be transmitted through the tubular sleeve. In addition, the tubular sleeve
1116 may also increase
the collapse strength of the end portions, 1114 and 1126, of the first and
second tubular members.
[00126] Referring to Fig. 10a, a first tubular member 1210 includes an
internally threaded
connection 1212 at an end portion 1214. As illustrated in Fig. l Ob, a first
end of a tubular sleeve 1216
having tapered portions, 1218 and 1220, at one end and tapered portions, 1222
and 1224, at another
end, is then mounted upon and receives the end portion 1114 of the first
tubular member 1110. In an
exemplary embodiment, a resilient elastomeric O-ring 1226 is then positioned
on the first tubular
member 1210 below the tapered portion 1224 of the tubular sleeve 1216 in order
to couple the tubular
23
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
sleeve to the first tubular member.
[00127] As illustrated in Fig. l Oc, an externally threaded connection 1228 of
an end portion 1230
of a second tubular member 1232 is then positioned within the tubular sleeve
1216 and threadably
coupled to the internally threaded connection 1212 of the end portion 1214 of
the first tubular member
1210. In an exemplary embodiment, a resilient elastomeric O-ring 1234 is then
positioned on the
second tubular member 1232 below the tapered portion 1220 of the tubular
sleeve 1216 in order to
couple the tubular sleeve to the first tubular member.
[00128] In an exemplary embodiment, the internally threaded connection 1212 of
the end portion
1214 of the first tubular member 1210 is a box connection, and the externally
threaded connection
1228 of the end portion 1230 of the second tubular member 1232 is a pin
connection. In an exemplary
embodiment, the internal diameter of the tubular sleeve 1216 is at least
approximately .020" greater
than the outside diameters of the end portions, 1214 and 1230, of the first
and second tubular members,
1210 and 1232. In this manner, during the threaded coupling of the first and
second tubular members,
1210 and 1232, fluidic materials within the first and second tubular members
may be vented from the
tubular members.
[00129] In an exemplary embodiment, as illustrated in Figs. 1 Od and 10e, the
first and second
tubular members, 1210 and 1232, and the tubular sleeve 1216 may then be
positioned within another
structure 32 such as, for example, a wellbore, and radially expanded and
plastically deformed, for
example, by moving an expansion cone 34 through the interiors of the first and
second tubular
members. The movement of the expansion cone 34 through the interiors of the
first and second tubular
members, 1210 and 1232, may be from top to bottom or from bottom to top.
[00130] In an exemplary embodiment, during the radial expansion and plastic
deformation of the
first and second tubular members, 1210 and 1232, the..tubular sleeve 1216 is
also radially expanded
and plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 1216 may be
maintained in circumferential tension and the end portions, 1214 and 1230, of
the first and second
tubular members, 1210 and 1232, may be maintained in circumferential
compression.
[00131] The use of the tubular sleeve 1216 during (a) the coupling of the
first tubular member
1210 to the second tubular member 1232, (b) the placement of the first and
second tubular members in
the structure 32, and (c) the radial expansion and plastic deformation of the
first and second tubular
members provides a number of significant benefits. For example, the tubular
sleeve 1216 protects the
exterior surfaces of the end portions, 1214 and 123 0, of the first and second
tubular members, 1210
and 1232, during handling and insertion of the tubular members within the
structure 32. In this
manner, damage to the exterior surfaces of the end portions, 1214 and 1230, of
the first and second
tubular members, 1210 and 1232, are prevented that could result in stress
concentrations that could
result in a catastrophic failure during subsequent radial expansion
operations. Furthermore, the tubular
sleeve 1216 provides an alignment guide that facilitates the insertion and
threaded coupling of the
24
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
second tubular member 1232 to the first tubular member 1210. In this manner,
misalignment that
could result in damage to the threaded connections, 1212 and 1228, of the
first and second tubular
members, 1210 and 1232, may be avoided. Furthermore, the tubular sleeve 1216
may prevent crack
propagation during the radial expansion and plastic deformation of the first
and second tubular
members, 1210 and 1232. In this manner, failure modes such as, for example,
longitudinal cracks in
the end portions, 1214 and 1230, of the first and second tubular members may
be limited in severity or
eliminated all together. In addition, after completing the radial expansion
and plastic deformation of
the first and second tubular members, 1210 and 1232, the tubular sleeve 1216
may provide a fluid tight
metal-to-metal seal between interior surface of the tubular sleeve and the
exterior surfaces of the end
portions, 1214 and 1230, of the first and second tubular members. In this
manner, fluidic materials are
prevented from passing through the threaded connections, 1212 and 1228, of the
first and second
tubular members, 1210 and 1232, into the annulus between the first and second
tubular members and
the structure 32. Furthermore, because, following the radial expansion and
plastic deformation of the
first and second tubular members, 1210 and 1232, the tubular sleeve 1216 may
be maintained in
circumferential tension and the end portions, 1214 and 1230, of the first and
second tubular members,
1210 and 1232, may be maintained in circumferential compression, axial loads
and/or torque loads
may be transmitted through the tubular sleeve. In addition, the tubular sleeve
1216 may also increase
the collapse strength of the end portions, 1214 and 123 0, of the first and
second tubular members 1210
and 1232.
[00132] Referring to Fig. 11 a, a first tubular member 1310 includes an
internally threaded
connection 1312 at an end portion 1314. As illustrated in Fig. 1 lb, a first
end of a tubular sleeve 1316
having tapered portions, 1318 and 1320, at opposite ends is then mounted upon
and receives the end
portion 1314 of the first tubular member 1310., In an exemplary embodiment, an
annular resilient
retaining member 1322 is then positioned on the first tubular member 1310
below the bottom end of
the tubular sleeve 1316 in order to couple the tubular sleeve to the first
tubular member.
[00133] As illustrated in Fig. 1 lc, an externally threaded connection 1324 of
an end portion 1326
of a second tubular member 1328 is then positioned within the tubular sleeve
1316 and threadably
coupled to the internally threaded connection 1312 of the end portion 1314 of
the first tubular member
1310. In an exemplary embodiment, an annular resilient retaining member 1330
is then positioned on
the second tubular member 1328 above the top end of the tubular sleeve 1316 in
order to couple the
tubular sleeve to the second tubular member.
[00134] In an exemplary embodiment, the internally threaded connection 1312 of
the end portion
1314 of the first tubular member 1310 is a box connection, and the externally
threaded connection
1324 of the end portion 1326 of the second tubular member 1328 is a pin
connection. In an exemplary
embodiment, the internal diameter of the tubular sleeve 1316 is at least
approximately .020" greater
than the outside diameters of the end portions, 1314 and 1326, of the first
and second tubular members,
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
1310 and 1328. In this manner, during the threaded coupling of the first and
second tubular members,
1310 and 1328, fluidic materials within the first and second tubular members
may be vented from the
tubular members.
[00135] In an exemplary embodiment, as illustrated in Figs. l ld and 1 le, the
first and second
tubular members, 1310 and 1328, and the tubular sleeve 1316 may then be
positioned within another
structure 32 such as, for example, a wellbore, and radially expanded and
plastically deformed, for
example, by moving an expansion cone 34 through the interiors of the first and
second tubular
members. The movement of the expansion cone 34 through the interiors of the
first and second tubular
members, 1310 and 1328, may be from top to bottom or from bottom to top.
[00136] In an exemplary embodiment, during the radial expansion and plastic
deformation of the
first and second tubular members, 1310 and 1328, the tubular sleeve 1316 is
also radially expanded
and plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 1316 may be
maintained in circumferential tension and the end portions, 1314 and 1326, of
the first and second
tubular members, 1310 and 1328, may be maintained in circumferential
compression.
[00137] The use of the tubular sleeve 1316 during (a) the coupling of the
first tubular member
1310 to the second tubulax member 1328, (b) the placement of the first and
second tubular members in
the structure 32, and (c) the radial expansion and plastic deformation of the
first and second tubular
members provides a number of significant benefits. For example, the tubular
sleeve 1316 protects the
exterior surfaces of the end portions, 1314 and 1326, of the first and second
tubular members, 1310
and 1328, during handling and insertion of the tubular members within the
structure 32. In this
manner, damage to the exterior surfaces of the end portions, 1314 and 1326, of
the first and second
tubular members, 1310 and 1328, are prevented that could result in stress
concentrations that could
result in a catastrophic failure during subsequent radial expansion
operations. Furthermore, the tubular
sleeve 1316 provides an alignment guide that facilitates the insertion and
threaded coupling of the
second tubular member 1328 to the first tubular member 1310. In this manner,
misalignment that
could result in damage to the threaded connections, 1312 and 1324, of the
first and second tubular
members, 1310 and 1328, may be avoided. Furthermore, the tubular sleeve 1316
may prevent crack
propagation during the radial expansion and plastic deformation of the first
and second tubular
members, 1310 and 1328. In this manner, failure modes such as, for example,
longitudinal cracks in
the end portions, 1314 and 1326, of the first and second tubular members may
be limited in severity or
eliminated all together. In addition, after completing the radial expansion
and plastic deformation of
the first and second tubular members, 1310 and 1328, the tubular sleeve 1316
may provide a fluid tight
metal-to-metal seal between interior surface of the tubular sleeve and the
exterior surfaces of the end
portions, 1314 and 1326, of the first and second tubular members. In this
manner, fluidic materials are
prevented from passing through the threaded connections, 1312 and 1324, of the
first and second
tubular members, 1310 and 1328, into the annulus between the first and second
tubular members and
26
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
the structure 32. Furthermore, because, following the radial expansion and
plastic deformation of the
first and second tubular members, 1310 and 1328, the tubular sleeve 1316 may
be maintained in
circumferential tension and the end portions, 1314 and 1326, of the first and
second tubular members,
1310 and 1328, may be maintained in circumferential compression, axial loads
and/or torque loads
may be transmitted through the tubular sleeve. In addition, the tubular sleeve
1316 may also increase
the collapse strength of the end portions, 1314 and 1326, of the first and
second tubular members, 1310
and 1328.
[00138] Referring to Fig. 12a, a first tubular member 1410 includes an
internally threaded
connection 1412 and an annular recess 1414 at an end portion 1416. As
illustrated in Fig. 12b, a first
end of a tubular sleeve 1418 that includes an external flange 1420 and tapered
portions, 1422 and
1424, at opposite ends is then mounted within the end portion 1416 of the
first tubular member 1410.
In an exemplary embodiment, the external flange 1420 of the tubular sleeve
1418 is received within
and is supported by the annular recess 1414 of the end portion 1416 of the
first tubular member 1410.
As illustrated in Fig. 12c, an externally threaded connection 1426 of an end
portion 1428 of a second
tubular member 1430 is then positioned around a second end of the tubular
sleeve 1418 and threadably
coupled to the internally threaded connection 1412 of the end portion 1414 of
the first tubular member
1410. In an exemplary embodiment, the external flange 1420 of the tubular
sleeve 1418 mates with
and is received within the annular recess 1416 of the end portion 1414 of the
first tubular member
1410, and the external flange of the tubular sleeve is retained in the annular
recess by the end portion
1428 of the second tubular member 1430. Thus, the tubular sleeve 1416 is
coupled to and is
surrounded by the internal surfaces of the first and second tubular members,
1410 and 1430.
[00139] In an exemplary embodiment, the internally threaded connection 1412 of
the end portion
1414 of the first tubular member 1410 is a box connection, and the externally
threaded connection
1426 of the end portion 1428 of the second tubular member 1430 is a pin
connection. In an exemplary
embodiment, the external diameter of the tubular sleeve 1418 is at least
approximately .020" less than
the inside diameters of the first and second tubular members, 1410 and 1430.
In this manner, during
the threaded coupling of the first and second tubular members, 1410 and 1430,
fluidic materials within
the first and second tubular members may be vented from the tubular members.
[00140] In an exemplary embodiment, as illustrated in Figs. 12d and 12e, the
first and second
tubular members, 1410 and 1430, and the tubular sleeve 1418 may then be
positioned within another
structure 32 such as, for example, a wellbore, and radially expanded and
plastically deformed, for
example, by moving an expansion cone 34 through the interiors of the first and
second tubular
members. The tapered portions, 1422 and 1424, of the tubular sleeve 1418
facilitate the movement of
the expansion cone 34 through the first and second tubular members, 1410 and
1430, and the
movement of the expansion cone 34 through the interiors of the first and
second tubular members,
1410 and 1430, may be from top to bottom or from bottom to top.
27
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
[00141] In an exemplary embodiment, during the radial expansion and plastic
deformation of the
first and second tubular members, 1410 and 1430, the tubular sleeve 1418 is
also radially expanded
and plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 1418 may be
maintained in circumferential compression and the end portions, 1414 and 1428,
of the first and second
tubular members, 1410 and 1430, may be maintained in circumferential tension.
[00142] In several alternative embodiments, the first and second tubular
members, 1410 and 1430,
are radially expanded and plastically deformed using other conventional
methods for radially
expanding and plastically deforming tubular members such as, for example,
internal pressurization
and/or roller expansion devices.
[00143] The use of the tubular sleeve 1418 during (a) the coupling of the
first tubular member
1410 to the second tubular member 1430, (b) the placement of the first and
second tubular members in
the structure 32, and (c) the radial expansion and plastic deformation of the
first and second tubular
members provides a number of significant benefits. For example, the tubular
sleeve 1418 provides an
alignment guide that facilitates the insertion and threaded coupling of the
second tubular member 1430
to the first tubular member 1410. In this maimer, misalignment that could
result in damage to the
threaded connections, 1412 and 1426, of the first and second tubular members,
1410 and 1430, may be
avoided. In addition, during the relative rotation of the second tubular
member with respect to the first
tubular member, required during the threaded coupling of the first and second
tubular members, the
tubular sleeve 1418 provides an indication of to what degree the first and
second tubular members are
threadably coupled. For example, if the tubular sleeve 1418 can be easily
rotated, that would indicate
that the first and second tubular members, 1410 and 143 0, are not fully
threadably coupled and in
intimate contact with the internal flange 1420 of the tubular sleeve.
Furthermore, the tubular sleeve
1418 may prevent crack propagation during the radial expansion and plastic
deformation of the first .u,
and second tubular members, 1410 and 1430. In this manner, failure modes such
as, for example,
longitudinal cracks in the end portions, 1414 and 1428, of the first and
second tubular members may be
limited in severity or eliminated all together. In addition, after completing
the radial expansion and
plastic deformation of the first and second tubular members, 1410 and 1430,
the tubular sleeve 1418
. may provide a fluid tight metal-to-metal seal between the exterior surface
of the tubular sleeve and the
interior surfaces of the end portions, 1414 and 1428, of the first and second
tubular members. In this
manner, fluidic materials are prevented from passing through the threaded
connections, 1412 and 1426,
of the first and second tubular members, 1410 and 143 0, into the annulus
between the first and second
tubular members and the structure 32. Furthermore, because, following the
radial expansion and
plastic deformation of the first and second tubular members, 1410 and 1430,
the tubular sleeve 1418
may be maintained in circumferential compression and the end portions, 1414
and 1428, of the first
and second tubular members, 1410 and 1430, may be maintained in
circumferential tension, axial loads
and/or torque loads may be transmitted through the tubular sleeve. In
addition, the tubular sleeve 1418
28
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
may also increase the collapse strength of the end portions, 1414 and 1428, of
the first and second
tubular members, 1410 and 1430.
[00144] Referring to Fig. 13a, an end of a first tubular member 1510 is
positioned within and
coupled to an end of a tubular sleeve 1512 having an internal flange 1514. In
an exemplary
embodiment, the end of the first tubular member 1510 abuts one side of the
internal flange 1514. As
illustrated in Fig. 13b, an end of second tubular member 1516 is then
positioned within and coupled to
another end of the tubular sleeve 1512. In an exemplary embodiment, the end of
the second tubular
member 1516 abuts another side of the internal flange 1514. In an exemplary
embodiment, the tubular
sleeve 1512 is coupled to the ends of the first and second tubular members,
1510 and 1516, by
expanding the tubular sleeve 1512 using heat and then inserting the ends of
the first and second tubular
members into the expanded tubular sleeve 1512. After cooling the tubular
sleeve 1512, the tubular
sleeve is coupled to the ends of the first and second tubular members, 1510
and 1516.
[00145] In an exemplary embodiment, as illustrated in Figs. 13c and 13d, the
first and second
tubular members, 1510 and 1516, and the tubular sleeve 1512 may then be
positioned within another
structure 32 such as, for example, a wellbore, and radially expanded and
plastically deformed, for
example, by moving an expansion cone 34 through the interiors of the first and
second tubular
members. The movement of the expansion cone 34 through the interiors of the
first and second tubular
members, 1510 and 1516, may be from top to bottom or from bottom to top.
[00146] In an exemplary embodiment, during the radial expansion and plastic
deformation of the
first and second tubular members, 1510 and 1516, the tubular sleeve 1512 is
also radially expanded
and plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 1512 may be
maintained in circumferential tension and the ends of the first and second
tubular members, 1510 and
1516, may be.maintained in circumferential compression.
[00147] The use of the tubular sleeve 1512 during (a) the placement of the
first and second tubular
members, 1510 and 1516, in the structure 32 and (b) the radial expansion and
plastic deformation of
the first and second tubular members provides a number of significant
benefits. For example, the
tubular sleeve 1512 may prevent crack propagation during the radial expansion
and plastic deformation
of the first and second tubular members, 1510 and 1516. In this manner,
failure modes such as, for
example, longitudinal cracks in the ends of the first and second tubular
members, 1510 and 1516, may
be limited in severity or eliminated all together. In addition, after
completing the radial expansion and
plastic deformation of the first and second tubular members, 1510 and 1516,
the tubular sleeve 1512
may provide a fluid tight metal-to-metal seal between the exterior surface of
the tubular sleeve and the
interior surfaces of the end of the first and second tubular members.
Furthermore, because, following
the radial expansion and plastic deformation of the first and second tubular
members, 1510 and 1516,
the tubular sleeve 1512 may be maintained in circumferential compression and
the ends of the first
and second tubular members, 1510 and 1516, may be maintained in
circumferential tension, axial loads
29
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
and/or torque loads may be transmitted through the tubular sleeve. In
addition, the tubular sleeve 1512
may also increase the collapse strength of the end portions of the first and
second tubular members,
1510 and 1516.
[00148] Referring to Fig. 14a, a first tubular member 1610 includes a
resilient retaining ring 1612
mounted within an ammlar recess 1614. As illustrated in Fig. 14b, the end of
the first tubular member
1610 is then inserted into and coupled to an end of a tubular sleeve 1616
including an internal flange
1618 and annular recesses, 1620 and 1622, positioned on opposite sides of the
internal flange, tapered
portions, 1624 and 1626, on one end of the tubular sleeve, and tapered
portions, 1628 and 1630, on the
other end of the tubular sleeve. In an exemplary embodiment, the resilient
retaining ring 1612 is
thereby positioned at least partially in the annular recesses, 1614 and 1620,
thereby coupling the first
tubular member 1610 to the tubular sleeve 1616, and the end of the first
tubular member 1610 abuts
one side of the internal flange 1618. During the coupling of the first tubular
member 1610 to the
tubular sleeve 1616, the tapered portion 1630 facilitates the radial
compression of the resilient retaining
ring 1612 during the insertion of the first tubular member into the tubular
sleeve.
[00149] As illustrated in Fig. 14c, an end of a second tubular member 1632
that includes a resilient
retaining ring 1634 mounted within an annular recess 1636 is then inserted
into and coupled to another
end of the tubular sleeve 1616. In an exemplary embodiment, the resilient
retaining ring 1634 is
thereby positioned at least partially in the annular recesses, 1636 and 1622,
thereby coupling the
second tubular member 1632 to the tubular sleeve 1616, and the end of the
second tubular member
1632 abuts another side of the internal flange 1618. During the coupling of
the second tubular member
1632 to the tubular sleeve 1616, the tapered portion 1626 facilitates the
radial compression of the
resilient retaining ring 1634 during the insertion of the second tubular
member into the tubular sleeve.
[00150] In an exemplary embodiment, as illustrated in Figs. 14d and 14e, the
first and second
tubular members, 1610 and 1632, and the tubular sleeve 1616 may then be
positioned within another
structure 32 such as, for example, a wellbore, and radially expanded and
plastically deformed, for
example, by moving an expansion cone 34 through the interiors of the first and
second tubular
members. The movement of the expansion cone 34 through the interiors of the
first and second tubular
members, 1610 and 1632, may be from top to bottom or from bottom to top.
[00151] In an exemplary embodiment, during the radial expansion and plastic
deformation of the
first and second tubular members, 1610 and 1632, the tubular sleeve 1616 is
also radially expanded
and plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 1616 may be
maintained in circumferential tension and the ends of the first and second
tubular members, 1610 and
1632, may be maintained in circumferential compression.
[00152] The use of the tubular sleeve 1616 during (a) the placement of the
first and second tubular
members, 1610 and 1632, in the structure 32, and (b) the radial expansion and
plastic deformation of
the first and second tubular members provides a number of significant
benefits. For example, the
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
tubular sleeve 1616 protects the exterior surfaces of the ends of the first
and second tubular members,
1610 and 1632, during handling and insertion of the tubular members within the
structure 32. In this
manner, damage to the exterior surfaces of the ends of the first and second
tubular member, 1610 and
1632, are prevented that could result in stress concentrations that could
result in a catastrophic failure
during subsequent radial expansion operations. Furthermore, the tubular sleeve
1616 may prevent
crack propagation during the radial expansion and plastic deformation of the
first and second tubular
members, 1610 and 1632. In this manner, failure modes such as, for example,
longitudinal cracks in
the ends of the first and second tubular members, 1610 and 1632, may be
limited in severity or
eliminated all together. In addition, after completing the radial expansion
and plastic deformation of
the first and second tubular members, 1610 and 1632, the tubular sleeve 1616
may provide a fluid tight
metal-to-metal seal between interior surface of the tubular sleeve and the
exterior surfaces of the ends
of the first and second tubular members. Furthermore, because, following the
radial expansion and
plastic deformation of the first and second tubular members, 1610 and 1632,
the tubular sleeve 1616
may be maintained in circumferential tension and the ends of the first and
second tubular members,
1610 and 1632, may be maintained in circumferential compression, axial loads
and/or torque loads
may be transmitted through the tubular sleeve. In addition, the tubular sleeve
1616 may also increase
the collapse strength of the end portions of the first and second tubular
members, 1610 and 1632.
[00153] Referring to Fig. 15a, a first tubular member 1700 defines a passage
1702 and a
counterbore 1704 at an end portion 1706. The counterbore 1704 includes a
tapered shoulder 1708, an
annular recess 1710, non-tapered internal threads, 1712, and tapered internal
threads 1714. A second
tubular member 1716 that defines a passage 1718 includes a recessed portion
1720 at an end portion
1722 that includes a tapered end portion 1724 that is adapted to mate with the
tapered shoulder 1708 of
the counterbore 1704 of the first tubular member 1700, non-tapered external
threads 1726 adapted to
mate with the non-tapered internal threads 1712 of the counterbore of the
first tubular member, and
tapered external threads 1728 adapted to mate with the tapered internal
threads 1714 of the counterbore
of the first tubular member. A sealing ring 1730 is received within the
annular recess 1710 of the
counterbore 1704 of the of the first tubular member 1700 for fluidicly sealing
the interface between the
counterbore of the first tubular member and the recessed portion 1720 of the
second tubular member
1716. In an exemplary embodiment, the threads, 1712, 1714, 1726, and 1728, are
left-handed threads
in order to prevent de-coupling of the first and second tubular members, 1700
and 1716, during
placement of the tubular members within the structure 32. In an exemplary
embodiment, the sealing
ring 1730 is an elastomeric sealing ring.
[00154] A tubular sleeve 1732 that defines a passage 1734 for receiving the
end portions, 1706 and
1722, of the first and second tubular members, 1700 and 1716, respectively,
includes an internal flange
1736 that mates with and is received within an annular recess 1738 that is
defined between an end face
1740 of the end portion of the first tubular member and an end face 1742 of
the recessed portion 1720
31
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
of the end portion of the second tubular member. In this manner, the tubular
sleeve 1732 is coupled to
the first and second tubular members, 1700 and 1716. The tubular sleeve 1732
further includes first
and second internal annular recesses, 1744 and 1746, internal tapered flanges,
1748 and 1750, and
external tapered flanges, 1752 and 1754.
[00155] Sealing members, 1756 and 1758, are received within and mate with the
internal annular
recesses, 1744 and 1746, respectively, of the tubular sleeve 1732 that
fluidicly seal the interface
between the tubular sleeve and the first and second tubular members, 1700 and
1716, respectively. A
sealing member 1760 is coupled to the exterior surface of the tubular sleeve
1732 for fluidicly sealing
the interface between the tubular sleeve and the interior surface of the
preexisting structure 32
following the radial expansion of the first and second tubular members, 1700
and 1716, and the tubular
sleeve using the expansion cone 34. In an exemplary embodiment, the sealing
members, 1756 and
1758, may be, for example, elastomeric or non-elastomeric sealing members
fabricated from nitrite,
viton, or Teflon) materials. In an exemplary embodiment, the sealing member
1760 is fabricated from
an elastomeric material.
[00156] In an exemplary embodiment, during the radial expansion and plastic
deformation of the
first and second tubular members, 1700 and 1716, the tubular sleeve 1732 is
also radially expanded
and plastically deformed. In an exemplary embodiment, as a result of the
radial expansion, the tubular
sleeve 1732 may be maintained in circumferential tension and the end portions,
1706 and 1722, of the
first and second tubular members, 1700 and 1716, may be maintained in
circumferential compression.
Furthermore, in an exemplary embodiment, during and following the radial
expansion and plastic
deformation of the first and second tubular members, 1700 and 1716,
respectively: (a) the sealing
members, 1756 and 1758, of the tubular sleeve 1732 engage and fluidicly seal
the interface between
the tubular sleeve and the end portions, 1706 and 1722, of the first
and.second tubular members, (b)
the internal tapered flanges, 1748 and 1750, of the tubular sleeve engage, and
couple the tubular sleeve
to, the end portions of the first and second tubular members, (c) the external
tapered flanges, 1752 and
1754, of the tubular sleeve engage, and couple the tubular sleeve to, the
structure 32, and (d) the
sealing member 1760 engages and fluidicly seals the interface between the
tubular sleeve and the
structure.
[00157] In several exemplary embodiments, the first and second tubular
members, 1700 and 1716,
are radially expanded and plastically deformed using the expansion cone 34 in
a conventional manner
and/or using one or more of the methods and apparatus disclosed in one or more
of the following: (1)
U.S. patent application serial no. 091454,139, attorney docket no.
25791.03.02, filed on 12/3/1999, (2)
U.S. patent application serial no. 09/510,913, attorney docket no. 25791.7.02,
filed on 2/23/2000, (3)
U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02,
filed on 2/10/2000, (4)
U.S. patent application serial no. 09/440,338, attorney docket no. 25791.9.02,
filed on 11/15/1999, (5)
U.S. patent application serial no. 09/523,460, attorney docket no.
25791.11.02, filed on 3/10/2000, (6)
32
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
U.S. patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, (7)
U.S. patent application serial no. 09/511,941, attorney docket no.
25791.16.02, filed on 2/24/2000, (8)
U.S. patent application serial no. 09/588,946, attorney docket no.
25791.17.02, filed on 6/7/2000, (9)
U.S. patent application serial no. 09/559,122, attorney docket no.
25791.23.02, filed on 4/26/2000,
(10) PCT patent application serial no. PCT/US00/18635, attorney docket no.
25791.25.02, filed on
7/9/2000, (11) U.S. provisional patent application serial no. 60/162,671,
attorney docket no. 25791.27,
filed on 11/1/1999, (12) U.S. provisional patent application serial no.
60/154,047, attorney docket no.
25791.29, filed on 9/16/1999, (13) U.S. provisional patent application serial
no. 60/159,082, attorney
docket no. 25791.34, filed on 10/12/1999, (14) U.S. provisional patent
application serial no.
60/159,039, attorney docket no. 25791.36, filed on 10/12/1999, (15) U.S.
provisional patent
application serial no. 60/159,033, attorney docket no. 25791.37, filed on
10/12/1999, (16) U.S.
provisional patent application serial no. 60/212,359, attorney docket no.
25791.38, filed on 6/19/2000,
(17) U.S. provisional patent application serial no. 60/165,228, attorney
docket no. 25791.39, filed on
11/12/1999, (18) U.S. provisional patent application serial no. 60/221,443,
attorney docket no.
25791.45, filed on 7/28/2000, (19) U.S. provisional patent application serial
no. 60/221,645, attorney
docket no. 25791.46, filed on 7/28/2000, (20) U.S. provisional patent
application serial no.
60/233,638, attorney docket no. 25791.47, filed on 9/18/2000, (21) U.S.
provisional patent application
serial no. 60/237,334, attorney docket no. 25791.48, filed on 10/2/2000, (22)
U.S. provisional patent
application serial no. 60/270,007, attorney docket no. 25791.50, filed on
2/20/2001, (23) U.S.
provisional patent application serial no. 60/262,434, attorney docket no.
25791.51, filed on 1/17/2001,
(24) U.S, provisional patent application serial no. 60/259,486, attorney
docket no. 25791.52, filed on
1/3/2001, (25) U.S. provisional patent application serial no. 60/303,740,
attorney docket no. 25791.61,
filed on 7/6/2001, (26) U.S. provisional patent application serial no.
60/313,453, attorney docket no.
25791.59, filed on 8/20/2001, (27) U.S. provisional patent application serial
no. 60/317,985, attorney
docket no. 25791.67, filed on 9/6/2001, (28) U.S. provisional patent
application serial no.
60/3318,386, attorney docket no. 25791.67.02, filed on 9/10/2001, (29) U.S.
utility patent application
serial no. 09/969,922, attorney docket no. 25791.69, filed on 10/3/2001, (30)
U.S. utility patent
application serial no. 10/016,467, attorney docket no. 25791.70, filed on
12/10/2001; (31) U.S.
provisional patent application serial no. 60/343,674, attorney docket no.
25791.68, filed on
12/27/2001; (32) U.S. provisional patent application serial no. 601346,309,
attorney docket no
25791.92, filed on 1/7/2002; (33) U.S. provisional patent application serial
no. 60/372,048, attorney
docket no. 25791.93, filed on 4/12/2002; (34) U.S. provisional patent
application serial no.
60/380,147, attorney docket no. 25791.104, filed on 5/6/2002; (35) U.S.
provisional patent application
serial no. 60/387,486, attorney docket no. 25791.107, filed on 6/10/2002; (36)
U.S. provisional patent
application serial no. 601387,961, attorney docket no. 25791.108, filed on
6/12/2002; and (37) U.S.
provisional patent application serial no. 60/391,703, attorney docket no.
25791.90, filed on 6/26/2002,
33
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
the disclosures of which are incorporated herein by reference.
[00158] In several alternative embodiments, the first and second tubular
members, 1700 and 1716,
are radially expanded and plastically deformed using other conventional
methods for radially
expanding and plastically deforming tubular members such as, for example,
internal pressurization
and/or roller expansion devices such as, for example, that disclosed in U.S.
patent application
publication no. US 2001/0045284 A1, the disclosure of which is incorporated
herein by reference.
[00159] The use of the tubular sleeve 1732 during (a) the threaded coupling of
the first tubular
member 1700 to the second tubular member 1716, (b) the placement of the first
and second tubular
members in the structure 32, and (c) the radial expansion and plastic
deformation of the first and
second tubular members provides a number of significant benefits. For example,
the tubular sleeve
1732 protects the exterior surfaces of the end portions, 1706 and 1722, of the
first and second tubular
members, 1700 and 1716, during handling and insertion of the tubular members
within the structure
32. In this manner, damage to the exterior surfaces of the end portions, 1706
and 1722, of the first and
second tubular member, 1700 and 1716, are prevented that could result in
stress concentrations that
could result in a catastrophic failure during subsequent radial expansion
operations. Furthermore, the
tubular sleeve 1732 provides an alignment guide that facilitates the insertion
and threaded coupling of
the second tubular member 1716 to the first tubular member 1700. In this
manner, misalignment that
could result in damage to the threaded connections, 1712, 1714, 1726, and
1728, of the first and
second tubular members, 1700 and 1716, may be avoided. In addition, during the
relative rotation of
the second tubular member with respect to the first tubular member, required
during the threaded
coupling of the first and second tubular members, the tubular sleeve 1732
provides an indication of to
what degree the first and second tubular members are threadably coupled. For
example, if the tubular
sleeve 1732 can be easily rotated, that would indicate that the first and
second tubular members, 1700
and 1716, are not fully threadably coupled and in intimate contact with the
internal flange 1736 of the
tubular sleeve. Furthermore, the tubular sleeve 1732 may prevent crack
propagation during the radial
expansion and plastic deformation of the first and second tubular members,
1700 and 1716. In this
mamier, failure modes such as, for example, longitudinal cracks in the end
portions, 1706 and 1722, of
the first and second tubular members may be limited in severity or eliminated
all together. In addition,
after completing the radial expansion and plastic deformation of the first and
second tubular members,
1700 and 1716, the tubular sleeve 16 may provide a fluid tight metal-to-metal
seal between interior
surface of the tubular sleeve and the exterior surfaces of the end portions,
1706 and 1722, of the first
and second tubular members. In this manner, fluidic materials are prevented
from passing through the
threaded connections, 1712, 1714, 1726, and 1728, of the first and second
tubular members, 1700 and
1716, into the annulus between the first and second tubular members and the
structure 32.
Furthermore, because, following the radial expansion and plastic deformation
of the first and second
tubular members, 1700 and 1716, the tubular sleeve 1732 may be maintained in
circumferential
34
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
tension and the end portions, 1706 and 1722, of the first and second tubular
members, 1700 and 1716,
may be maintained in circumferential compression, axial loads and/or torque
loads may be transmitted
through the tubular sleeve. In addition, the tubular sleeve 1732 may also
increase the collapse strength
of the end portions, 1706 and 1722, of the first and second tubular members,
1700 and 1716.
[00160] In an exemplary experimental implementation, following the radial
expansion and plastic
deformation of the first and second tubular members, 1700 and 1716, and the
tubular sleeve 1732, the
threads, 1712, 1714, 1726, and 1728, of the end portions, 1706 and 1722, of
the first and second
tubular members were unexpectedly deformed such that a fluidic seal was
unexpectedly formed
between and among the threads of the first and second tubular members. In this
manner, a fluid tight
seal was unexpectedly provided between the first and second tubular member,
1700 and 1716, due to
the presence of the tubular sleeve 1732 during the radial expansion and
plastic deformation of the end
portions, 1706 and 1722, of the first and second tubular members.
[00161] In an exemplary embodiment, the rate and degree of radial expansion
and plastic
deformation of the first and second tubular members, 1700 and 1716, and the
tubular sleeve 1732 are
adjusted to generate sufficient localized heating to result in amorphous
bonding or welding of the
threads, 1712, 1714, 1726, and 1728. As a result, the first and second tubular
members, 1700 and
1716, may be amorphously bonded resulting a joint between the first and second
tubulars that is nearly
metallurgically homogeneous.
[00162] In an alternative embodiment, as illustrated in Fig. 15c, a metallic
foil 1762 of a suitable
alloy is placed between and among the threads, 1712, 1714, 1726, and 1728, and
during the radial
expansion and plastic deformation of the first and second tubular members,
1700 and 1716, and the
tubular sleeve 1732, localized heating of the region proximate the threads,
1712, 1714, 1726, and
1728, results in amorphous bonding or a brazing joint of the threads. As a
result, the first and second
tubular members, 1700 and 1716, may be amorphously bonded resulting a joint
between the first and
second tubulars that is nearly metallurgically homogeneous.
[00163] In an exemplary embodiment, as illustrated in Fig. 16, a plurality of
overlapping wellbore
casing strings 1800a-1800h, are positioned within a borehole 1802 that
traverses a subterranean source
1804 of geothermal energy. In this manner, geothermal energy may then be
extracted from the
subterranean source 1804 geothermal energy using conventional methods of
extraction. In an
exemplary embodiment, one or more of the wellbore casing strings 1800 include
one or more of the
first and second tubular members, 10, 28, 910, 938, 1010, 1036, 1110, 1128,
1210, 1232, 1310, 1328,
1410, 1430, 1510, 1516, 1610, 1632, 1700 and/or 1716, that are coupled end-to-
end and include one
or more of the tubular sleeves, 16, 110, 210, 310, 410, 510, 610, 710, 810,
918, 1 O 18, 1116, 1216,
1316, 1418, 1512, 1616 and/or 1732.
[00164] In an exemplary embodiment, the wellbore casing strings, 1800a-1800h,
are radially
expanded and plastically deformed in overlapping fashion within the borehole
1802.
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
[00165] For example, the wellbore casing string 1800a is positioned within the
borehole 1802 and
then radially expanded and plastically deformed. The wellbore casing string
1800b is then positioned
within the borehole 1802 in overlapping relation to the wellbore casing string
1800a and then radially
expanded and plastically deformed. In this manner, a mono-diameter wellbore
casing may be formed
that includes the overlapping wellbore casing strings 1800a and 1800b. This
process may then be
repeated for wellbore casing strings 1800c-1800h. As a result, a mono-diameter
wellbore casing may
be produced that extends from a surface location to the source 1804 of
geothermal energy in which the
inside diameter of a passage 1806 defined by the interiors of the wellbore
casing strings 1800a-1800h
is constant. In this manner, the geothermal energy from the source 1804 may be
efficiently and
economically extracted. Furthermore, because variations in the inside diameter
of the wellbore casing
strings 1800 is eliminated by the resulting mono-diameter design, the depth of
the borehole 1802 may
be virtually limitless. As a result, using the teachings of the present
exemplary embodiments, sources
of geothermal energy can now be extracted from depths of over 50,000 feet.
[00166] In several exemplary embodiments, the wellbore casing strings 1800a-
1800h are radially
expanded and plastically deformed using the expansion cone 34 using one or
more of the methods and
apparatus disclosed in one or more ofthe following: (1) U.S. patent
application serial no. 09/454,139,
attorney docket no. 25791.03.02, filed on 12/3/1999, (2) U.S. patent
application serial no. 09/510,913,
attorney docket no. 25791.7.02, filed on 2/23/2000, (3) U.S. patent
application serial no. 09/502,350,
attorney docket no. 25791.8.02, filed on 2/10/2000, (4) U.S. patent
application serial no. 09/440,338,
attorney docket no. 25791.9.02, filed on 11/15/1999, (5) U.S. patent
application serial no. 09/523,460,
attorney docket no. 25791.11.02, filed on 3/10/2000, (6) U.S. patent
application serial no. 09/512,895,
attorney docket no. 25791.12.02, filed on 2/24/2000, (7) U.S. patent
application serial no. 09/511,941,
attorney docket no. 25791.16.02, filed on 2/24/2000, (8) U.S. patent
application serial no. 09/588,946,
attorney docket no. 25791.17.02, filed on 6/7/2000, (9) U.S. patent
application serial no. 09/559,122,
attorney docket no. 25791.23.02, filed on 4/26/2000, (10) PCT patent
application serial no.
PCT/LTS00/18635, attorney docket no. 25791.25.02, filed on 7/9/2000, (11) U.S.
provisional patent
application serial no. 60/162,671, attorney docket no. 25791.27, filed on
11/1/1999, (12) U.S.
provisional patent application serial no. 60/154,047, attorney docket no.
25791.29, filed on 9/16/1999,
(13) U.S. provisional patent application serial no. 60/159,082, attorney
docket no. 25791.34, filed on
10/12/1999, (14) U.S. provisional patent application serial no. 60/159,039,
attorney docket no.
25791.36, filed on 10/12/1999, (15) U.S. provisional patent application serial
no. 601159,033, attorney
docket no. 25791.37, filed on 10/12/1999, (16) U.S. provisional patent
application serial no.
601212,359, attorney docket no. 25791.38, filed on 6/19/2000, (17) U.S.
provisional patent application
serial no. 60/165,228, attorney docket no. 25791.39, filed on 11/12/1999, (18)
U.S. provisional patent
application serial no. 60/221,443, attorney docket no. 25791.45, filed on
7/28/2000, (19) U.S.
provisional patent application serial no. 60/221,645, attorney docket no.
25791.46, filed on 7/28/2000,
36
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
(20) U.S. provisional patent application serial no. 60/233,638, attorney
docket no. 25791.47, filed on
9/18/2000, (21) U.S. provisional patent application serial no. 60/237,334,
attorney docket no.
25791.48, filed on 10/2/2000, (22) U.S. provisional patent application serial
no. 60/270,007, attorney
docket no. 25791.50, filed on 2/20/2001, (23) U.S. provisional patent
application serial no.
60/262,434, attorney docket no. 25791.51, filed on 1/17/2001, (24) U.S,
provisional patent application
serial no. 60/259,486, attorney docket no. 25791.52, filed on 1/3/2001, (25)
U.S. provisional patent
application serial no. 60/303,740, attorney docket no. 25791.61, filed on
7/6/2001, (26) U.S.
provisional patent application serial no. 60/313,453, attorney docket no.
25791.59, filed on 8/20/2001,
(27) U.S. provisional patent application serial no. 60/317,985, attorney
docket no. 25791.67, filed on
9/6/2001, (28) U.S. provisional patent application serial no. 60/3318,386,
attorney docket no.
25791.67.02, filed on 9/10/2001, (29) U.S. utility patent application serial
no. 09/969,922, attorney
docket no. 25791.69, filed on 10/3/2001, (30) U.S. utility patent application
serial no. 10/016,467,
attorney docket no. 25791.70, filed on 12/10/2001; (31) U.S. provisional
patent application serial no.
60/343,674, attorney docket no. 25791.68, filed on 12/27/2001; (32) U.S.
provisional patent
application serial no. 60/346,309, attorney docket no 25791.92, filed on
1/7/2002; (33) U.S.
provisional patent application serial no. 60/372,048, attorney docket no.
25791.93, filed on 4/12/2002;
(34) U.S. provisional patent application serial no. 60/380,147, attorney
docket no. 25791.104, filed on
5/6/2002; (35) U.S. provisional patent application serial no. 60/387,486,
attorney docket no.
25791.107, filed on 6/10/2002; (36) U.S. provisional patent application serial
no. 60/387,961, attorney
docket no. 25791.108, filed on 6/12/2002; and (37) U.S. provisional patent
application serial no.
60/391,703, attorney docket no. 25791.90, filed on 6/26/2002, the disclosures
of which are
incorporated herein by reference.
[00167] Referring to Fig. 17a, a first tubular member 1900 defines a passage
1902 and a
counterbore 1904 at an end portion 1906. The counterbore 1904 includes non-
tapered internal threads
1908, and tapered internal threads 1910. A second tubular member 1912 that
defines a passage 1914
includes a recessed portion 1916 at an end portion 1918 that includes non-
tapered external threads
1920 adapted to mate with the non-tapered internal threads 1908 of the
counterbore of the first tubular
member, and tapered external threads 1922 adapted to mate with the tapered
internal threads 1910 of
the counterbore of the first tubular member. In an exemplary embodiment, the
threads, 1908, 1910,
1920, and 1922, are left-handed threads in order to prevent de-coupling of the
first and second tubular
members, 1900 and 1912, during handling of tubular members.
[00168] A tubular sleeve 1924 that defines a passage 1926 for receiving the
end portions, 1906 and
1918, of the first and second tubular members, 1900 and 1912, respectively,
includes an internal flange
1928 that mates with and is received within an annular recess 1930 that is
defined between an end face
1932 of the end portion of the first tubular member and an end face 1934 of
the recessed portion 1916
of the end portion of the second tubular member. In this manner, the tubular
sleeve 1924 is coupled to
37
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
the first and second tubular members, 1900 and 1912.
[00169] An adjustable expansion cone 1936 supported by a support member 1938
may then
lowered into the first and second tubular members, 1900 and 1912, to a
position proximate the vicinity
of the threads, 1908, 1910, 1920, and 1922. As illustrated in Fig. 17b, The
expansion cone 1936 may
then be controllably increased in size until the outside circumference of the
expansion cone engages
and radially expands and plastically deforms the end portions of the first and
second tubular members,
1900 and 1912, proximate the expansion cone. The expansion cone 1936 may then
be displaced in the
longitudinal direction 1940 thereby radially expanding and plastically
deforming the remaining
portions of the first and second tubular members, 1900 and 1912, in the
vicinity of the threads, 1908,
1910, 1920, and 1922. In several exemplary embodiments, the amount of radial
expansion ranged
from less than about one percent to less than about five percent.
[00170] After completing the radial expansion and plastic deformation of the
portions 1942 of the
first and second tubular members, 1900 and 1912, in the vicinity of the
threads, 1908, 1910, 1920, and
1922, the expansion cone 1936 may then be controllably reduced in size until
the outside
circumference of the expansion cone disengages from the portion of the second
tubular above the
portion of the second tubular member in the vicinity of the threads. In this
manner, only the portions
1942 of the first and second tubular members, 1900 and 1912, in the vicinity
of the threads, 1908,
1910, 1920, and 1922, are radially expanded and plastically deformed.
[00171] In several exemplary embodiments, the portions 1942 of the first and
second tubular
members, 1900 and 1912, in the vicinity of the threads, 1908, 1910, 1920, are
radially expanded and
plastically deformed using one or more of the methods and apparatus disclosed
in one or more of the
following: (1) U.S. patent application serial no. 09/454,139, attorney docket
no. 25791.03.02, filed on
12/3/1999, (2) U.S. patent application serial no. 09/510,913, attorney docket
no. 25791.7.02, filed on
2/23/2000, (3) U.S. patent application serial no. 09/502,350, attorney docket
no. 25791.8.02, filed on
2/10/2000, (4) U.S. patent application serial no. 09/440,338, attorney docket
no. 25791.9.02, filed on
11/15/1999, (5) U.S. patent application serial no. 09/523,460, attorney docket
no. 25791.11.02, filed
on 3/10/2000, (6) U.S. patent application serial no. 09/512,895, attorney
docket no. 25791.12.02, filed
on 2/24/2000, (7) U.S. patent application serial no. 09/511,941, attorney
docket no. 25791.16.02, filed
on 2/24/2000, (8) U.S. patent application serial no. 09/588,946, attorney
docket no. 25791.17.02, filed
on 6/7/2000, (9) U.S. patent application serial no. 091559,122, attorney
docket no. 25791.23.02, filed
on 4/26/2000, (10) PCT patent application serial no. PCT/LJS00/18635, attorney
docket no.
25791.25.02, filed on 7/9/2000, (11) U.S. provisional patent application
serial no. 60/162,671, attorney
docket no. 25791.27, filed on 11/1/1999, (12) U.S. provisional patent
application serial no.
60/154,047, attorney docket no. 25791.29, filed on 9/1611999, (13) U.S.
provisional patent application
serial no. 60/159,082, attorney docket no. 25791.34, filed on 10/12/1999, (14)
U.S. provisional patent
application serial no. 601159,039, attorney docket no. 25791.36, filed on
10112/1999, (15) U.S.
38
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
provisional patent application serial no. 60/159,033, attorney docket no.
25791.37, filed on
10/12/1999, (16) U.S. provisional patent application serial no. 60/212,359,
attorney docket no.
25791.38, filed on 6/19/2000, (17) U.S. provisional patent application serial
no. 60/165,228, attorney
docket no. 25791.39, filed on 11/12/1999, (18) U.S. provisional patent
application serial no.
60/221,443, attorney docket no. 25791.45, filed on 7/28/2000, (19) U.S.
provisional patent application
serial no. 60/221,645, attorney docket no. 25791.46, filed on 7/28/2000, (20)
U.S. provisional patent
application serial no. 60/233,638, attorney docket no. 25791.47, filed on
9/18/2000, (21) U.S.
provisional patent application serial no. 60/237,334, attorney docket no.
25791.48, filed on 10/2/2000,
(22) U.S. provisional patent application serial no. 60/270,007, attorney
docket no. 25791.50, filed on
2/20/2001, (23) U.S. provisional patent application serial no. 60/262,434,
attorney docket no.
25791.51, filed on 1/17/2001, (24) U.S, provisional patent application serial
no. 60/259,486, attorney
docket no. 25791.52, filed on 1/3/2001, (25) U.S. provisional patent
application serial no. 60/303,740,
attorney docket no. 25791.61, filed on 7/6/2001, (26) U.S. provisional patent
application serial no.
60/313,453, attorney docket no. 25791.59, filed on 8/20/2001, (27) U.S.
provisional patent application
serial no. 60/317,985, attorney docket no. 25791.67, filed on 9/6/2001, (28)
U.S. provisional patent
application serial no. 60/3318,386, attorney docket no. 25791.67.02, filed on
9/10/2001, (29) U:S.
utility patent application serial no. 09/969,922, attorney docket no.
25791.69, filed on 10/3/2001, (30)
U.S. utility patent application serial no. 10/016,467, attorney docket no.
25791.70, filed on
12/10/2001; (31) U.S. provisional patent application serial no. 60/343,674,
attorney docket no.
25791.68, filed on 12/27/2001; (32) U.S. provisional patent application serial
no. 60/346,309, attorney
docket no 25791.92, filed on 1/7/2002; (33) U.S. provisional patent
application serial no. 60/372,048,
attorney docket no. 25791.93, filed on 4/1212002; (34) U.S. provisional patent
application serial no.
60/380,147, attorney docket no. 25791.104, filed on 5/6/2002; (35) U.S.
provisional patent application
serial no. 60/387,486, attorney docket no. 25791.107, filed on 6/10/2002; (36)
U.S. provisional patent
application serial no. 60/387,961, attorney docket no. 25791.108, filed on
6/12/2002; and (37) U.S.
provisional patent application serial no. 60/391,703, attorney docket no.
25791.90, filed on 6/26/2002,
the disclosures of which are incorporated herein by reference.
[00172] As illustrated in Fig. 17c, in an exemplary experimental
implementation, prior to the radial
expansion and plastic deformation of the portions 1942 of the first and second
tubular members, 1900
and 1912, in the vicinity of the threads, 1908, 1910, 1920, and 1922, a
variable gap 1944 is typically
present between the threads, 1908 and 1920, and 1910 and 1922, that may permit
fluidic materials to
pass there through. The gap 1944 may be present, for example, in the radial,
longitudinal and/or
circumferential directions. The leakage of fluidic materials through the gap
1944 can cause serious
problems, for example, in the extraction of subterranean fluids during oil or
gas exploration and
production operations, during the transport of hydrocarbons using underground
pipelines, during the
transport of pressurized fluids in a chemical processing plant, or within the
heat exchanger tubes of a
39
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
power plant.
[00173] In an exemplary experimental implementation, as illustrated in Fig.
17d, following the
radial expansion and plastic deformation of the portion 1942 of the first and
second tubular members,
1900 and 1912, in the vicinity of the threads, 1908, 1910, 1920, and 1922, the
gap 1944 between the
threads was unexpectedly eliminated thereby creating a fluid tight seal. As a
result a fluid tight seal
may be provided within the threads, 1908, 1910, 1920, and 1922, of the first
and second tubular
members, 1900 and 1912, without an elastomeric, or other conventional, sealing
element present.
[00174] Furthermore, in an exemplary experimental implementation, following
the radial
expansion and plastic deformation of the portions 1942 of the first and second
tubular members, 1900
and 1912, in the vicinity of the threads, 1908, 1910, 1920, and 1922, a fluid
tight seal was also created
between the interior circumference of the tubular sleeve 1924 and the exterior
circumferences of the
first and second tubular members, 1900 and 1912.
[00175] Thus, the teachings of the present illustrative embodiments of Figs.
17a-17d may also be
used to provide a fluid tight seal between the first and second tubular
members, 10, 28, 910, 938, 1010,
1036, 1110, 1128, 1210, 1232, 1310, 1328, 1410, 1430, 1510, 1516, 1610, 1632,
1700 and/or 1716,
that are coupled end-to-end and include one or more of the tubular sleeves,
16, 110, 210, 310, 410,
510, 610, 710, 810, 918, 1018, 1116, 1216, 1316, 1418, 1512, 1616 and/or 1732.
A fluid tight seal
may thereby be formed within the threaded connection between the adjacent
tubular members and/or
between the tubular sleeve and the adjacent tubular members.
[00176] More generally, the teachings of the present illustrative embodiments
may be used to solve
the problem of providing a fluid tight seal between all types of tubular
members such as, for example,
wellbore casings, pipes, underground pipelines, piping used in the transport
of pressurized fluids in a
chemical processing plant, or within the heat exchanger tubes of a power
plant.
[00177] Furthermore, the teachings of the present illustrative embodiments may
be used to solve
the problem of providing a fluid tight seal between all types of tubular
members such as, for example,
wellbore casings, chemical processing pipes and underground pipelines, without
having to radially
expand and plastically deform the entire length of the tubular members.
Instead, only those portions of
the tubular members proximate the tubular sleeve provided adjacent to the
joint between the tubulax
members needs to be radially expanded and plastically deformed. Furthermore,
in an exemplary
embodiment, the amount of radial expansion and plastic deformation ranged from
less than about one
percent to less than about five percent. As a result, the amount of time and
resources typically needed
to perform the radial expansion and plastic deformation is economical.
[00178] More generally, the teachings of the exemplary embodiments may be used
to provide an
inexpensive and reliable fluid tight seal between tubular members. In this
manner, expensive and
unreliable methods of providing a fluid tight seal between tubular members
such as, for example, those
methods utilized in the chemical processing industries and in power plant heat
exchangers may be
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
replaced with the teachings of the present illustrative embodiments.
[00179] Furthermore, the teachings of the exemplary embodiments provide a
method of radially
expanding and plastically deforming the ends of adjacent coupled tubular
members in which the
freedom of movement of the adjacent ends of the coupled tubular members is
constrained by the
presence of the tubular sleeve. As a result, during the subsequent radial
expansion process, the
adjacent ends of the coupled tubular members are compressed into the plastic
region of the stress-strain
curve. Consequently, the material of the adjacent ends of the coupled tubular
members such as, for
example, the internal and external threads, flow into and fill any gaps or
voids that may have existed
within the junction of the coupled tubular members thereby providing a fluid
tight seal. The creation
of the fluid tight seal within the junction of the adjacent tubular members
was an unexpected result that
was discovered during experimental analysis and testing of the present
exemplary embodiments. In
fact, also unexpectedly, during a further exemplary analysis and testing of
the present exemplary
embodiments, a fluid tight seal was maintained within the junction between two
adjacent tubulars
despite being bent over 60 degrees relative to one another.
[00180] Thus the present exemplary embodiments will eliminate the need for
expensive high
precision threaded connection for tubular members in order to provide a fluid
tight seal. Instead, a
fluid tight seal can now be provided using a combination of less expensive
conventional threaded
connection and a tubular sleeve that are then radially expanded to provide a
fluid tight seal. Thus, the
commercial application of the present exemplary embodiments will dramatically
reduce the cost of oil
and gas exploration and production. Furthermore, the teachings of the present
exemplary embodiments
can be extended to provide a fluid tight seal between adjacent tubular members
in other applications
such as, for example, underground pipelines, piping in chemical processing
plants, and piping in power
plants, in which conventional, inexpensive, piping with conventional threaded
connections can be
coupled together with a tubular sleeve and then radially expanded to provide
an inexpensive and
reliable fluid tight seal between the adjacent pipe sections.
[00181] Referring to Figs. 18a and 18b, in an alternative embodiment, a
conventional rotary
expansion tool 2000 may then lowered into the first and second tubular
members, 1900 and 1912, to a
position proximate the vicinity of the threads, 1908, 1910, 1920, and 1922. In
an exemplary
embodiment, the rotary expansion tool 2000 may be, for example, a rotary
expansion tool as disclosed
in U.S. Patent Application Publication No. US 2001/0045284, published on
November 29, 2001, the
disclosure of which is incorporated herein by reference.
[00182] As illustrated in Fig. 18b, The rotary expansion tool 2000 may then be
controllably
increased in size and operated until the outside circumference of the rotary
expansion tool engages and
radially expands and plastically deforms the end portions of the first and
second tubular members,
1900 and 1912, proximate the expansion cone. The rotary expansion tool 2000
may then be displaced
in the longitudinal direction 2002 thereby radially expanding and plastically
deforming the remaining
41
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
portions of the first and second tubular members, 1900 and 1912, in the
vicinity of the threads, 1908,
1910, 1920, and 1922. In an exemplary embodiment, the amount of radial
expansion is less than about
five percent. After completing the radial expansion and plastic deformation of
the portion 1942 of the
first and second tubular members, 1900 and 1912, in the vicinity of the
threads, 1908, 1910, 1920, and
1922, the rotary expansion tool 2000 may then be controllably reduced in size
until the outside
circumference of the expansion cone disengages from the portion of the second
tubular above the
portion of the second tubular member in the vicinity of the threads. In this
manner, only the portions of
the first and second tubular members, 1900 and 1912, in the vicinity of the
threads, 1908, 1910, 1920,
and 1922, are radially expanded and plastically deformed.
[00183] More generally still, as illustrated in Fig. 19, the teachings of the
present exemplary
embodiments provide a method 2100 of providing a fluid tight seal between a
pair of adjacent tubular
members in which the location of a fluid leak may be detected in the junction
between a pair of
adjacent tubular members in step 2102. In an exemplary embodiment, in step
2102, a pressurized fluid
may be injected through the adjacent coupled tubular members and the amount,
if any, of any fluid
leakage through the junctions between the adjacent tubular members monitored.
[00184] If the amount of fluid leakage through the junctions of the adjacent
tubular members
exceeds a predetermined amount, then a tubular sleeve may then be coupled to
and overlapping the
junction between the adjacent tubular members in step 2104. And, finally, in
step 2106, the portions
of the tubular members proximate the tubular sleeve may then be radially
expanded. In this manner, a
cost efficient and reliable method for repairing leaks in the junctions
between adjacent tubular
members may be provided.
[00185] Referring to Fig. 20, in an exemplary embodiment, after radially
expanding and plastically
deforming the first and second tubular members, 1900 and 1912, and the tubular
sleeve 1924, an
energy source 2202 may be operably coupled to the second tubular member. The
energy source 2202
may include, for example, a source of electrical, acoustic, and/or thermal
energy. A controller 2204
may also be operably coupled to the energy source 2202 for controlling the
operation of the energy
source. In an exemplary embodiment, the first and second tubular members, 1900
and 1912, and the
tubular sleeve 1924 are positioned within a borehole 2206 that traverses a
subterranean formation
2208, and the energy source 2202 and the controller 2204 are positioned on the
surface.
[00186] During operation, electrical, acoustic, and/or thermal energy may then
be transmitted
through the first and second tubular members, 1900 and 1912, and the tubular
sleeve 1924, using the
energy source 2202 and controller 2204. In an exemplary embodiment, the first
tubular member 1900
may be operably coupled to an earth ground 2206 such as, for example, a
subterranean formation. In
this manner, the transmission of electrical, acoustic, and/or thermal energy
through the tubular
members, 1900 and 1912, and the tubular sleeve 1924, may be enhanced. The
enhanced coupling of
the first and second tubular members, 1900 and 1912, provided by the addition
of the tubular sleeve
42
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
1924 during the radial expansion process, provides a enhanced conductive
pathway for electrical,
thermal, and/or acoustic energy.
[00187] In an exemplary embodiment, the transmitted electrical, acoustic,
and/or thermal energy
may be used, for example, to transmit communication signals to downhole tools,
heat the first and
second tubular members, 1900 and 1912, and tubular sleeve 1924, and/or to
inject energy into the
surrounding subterranean formation. In this manner, information may be
transmitted through the
tubular members, 1900 and 1912, and tubular sleeve 1924 to downhole tools. As
will be recognized
by persons having ordinary skill in the art, the transmission of an electrical
current through the first and
second tubular members, 1900 and 1912, will cause resistance heating of the
tubular members. In this
manner, the surrounding subterranean formation may be heated to thereby
facilitate the extraction and
recovery of hydrocarbons.
[00188] More generally, the teachings of the exemplary embodiment of Fig. 20
may be applied to
one or more of the teachings of the exemplary embodiments of Figs. 1 a-19 in
order to transmit
electrical, acoustic, and/or thermal energy through the corresponding radially
expanded and plastically
deformed tubular members and sleeves. In particular, the enhanced coupling of
the tubular members
of the exemplary embodiments of Figs. 1 a-19, provided by the addition of the
corresponding tubular
sleeves during the radial expansion process, provides an enhanced conductive
pathway for the
transmission of electrical, thermal and/or acoustic energy through the
radially expanded tubular
members.
[00189] More generally still, the teachings of Fig. 20 may applied to the one
or more of the
teachings of the exemplary embodiments of Figs. 1 a-19 in order to transmit
electrical, acoustic, and/or
thermal energy through the corresponding tubular members and sleeves, prior to
the radial expansion
and plastic deformation of the tubular members and sleeves. In particular, the
enhanced coupling of
the tubular members of the exemplary embodiments of Figs. la-19, provided by
the addition of the
corresponding tubular sleeves, prior to the radial expansion process, provides
an enhanced conductive
pathway for the transmission of electrical, thermal and/or acoustic energy
through the radially
expanded tubular members.
[00190] A method of radially expanding and plastically deforming a first
tubular member and a
second tubular member has been described that includes inserting an end of the
first tubular member
into an end of a tubular sleeve having an internal flange into abutment with
the internal flange,
inserting an end of the second tubular member into another end of the tubular
sleeve, threadably
coupling the ends of the first and second tubular member within the tubular
sleeve until both ends of
the first and second tubular members abut the internal flange of the tubular
sleeve, and displacing an
expansion cone through the interiors of the first and second tubular members.
In an exemplary
embodiment, the internal flange of the tubular sleeve is positioned between
the ends of the tubular
sleeve. In an exemplary embodiment, the internal flange of the tubular sleeve
is positioned at one end
43
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
of the tubular sleeve. In an exemplary embodiment, the tubular sleeve further
includes one or more
sealing members for sealing the interface between the tubular sleeve and at
least one of the tubular
members. In an exemplary embodiment, the method further includes placing the
tubular members in
another structure, and displacing the expansion cone through the interiors of
the first and second
tubular members. In an exemplary embodiment, the method further includes
radially expanding the
tubular sleeve into engagement with the structure. In an exemplary embodiment,
the method further
includes sealing an annulus between the tubular sleeve and the other
structure. In an exemplary
embodiment, the other structure comprises a wellbore. In an exemplary
embodiment, the other
structure comprises a wellbore casing. In an exemplary embodiment, the tubular
sleeve further
comprises a sealing element coupled to the exterior of the tubular sleeve. In
an exemplary
embodiment, the tubular sleeve is metallic. In an exemplary embodiment, the
tubular sleeve is non-
metallic. In an exemplary embodiment, the tubular sleeve is plastic. In an
exemplary embodiment, the
tubular sleeve is ceramic. In an exemplary embodiment, the method further
includes breaking the
tubular sleeve. In an exemplary embodiment, the tubular sleeve includes one or
more longitudinal
slots. In an exemplary embodiment, the tubular sleeve includes one or more
radial passages.
[00191] A method of radially expanding and plastically deforming a first
tubular member and a
second tubular member has also been described that includes inserting an end
of the first tubular
member into an end of a tubular sleeve, coupling the end of the tubular sleeve
to the end of the first
tubular member, inserting an end of the second tubular member into another end
of the tubular sleeve,
threadably coupling the ends of the first and second tubular member within the
tubular sleeve, coupling
the other end of the tubular sleeve to the end of the second tubular member,
and displacing an
expansion cone through the interiors of the first and second tubular members.
In an exemplary
embodiment, coupling the ends of the tubular sleeve to the ends of the first
and second tubular
members includes coupling the ends of the tubular sleeve to the ends of the
first and second tubular
members using locking rings. In an exemplary embodiment, coupling the ends of
the tubular sleeve to
the ends of the first and second tubular members using locking rings includes
wedging the locking
rings between the ends of the tubular sleeve and the ends of the first and
second tubular members. In
an exemplary embodiment, coupling the ends of the tubular sleeve to the ends
of the first and second
tubular members using locking rings includes affixing the locking rings to the
ends of the first and
second tubular members. In an exemplary embodiment, the locking rings are
resilient. In an
exemplary embodiment, the locking rings are elastomeric. In an exemplary
embodiment, coupling the
ends of the tubular sleeve to the ends of the first and second tubular members
includes crimping the
ends of the tubular sleeve onto the ends of the first and second tubular
members. In an exemplary
embodiment, the tubular sleeve further includes one or more sealing members
for sealing the interface
between the tubular sleeve and at least one of the tubular members. In an
exemplary embodiment, the
method further includes placing the tubular members in another structure, and
displacing the expansion
44
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
cone through the interiors of the first and second tubular members. In an
exemplary embodiment, the
method further includes radially expanding the tubular sleeve into engagement
with the structure. In
an exemplary embodiment, the method further includes sealing an annulus
between the tubular sleeve
and the other structure. In an exemplary embodiment, the other structure is a
wellbore. In an
exemplary embodiment, the other structure is a wellbore casing. In an
exemplary embodiment, the
tubular sleeve further includes a sealing element coupled to the exterior of
the tubular sleeve. In an
exemplary embodiment, the tubular sleeve is metallic. In an exemplary
embodiment, the tubular sleeve
is non-metallic. In an exemplary embodiment, the tubular sleeve is plastic. In
an exemplary
embodiment, the tubular sleeve is ceramic. In an exemplary embodiment, the
method further includes
breaking the tubular sleeve. In an exemplary embodiment, the tubular sleeve
includes one or more
longitudinal slots. In an exemplary embodiment, the tubular sleeve includes
one or more radial
passages.
[00192] A method of radially expanding and plastically deforming a first
tubular member and a
second tubular member has also been described that includes inserting an end
of a tubular sleeve
having an external flange into an end of the first tubular member until the
external flange abuts the end
of the first tubular member, inserting the other end of the tubular sleeve
into an end of a second tubular
member, threadably coupling the ends of the first and second tubular member
within the tubular sleeve
until both ends of the first and second tubular members abut the external
flange of the tubular sleeve,
and displacing an expansion cone through the interiors of the first and second
tubular members. In an
exemplary embodiment, the external flange of the tubular sleeve is positioned
between the ends of the
tubular sleeve. In an exemplary embodiment, the external flange of the tubular
sleeve is positioned at
one end of the tubular sleeve. In an exemplary embodiment, the tubular sleeve
further includes one or
more sealing members for sealing the interface between the tubular sleeve and
at least one of the
tubular members. In an exemplary embodiment, the method further includes
placing the tubular
members in another structure, and displacing the expansion cone through the
interiors of the first and
second tubular members. In an exemplary embodiment, the other structure
comprises a wellbore. In
an exemplary embodiment, the other structure comprises a wellbore casing. In
an exemplary
embodiment, the tubular sleeve is metallic. In an exemplary embodiment, the
tubular sleeve is non-
metallic. In an exemplary embodiment, the tubulax sleeve is plastic. In an
exemplary embodiment, the
tubular sleeve is ceramic. In an exemplary embodiment, the method further
includes breaking the
tubular sleeve. In an exemplary embodiment, the tubular sleeve includes one or
more longitudinal
slots. In an exemplary embodiment, the tubular sleeve includes one or more
radial passages.
[00193] A method of radially expanding and plastically deforming a first
tubular member and a
second tubular member has also been described that includes inserting an end
of the first tubular
member into an end of a tubular sleeve having an internal flange into abutment
with the internal flange,
inserting an end of the second tubular member into another end of the tubular
sleeve into abutment
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
with the internal flange, coupling the ends of the first and second tubular
member to the tubular sleeve,
and displacing an expansion cone through the interiors of the first and second
tubular members. In an
exemplary embodiment, the internal flange of the tubular sleeve is positioned
between the ends of the
tubular sleeve. In an exemplary embodiment, the internal flange of the tubular
sleeve is positioned at
one end of the tubular sleeve. In an exemplary embodiment, the tubular sleeve
further comprises one
or more sealing members for sealing the interface between the tubular sleeve
and at least one of the
tubular members. In an exemplary embodiment, the method further includes
placing the tubular
members in another structure, and displacing the expansion cone through the
interiors of the first and
second tubular members. In an exemplary embodiment, the method further
includes radially
expanding the tubular sleeve into engagement with the structure. In an
exemplary embodiment, the
method further includes sealing an annulus between the tubular sleeve and the
other structure. In an
exemplary embodiment, the other structure is a wellbore. In an exemplary
embodiment, the other
structure is a wellbore casing. In an exemplary embodiment, the tubular sleeve
further includes a
sealing element coupled to the exterior of the tubular sleeve. In an exemplary
embodiment, the tubular
sleeve is metallic. In an exemplary embodiment, the tubular sleeve is non-
metallic. In an exemplary
embodiment, the tubular sleeve is plastic. In an exemplary embodiment, the
tubular sleeve is ceramic.
In an exemplary embodiment, the method further includes breaking the tubular
sleeve. In an
exemplary embodiment, the tubular sleeve includes one or more longitudinal
slots. In an exemplary
embodiment, the tubular sleeve includes one or more radial passages. In an
exemplary embodiment,
coupling the ends of the first and second tubular member to the tubular sleeve
includes heating the
tubular sleeve and inserting the ends of the first and second tubular members
into the tubular sleeve. In
an exemplary embodiment, coupling the ends of the first and second tubular
member to the tubular
sleeve includes coupling the tubular sleeve to the ends of the first and
second tubular members using a
locking ring.
[00194] A method has been described that includes coupling an end of a first
tubular member to an
end of a tubular sleeve, coupling an end of a second tubular member to another
end of the tubular
sleeve, coupling the ends of the first and second tubular members, and
radially expanding and
plastically deforming the first tubular member and the second tubular member.
In an exemplary
embodiment, the tubular sleeve includes an internal flange. In an exemplary
embodiment, coupling the
end of the first tubular member to the end of the tubular sleeve includes
inserting the end of the first
tubular member into the end of the tubular sleeve into abutment with the
internal flange. In an
exemplary embodiment, coupling the end of the second tubular member to the
other end of the tubular
sleeve includes inserting the end of the second tubular member into the other
end of the tubular sleeve
into abutment with the internal flange. In an exemplary embodiment, coupling
the end of the second
tubular member to the other end of the tubular sleeve includes inserting the
end of the second tubular
member into the other end of the tubular sleeve into abutment with the
internal flange. In an
46
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
exemplary embodiment, the tubular sleeve includes an external flange. In an
exemplary embodiment,
coupling the end of the first tubular member to the end of the tubular sleeve
includes inserting the end
of the tubular sleeve into the end of the first tubular member until the end
of the first tubular member
abuts the external flange. In an exemplary embodiment, coupling the end of the
second tubular
member to the other end of the tubular sleeve includes inserting the other end
of the tubular sleeve into
the end of the second tubular member until the end of the second tubular
member abuts the external
flange. In an exemplary embodiment, coupling the end of the second tubular
member to the other end
of the tubular sleeve includes inserting the other end of the tubular sleeve
into the end of the second
tubular member until the end of the second tubular member abuts the external
flange. In an exemplary
embodiment, coupling the end of the first tubular member to the end of the
tubular sleeve includes
inserting a retaining ring between the end of the first tubular member and the
end of the tubular sleeve.
In an exemplary embodiment, coupling the end of the second tubular member to
the other end of the
tubular sleeve includes inserting another retaining ring between the end of
the second tubular member
and the other end of the tubular sleeve. In an exemplary embodiment, coupling
the end of the second
tubular member to the other end of the tubular sleeve includes inserting a
retaining ring between the
end of the first tubular member and the other end of the tubular sleeve. In an
exemplary embodiment,
the retaining ring is resilient. In an exemplary embodiment, the retaining
ring and the other retaining
ring are resilient. In an exemplary embodiment, the retaining ring is
resilient. In an exemplary
embodiment, coupling the end of the first tubular member to the end of the
tubular sleeve includes
deforming the end of the tubular sleeve. In an exemplary embodiment, coupling
the end of the second
tubular member to the other end of the tubular sleeve includes deforming the
other end of the tubular
sleeve. In an exemplary embodiment, coupling the end of the second tubular
member to the other end
of the tubular sleeve includes deforming the other end of the tubular sleeve.
In an exemplary
embodiment, coupling the end of the first tubular member to the end of the
tubular sleeve includes
coupling a retaining ring to the end of the first tubular member. In an
exemplary embodiment,
coupling the end of the second tubular member to the other end of the tubular
sleeve includes coupling
another retaining ring to the end of the second tubular member. In an
exemplary embodiment,
coupling the end of the second tubular member to the other end of the tubular
sleeve includes coupling
a retaining ring to the end of the second tubular member. In an exemplary
embodiment, the retaining
ring is resilient. In an exemplary embodiment, the retaining ring and the
other retaining ring are
resilient. In an exemplary embodiment, the retaining ring is resilient. In an
exemplary embodiment,
coupling the end of the first tubular member to the end of the tubular sleeve
includes heating the end of
the tubular sleeve, and inserting the end of the first tubular member into the
end of the tubular sleeve.
In an exemplary embodiment, coupling the end of the second tubular member to
the other end of the
tubular sleeve includes heating the other end of the tubular sleeve, and
inserting the end of the second
tubular member into the other end of the tubular sleeve. In an exemplary
embodiment, coupling the
47
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
end of the second tubular member to the other end of the tubular sleeve
includes heating the other end
of the tubular sleeve, and inserting the end of the second tubular member into
the other end of the
tubular sleeve. In an exemplary embodiment, coupling the end of the first
tubular member to the end
of the tubular sleeve includes inserting the end of the first tubular member
into the end of the tubular
sleeve, and latching the end of the first tubular member to the end of the
tubular sleeve. In an
exemplary embodiment, coupling the end of the second tubular member to the
other end of the tubular
sleeve includes inserting the end of the second tubular member into the end of
the tubular sleeve, and
latching the end of the second tubular member to the other end of the tubular
sleeve. In an exemplary
embodiment, coupling the end of the second tubular member to the other end of
the tubular sleeve
includes inserting the end of the second tubular member into the end of the
tubular sleeve, and latching
the end of the second tubular member to the other end of the tubular sleeve.
In an exemplary
embodiment, the tubular sleeve further comprises one or more sealing members
for sealing the
interface between the tubular sleeve and at least one of the tubular members.
In an exemplary
embodiment, the method further includes placing the tubular members in another
structure, and then
radially expanding and plastically deforming the first tubular member and the
second tubular member.
In an exemplary embodiment, the method further includes radially expanding the
tubular sleeve into
engagement with the structure. In an exemplary embodiment, the method further
includes sealing an
annulus between the tubular sleeve and the other structure. In an exemplary
embodiment, the other
structure is a wellbore. In an exemplary embodiment, the other structure is a
wellbore casing. In an
exemplary embodiment, the tubular sleeve further includes a sealing element
coupled to the exterior of
the tubular sleeve. In an exemplary embodiment, the tubular sleeve is
metallic. In an exemplary
embodiment, the tubular sleeve is non-metallic. In an exemplary embodiment,
the tubular sleeve is
plastic. In an exemplary embodiment, the tubular sleeve is ceramic. In an
exemplary embodiment, the
method further includes breaking the tubular sleeve. In an exemplary
embodiment, the tubular sleeve
includes one or more longitudinal slots. In an exemplary embodiment, the
tubular sleeve includes one
or more radial passages. In an exemplary embodiment, radially expanding and
plastically deforming
the first tubular member, the second tubular member, and the tubular sleeve
includes displacing an
expansion cone within and relative to the first and second tubular members. In
an exemplary
embodiment, radially expanding and plastically deforming the first tubular
member, the second tubular
member, and the tubular sleeve includes applying radial pressure to the
interior surfaces of the first and
second tubular member using a rotating member. In an exemplary embodiment, the
method further
includes amorphously bonding the first and second tubular members during the
radial expansion and
plastic deformation of the first and second tubular members. In an exemplary
embodiment, the method
further includes welding the first and second tubular members during the
radial expansion and plastic
deformation of the first and second tubular members. In an exemplary
embodiment, the method further
includes providing a fluid tight seal within the threaded coupling between the
first and second tubular
48
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
members during the radial expansion and plastic deformation of the first and
second tubular members.
In an exemplary embodiment, the method further includes placing the tubular
sleeve in circumferential
tension, placing the end of the first tubular member in circumferential
compression, and placing the
end of the second tubular member in circumferential compression. In an
exemplary embodiment, the
method further includes placing the tubular sleeve in circumferential
compression, placing the end of
the first tubular member in circumferential tension, and placing the end of
the second tubular member
in circumferential tension. In an exemplary embodiment, radially expanding and
plastically deforming
the first tubular member and the second tubular member includes radially
expanding and plastically
deforming only the portions of the first and second members proximate the
tubular sleeve. In an
exemplary embodiment, the method further includes providing a fluid tight seal
between the tubular
sleeve and at least one of the first and second tubular members. In an
exemplary embodiment, the first
tubular member includes internal threads, and the second tubular member
includes external threads that
engage the internal threads of the first tubular member. In an exemplary
embodiment, radially
expanding and plastically deforming the first tubular member and the second
tubular member includes
radially expanding and plastically deforming only the portions of the first
and second members
proximate the threads of the first and second tubular members. In an exemplary
embodiment, the
method further includes providing a fluid tight seal between the threads of
the first and second tubular
members. In an exemplary embodiment, the method further includes providing a
fluid tight seal
between the tubular sleeve and at least one of the first and second tubular
members. In an exemplary
embodiment, the first and second tubular members are wellbore casings. In an
exemplary embodiment,
the first and second tubular members are pipes.
[00195] A method has been described that includes providing a tubular sleeve
including an internal
flange positioned between the ends of the tubular sleeve, inserting an end of
a first tubular member into
an end of the tubular sleeve into abutment with the internal flange, inserting
an end of a second tubular
member into another end of the tubular sleeve into abutment the internal
flange, threadably coupling
the ends of the first and second tubular members, radially expanding and
plastically deforming the first
tubular member and the second tubular member, placing the tubular sleeve in
circumferential tension,
placing the end of the first tubular member in circumferential compression,
and placing the end of the
second tubular member in circumferential compression.
[00196] A method has been described that includes providing a tubular sleeve
including an
external flange positioned between the ends of the tubular sleeve, inserting
an end of the tubular sleeve
into an end of a first tubular member until the end of the first tubular
member abuts with the external
flange, inserting another end of the tubular sleeve into an end of the second
tubular member until the
end of the second tubular member abuts the external flange, threadably
coupling the ends of the first .
and second tubular members, radially expanding and plastically deforming the
first tubular member
and the second tubular member, placing the tubular sleeve in circumferential
compression, placing the
49
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
end of the first tubular member in circumferential tension, and placing the
end of the second tubular
member in circumferential tension.
[00197] A method has been described that includes providing a tubular sleeve
including an internal
flange positioned between the ends of the tubular sleeve, inserting an end of
a first tubular member into
an end of the tubular sleeve into abutment with the internal flange, inserting
an end of a second tubular
member into another end of the tubular sleeve into abutment the internal
flange, threadably coupling
the ends of the first and second tubular members, radially expanding and
plastically deforming only the
portions of the first tubular member and the second tubular member proximate
the threads of the first
and second tubular members, placing the tubular sleeve in circumferential
tension, placing the end of
the first tubular member in circumferential compression, and placing the end
of the second tubular
member in circumferential compression.
[00198] A method has been described that includes providing a tubular sleeve
including an
external flange positioned between the ends of the tubular sleeve, inserting
an end of the tubular sleeve
into an end of a first tubular member until the end of the first tubular
member abuts with the external
flange, inserting another end of the tubular sleeve into an end of the second
tubular member until the
end of the second tubular member abuts the external flange, threadably
coupling the ends of the first
and second tubular members, radially expanding and plastically deforming only
the portions of the first
tubular member and the second tubular member proximate the threads of the
first and second tubular
members, placing the tubular sleeve in circumferential compression, placing
the end of the first tubular
member in circumferential tension, and placing the end of the second tubular
member in
circumferential tension.
[00199] An apparatus has been described that includes a tubular sleeve, a
first tubular member
coupled to an end of the tubular sleeve, and a second tubular member coupled
to another end of the
tubular sleeve. In an exemplary embodiment, the tubular sleeve is in
circumferential tension, the end
portion of the first tubular member is in circumferential compression, and the
end portion of the second
tubular member is in circumferential compression. In an exemplary embodiment,
the tubular sleeve is
in circumferential compression, the end portion of the first tubular member is
in circumferential
tension, and the end portion of the second tubular member is in
circumferential tension. In an
exemplary embodiment, the tubular sleeve includes an internal flange. In an
exemplary embodiment,
the end portion of the first tubular member is received within an end of the
tubular sleeve, and the end
portion of the second tubular member is received within another end of the
tubular sleeve. In an
exemplary embodiment, the end portions of the first and second tubular members
abut the internal
flange of the tubular sleeve. In an exemplary embodiment, the end portion of
the first tubular member
is received within an end of the tubular sleeve. In an exemplary embodiment,
the end portions of the
first and second tubular members abut the internal flange of the tubular
sleeve. In an exemplary
embodiment, the end portion of the second tubular member is received within an
end of the tubular
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
sleeve. In an exemplary embodiment, the end portions of the first and second
tubular members abut
the internal flange of the tubular sleeve. In an exemplary embodiment, the
internal flange of the
tubular sleeve is positioned between the ends of the tubular sleeve. In an
exemplary embodiment, the
internal flange of the tubular sleeve is positioned at an end of the tubular
sleeve. In an exemplary
embodiment, the tubular sleeve includes an external flange. In an exemplary
embodiment, an end
portion of the tubular sleeve is received within the first tubular member; and
another end portion of the
tubular sleeve is received within the end portion of the second tubular
member. In an exemplary
embodiment, the end portions of the first and second tubular members abut the
external flange of the
tubular sleeve. In an exemplary embodiment, an end portion of the tubular
sleeve is received within
the end portion of the first tubular member. In an exemplary embodiment, the
end portions of the first
and second tubular members abut the external flange of the tubular sleeve. In
an exemplary
embodiment, an end portion of the tubular sleeve is received within the end
portion of the second
tubular member. In an exemplary embodiment, the end portions of the first and
second tubular
members abut the external flange of the tubular sleeve. In an exemplary
embodiment, the external
flange of the tubular sleeve is positioned between the ends of the tubular
sleeve. In an exemplary
embodiment, the external flange of the tubular sleeve is positioned at an end
of the tubular sleeve. In
an exemplary embodiment, the tubular sleeve further comprises one or more
sealing members for
sealing the interface between the tubular sleeve and at least one of the
tubular members. In an
exemplary embodiment, the apparatus further includes a retaining ring
positioned between the end of
the first tubular member and the end of the tubular sleeve. In an exemplary
embodiment, the apparatus
further includes another retaining ring positioned between the end of the
second tubular member and
the other end of the tubular sleeve. In an exemplary embodiment, the apparatus
further includes a
retaining ring positioned between the end of the first tubular member and the
other end of the tubular
sleeve. In an exemplary embodiment, the retaining ring is resilient. In an
exemplary embodiment, the
retaining ring and the other retaining ring are resilient. In an exemplary
embodiment, the retaining ring
is resilient. In an exemplary embodiment, the end of the tubular sleeve is
deformed onto the end of the
first tubular member. In an exemplary embodiment, the other end of the tubular
sleeve is deformed
onto the end of the second tubular member. In an exemplary embodiment, the
other end of the tubular
sleeve is deformed onto the end of the second tubular member. In an exemplary
embodiment, the
apparatus further includes a retaining ring coupled to the end of the first
tubular member for retaining
the tubular sleeve onto the end of the first tubular member. In an exemplary
embodiment, the
apparatus further includes another retaining ring coupled to the end of the
second tubular member for
retaining the other end of the tubular sleeve onto the end of the second
tubular member. In an
exemplary embodiment, the apparatus further includes a retaining ring coupled
to the end of the second
tubular member for retaining the other end of the tubular sleeve onto the end
of the second tubular
member. In an exemplary embodiment, the retaining ring is resilient. In an
exemplary embodiment,
51
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
the retaining ring and the other retaining ring are resilient. In an exemplary
embodiment, the retaining
ring is resilient. In an exemplary embodiment, the apparatus further includes
a locking ring for
coupling the end of the first tubular member to the end of the tubular sleeve.
In an exemplary
embodiment, the apparatus further includes another locking ring for coupling
the end of the second
tubular member to the other end of the tubular sleeve. In an exemplary
embodiment, the apparatus
further includes a locking ring for coupling the end of the second tubular
member to the other end of
the tubular sleeve. In an exemplary embodiment, the apparatus further includes
a structure for
receiving the first and second tubular members and the tubular sleeve, and the
tubular sleeve contacts
the interior surface of the structure. In an exemplary embodiment, the tubular
sleeve further includes a
sealing member for fluidicly sealing the interface between the tubular sleeve
and the structure. In an
exemplary embodiment, the other structure is a wellbore. In an exemplary
embodiment, the other
structure is a wellbore casing. In an exemplary embodiment, the tubular sleeve
further includes a
sealing element coupled to the exterior surface of the tubular sleeve. In an
exemplary embodiment, the
tubular sleeve is metallic. In an exemplary embodiment, the tubular sleeve is
non-metallic. In an
exemplary embodiment, the tubular sleeve is plastic. In an exemplary
embodiment, the tubular sleeve
is ceramic. In an exemplary embodiment, the tubular sleeve is frangible. In an
exemplary
embodiment, the tubular sleeve includes one or more longitudinal slots. In an
exemplary embodiment,
the tubular sleeve includes one or more radial passages. In an exemplary
embodiment, the first and
second tubular members are amorphously bonded. In an exemplary embodiment, the
first and second
tubular members are welded. In an exemplary embodiment, the internal threads
of the first tubular
member and the internal threads of the second tubular member together provide
a fluid tight seal. In an
exemplary embodiment, only the portions of the first and second tubular
members proximate the
tubular sleeve are plastically deformed. In an exemplary embodiment, a fluid
tight seal is provided
between the tubular sleeve and at least one of the first and second tubular
members. In an exemplary
embodiment, the first tubular member includes internal threads; and wherein
the second tubular
member includes external threads that engage the internal threads of the first
tubular member. In an
exemplary embodiment, only the portions of the first and second members
proximate the threads of the
first and second tubular members are plastically deformed. In an exemplary
embodiment, a fluid tight
seal is provided between the threads of the first and second tubular members.
In an exemplary
embodiment, a fluid tight seal is provided between the tubular sleeve and at
least one of the first and
second tubular members.
[00200] An apparatus has been described that includes a tubular sleeve
including an internal flange
positioned between the ends of the tubular sleeve, a first tubular member
received within an end of the
tubular sleeve in abutment with the internal flange that comprises internal
threads, and a second tubular
member received within another end of the tubular sleeve in abutment with the
internal flange that
comprises external threads that engage the internal threads of the first
tubular member. The tubular
52
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
sleeve is in circumferential tension, the end of first tubular member is in
circumferential compression,
and the end of the second tubular member is in circumferential compression.
[00201] An apparatus has been described that includes a tubular sleeve
comprising an external
flange positioned between the ends of the tubular sleeve, a first tubular
member that receives an end of
the tubular sleeve and abuts the external flange that comprises internal
threads, and a second tubular
member that receives another end of the tubular sleeve that abuts the external
flange that comprises
external threads that engage the internal threads of the first tubular member.
The tubular sleeve is in
circumferential compression, the first tubular member is in circumferential
tension, and the second
tubular member is in circumferential tension.
[00202] An apparatus has been described that includes a tubular sleeve
comprising an internal
flange positioned between the ends of the tubular sleeve, a first tubular
member received within an end
of the tubular sleeve in abutment with the internal flange that comprises
internal threads, and a second
tubular member received within another end of the tubular sleeve in abutment
with the internal flange
that comprises external threads that engage the internal threads of the first
tubular member. The
tubular sleeve is in circumferential tension, the end of first tubular member
is in circumferential
compression, the end of the second tubular member is in circumferential
compression, a fluid tight seal
is provided between the tubular sleeve and at least one of the first and
second tubular members, and a
fluid tight seal is provided between the threads of the first and second
tubular members.
[00203] An apparatus has been described that includes a tubular sleeve
comprising an external
flange positioned between the ends of the tubular sleeve, a first tubular
member that receives an end of
the tubular sleeve and abuts the external flange that comprises internal
threads, and a second tubular
member that receives another end of the tubular sleeve that abuts the external
flange that comprises
external threads that engage the internal threads of the first tubular member.
The tubular sleeve is in
circumferential compression, the first tubular member is in circumferential
tension, the second tubular
member is in circumferential tension, a fluid tight seal is provided between
the tubular sleeve and at
least one of the first and second tubular members, and a fluid tight seal is
provided between the threads
of the first and second tubular members.
[00204] A method of extracting geothermal energy from a subterranean source of
geothermal
energy has been described that includes drilling a borehole that traverses the
subterranean source of
geothermal energy, positioning a first casing string within the borehole,
radially expanding and
plastically deforming the first casing string within the borehole, positioning
a second casing string
within the borehole that traverses the subterranean source of geothermal
energy, overlapping a portion
of the second casing string with a portion of the first casing string,
radially expanding and plastically
deforming the second casing string within the borehole, and extracting
geothermal energy from the
subterranean source of geothermal energy using the first and second casing
strings. In an exemplary
embodiment, the interior diameter of a passage defined by the first and second
casing strings is
53
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
constant. In an exemplary embodiment, at least one of the first and second
casing strings includes a
tubular sleeve, a first tubular member coupled to an end of the tubular sleeve
comprising internal
threads at an end portion, and a second tubular member coupled to another end
of the tubular sleeve
comprising external threads at an end portion that engage the internal threads
of the end portion of the
first tubular member.
[00205] A method of extracting geothermal energy from a subterranean source of
geothermal
energy has been described that includes drilling a borehole that traverses the
subterranean source of
geothermal energy, positioning a first casing string within the borehole,
radially expanding and
plastically deforming the first casing string within the borehole, positioning
a second casing string
within the borehole that traverses the subterranean source of geothermal
energy, overlapping a portion
of the second casing string with a portion of the first casing string,
radially expanding and plastically
deforming the second casing string within the borehole, and extracting
geothermal energy from the
subterranean source of geothermal energy using the first and second casing
strings. the interior
diameter of a passage defined by the first and second casing strings is
constant, and at least one of the
first and second casing strings includes a tubular sleeve comprising an
internal flange positioned
between the ends of the tubular sleeve, a first tubular member received within
an end of the tubular
sleeve in abutment with the internal flange that comprises internal threads,
and a second tubular
member received within another end of the tubular sleeve in abutment with the
internal flange that
comprises external threads that engage the internal threads of the first
tubular member.
[00206] A method of extracting geothermal energy from a subterranean source of
geothermal
energy has been described that includes drilling a borehole that traverses the
subterranean source of
geothermal energy, positioning a first casing string within the borehole,
radially expanding and
plastically deforming the first casing string within the borehole, positioning
a second casing string
within the borehole that traverses the subterranean source of geothermal
energy, overlapping a portion
of the second casing string with a portion of the first casing string,
radially expanding and plastically
deforming the second casing string within the borehole, and extracting
geothermal energy from the
subterranean source of geothermal energy using the first and second casing
strings. The interior
diameter of a passage defined by the first and second casing strings is
constant, and at least one of the
first and second casing strings include: a tubular sleeve comprising an
external flange positioned
between the ends of the tubular sleeve, a first tubular member that receives
an end of the tubular sleeve
that abuts external flange that comprises internal threads, and a second
tubular member that receives
another end of the tubular sleeve that abuts the external flange that
comprises external threads that
engage the internal threads of the first tubular member.
[00207] A method of extracting geothermal energy from a subterranean source of
geothermal
energy has been described that includes drilling a borehole that traverses the
subterranean source of
geothermal energy, positioning a first casing string within the borehole,
radially expanding and
54
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
plastically deforming the first casing string within the borehole, positioning
a second casing string
within the borehole that traverses the subterranean source of geothermal
energy, overlapping a portion
of the second casing string with a portion of the first casing string,
radially expanding and plastically
deforming the second casing string within the borehole, and extracting
geothermal energy from the
subterranean source of geothermal energy using the first and second casing
strings. The interior
diameter of a passage defined by the first and second casing strings is
constant, and at least one of the
first and second casing strings include a tubular sleeve comprising an
internal flange positioned
between the ends of the tubular sleeve, a first tubular member received within
an end of the tubular
sleeve in abutment with the internal flange that comprises internal threads,
and a second tubular
member received within another end of the tubular sleeve in abutment with the
internal flange that
comprises external threads that engage the internal threads of the first
tubular member. The tubular
sleeve is in circumferential tension, the first tubular member is in
circumferential compression, the
second tubular member is in circumferential compression, a fluid tight seal is
provided between the
tubular sleeve and at least one of the first and second tubular members, and a
fluid tight seal is
provided between the threads of the first and second tubular members.
[00208] A method of extracting geothermal energy from a subterranean source of
geothermal
energy has been described that includes drilling a borehole that traverses the
subterranean source of
geothermal energy, positioning a first casing string within the borehole,
radially expanding and
plastically deforming the first casing string within the borehole, positioning
a second casing string
within the borehole that traverses the subterranean source of geothermal
energy, overlapping a portion
of the second casing string with a portion of the first casing string,
radially expanding and plastically
deforming the second casing string within the borehole, and extracting
geothermal energy from the
subterranean source of geothermal energy using the first and second casing
strings. The interior
diameter of a passage defined by the first and second casing strings is
constant, and wherein at least
one of the first and second casing strings include a tubular sleeve comprising
an external flange
positioned between the ends of the tubular sleeve, a first tubular member that
receives an end of the
tubular sleeve that abuts external flange that comprises internal threads, and
a second tubular member
that receives another end of the tubular sleeve that abuts the external flange
that comprises external
threads that engage the internal threads of the first tubular member. The
tubular sleeve is in
circumferential compression, the first tubular member is in circumferential
tension, the second tubular
member is in circumferential tension, a fluid tight seal is provided between
the tubular sleeve and at
least one of the first and second tubular members, and a fluid tight seal is
provided between the threads
of the first and second tubular members.
[00209] An apparatus for extracting geothermal energy from a subterranean
source of geothermal
energy has been described that includes a borehole that traverses the
subterranean source of geothermal
energy, a first casing string positioned within the borehole, and a second
casing positioned within the
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
borehole that overlaps with the first casing string that traverses the
subterranean source of geothermal
energy. The first casing string and the second casing string are radially
expanded and plastically
deformed within the borehole. In an exemplary embodiment, the interior
diameter of a passage defined
by the first and second casing strings is constant. In an exemplary
embodiment, at least one of the first
and second casing strings include a tubular sleeve, a first tubular member
coupled to an end of the
tubular sleeve comprising internal threads at an end portion, and a second
tubular member coupled to
another end of the tubular sleeve comprising external threads at an end
portion that engage the internal
threads of the end portion of the first tubular member.
[00210] An apparatus for extracting geothermal energy from a subterranean
source of geothermal
energy has been described that includes a borehole that traverses the
subterranean source of geothermal
energy, a first casing string positioned within the borehole, a second casing
string within the borehole
that traverses the subterranean source of geothermal energy that overlaps with
the first casing string.
The first and second casing strings are radially expanded and plastically
deformed within the borehole,
the inside diameter of a passage defined by the first and second casing
strings is constant, and at least
one of the first and second casing strings includes a tubular sleeve
comprising an internal flange
positioned between the ends of the tubular sleeve, a first tubular member
received within an end of the
tubular sleeve in abutment with the internal flange that comprises internal
threads, and a second tubular
member received within another end of the tubular sleeve in abutment with the
internal flange that
comprises external threads that engage the internal threads of the first
tubular member.
[00211] An apparatus for extracting geothermal energy from a subterranean
source of geothermal
energy has been described a borehole that traverses the subterranean source of
geothermal energy, a
first casing string positioned within the borehole, and a second casing string
positioned within the
borehole that traverses the subterranean source of geothermal energy that
overlaps with the first casing
string. The interior diameter of a passage defined by the first and second
casing strings is constant, and
wherein at least one of the first and second casing strings include: a tubular
sleeve comprising an
external flange positioned between the ends of the tubular sleeve, a first
tubular member that receives
an end of the tubular sleeve that abuts external flange that comprises
internal threads, and a second
tubular member that receives another end of the tubular sleeve that abuts the
external flange that
comprises external threads that engage the internal threads of the first
tubular member.
[00212] An apparatus for extracting geothermal energy from a subterranean
source of geothermal
energy has been described that includes a borehole that traverses the
subterranean source of geothermal
energy, a first casing string positioned within the borehole, and a second
casing string within the
borehole that traverses the subterranean source of geothermal energy that
overlaps with the first casing
string. The first and second casing strings are radially expanded and
plastically deformed within the
borehole. The inside diameter of a passage defined by the first and second
casing strings is constant,
and at least one of the first and second casing strings include: a tubular
sleeve comprising an internal
56
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
flange positioned between the ends of the tubular sleeve, a first tubular
member received within an end
of the tubular sleeve in abutment with the internal flange that comprises
internal threads, a second
tubular member received within another end of the tubular sleeve in abutment
with the internal flange
that comprises external threads that engage the internal threads of the first
tubular member, the tubular
sleeve is in circumferential tension, the first tubular member is in
circumferential compression, the
second tubular member is in circumferential compression, a fluid tight seal is
provided between the
tubular sleeve and at least one of the first and second tubular members, and a
fluid tight seal is
provided between the threads of the first and second tubular members.
[00213] An apparatus for extracting geothermal energy from a subterranean
source of geothermal
energy has been described that includes a borehole that traverses the
subteiTanean source of geothermal
energy, a first casing string positioned within the borehole, and a second
casing string positioned
within the borehole that traverses the subterranean source of geothermal
energy that overlaps with the
first casing string. The interior diameter of a passage defined by the first
and second casing strings is
constant, and at least one of the first and second casing strings include: a
tubular sleeve comprising an
external flange positioned between the ends of the tubular sleeve, a first
tubular member that receives
an end of the tubular sleeve that abuts external flange that comprises
internal threads, and a second
tubular member that receives another end of the tubular sleeve that abuts the
external flange that
comprises external threads that engage the internal threads of the first
tubular member. The tubular
sleeve is in circumferential compression, the first tubular member is in
circumferential tension, the
second tubular member is in circumferential tension, a fluid tight seal is
provided between the tubular
sleeve and at least one of the first and second tubular members, and a fluid
tight seal is provided
between the threads of the first and second tubular members.
[00214] A method has been described that includes coupling an end of a first
tubular member to an
end of a tubular sleeve, coupling an end of a second tubular member to another
end of the tubular
sleeve, coupling the ends of the first and second tubular members, injecting a
pressurized fluid through
the first and second tubular members, determining if any of the pressurized
fluid leaks through the
coupled ends of the first and second tubular members, and if a predetermined
amount of the
pressurized fluid leaks through the coupled ends of the first and second
tubular members, then
coupling a tubular sleeve to the ends of the first and second tubular members
and radially expanding
and plastically deforming only the portions of the first and second tubular
members proximate the
tubular sleeve. In an exemplary embodiment, radially expanding and plastically
deforming only the
portions of the first and second tubular members proximate the tubular sleeve
includes displacing an
expansion cone within and relative to the first and second tubular members. In
an exemplary
embodiment, radially expanding and plastically deforming only the portions of
the first and second
tubular members proximate the tubular sleeve includes applying radial pressure
to the interior surfaces
of the first and second tubular member proximate the tubular sleeve using a
rotating member.
57
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
[00215] A method has been described that includes coupling an end of a first
tubular member to an
end of a tubular sleeve, coupling an end of a second tubular member to another
end of the tubular
sleeve, coupling the ends of the first and second tubular members, radially
expanding and plastically
deforming the first tubular member and the second tubular member, and
transmitting energy through
the first and second tubular members. In an exemplary embodiment, the energy
is electrical energy. In
an exemplary embodiment, the electrical energy is a communication signal. In
an exemplary
embodiment, the energy is thermal energy. In an exemplary embodiment, the
energy is acoustic
energy. In an exemplary embodiment, the energy is transmitted through the
first and second tubular
members prior to radially expanding and plastically deforming the first and
second tubular members.
In an exemplary embodiment, the energy is transmitted through the first and
second tubular members
after radially expanding and plastically deforming the first and second
tubular members. In an
exemplary embodiment, the method further includes placing the tubular members
in another structure,
then radially expanding the tubular members, and transmitting energy through
the first and second
tubular members.
[00216] A system has been described that includes a source of energy, a
borehole formed in the
earth, a first tubular member positioned within the borehole operably coupled
to the source of energy, a
second tubular member positioned within the borehole coupled to the first
tubular member, and a
tubular sleeve positioned within the borehole coupled to the first and second
tubular members. The
first tubular member, second tubular member, and the tubular sleeve are
plastically deformed into
engagement with one another. In an exemplary embodiment, the source of energy
is a source of
electrical energy. In an exemplary embodiment, the source of energy is a
source of thermal energy. In
an exemplary embodiment, the source of energy is a source of acoustic energy.
[00217] A method of operating a well for extracting hydrocarbons from a
subterranean formation
has been described that includes drilling a borehole into the earth that
traverses the subterranean
formation, positioning a wellbore casing in the borehole, transmitting energy
through the wellbore
casing, and extracting hydrocarbons from the subterranean formation. The
wellbore casing includes a
first tubular member, a second tubular member coupled to the first tubular
member, and a tubular
sleeve coupled to the first and second tubular member. The first tubular
member, the second tubular
member, and the tubular sleeve are plastically deformed into engagement with
one another. In an
exemplary embodiment, the energy is electrical energy. In an exemplary
embodiment, the energy is
thermal energy. In an exemplary embodiment, the energy is acoustic energy.
[00218] It is understood that variations may be made in the foregoing without
departing from the
scope of the invention. For example, the teachings of the present illustrative
embodiments may be
used to provide a wellbore casing, a pipeline, or a structural support.
Furthermore, the elements and
teachings of the various illustrative embodiments may be combined in whole or
in part in some or all of
the illustrative embodiments.
58
CA 02493086 2005-O1-19
WO 2004/010039 PCT/US2003/019993
[00219] Although illustrative embodiments of the invention have been shown and
described, a
wide range of modification, changes and substitution is contemplated in the
foregoing disclosure. W
some instances, some features of the present invention may be employed without
a corresponding use
of the other features. Accordingly, it is appropriate that the appended claims
be construed broadly and
in a manner consistent with the scope of the invention.
59
