Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS AND METHOD FOR RADIALLY EXPANDING A WELLBORE CASING
USING AN EXPANSION MANDREL AND A ROTARY EXPANSION TOOL
Cross Reference To Related Applications
[001] The present application claims the benefit of the filing date of U.S.
provisional patent
application serial no. 60/454,896, attorney docket no. 25791.236, filed on
March 14, 2003,
the disclosure of which is incorporated herein by reference.
[002] The present application is related to the following: (1 ) U.S. Patent
Number 6,497,289,
which was filed as U.S. Patent Application serial no. 09/454,139, attorney
docket no.
25791.03.02, filed on 12/3/1999, which claims priority from provisional
application
601111,293, filed on 12/7/98, (2) U.S. patent application serial no.
09/510,913, attorney
docket no. 25791.7.02, filed on 2/23/2000, which claims priority from
provisional application
60/121,702, filed on 2/25/99, (3) U.S. patent application serial no.
09/502,350, attorney
docket no. 25791.8.02, filed on 2/10/2000, which claims priority from
provisional~application
60/119,611, filed on 2/11/99, (4) U.S. patent no. 6,328,113, which was filed
as U.S. Patent
Application serial number 09/440,338, attorney docket number 25791.9.02, filed
on
11/15/99, which claims priority from provisional application 60/108,558, filed
on 11/16/98, (5)
U.S. patent application serial no. 10/169,4.34, atfiorney docket no.
25791.10.04., filed on
7/1/02, which claims priority from provisional application 60/183,546, filed
on 2/18/00, (6)
U.S. patent application serial no. 09/523,468, attorney docket no.
25791.11.02, filed on
3/10/2000, which claims priority from provisional application 60/124,042,
filed on 3/11/99, (7)
U.S. patent number 6,568,471, which was filed as patent application serial no.
09/512,895,
attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority
from provisional
application 60/121,841, filed on 2/26/99, (8) U.S. patent number 8,575,24.0,
evhich was filed
as patenfi application serial no. 09/511,941, attorney docket no. 25791.16.02,
filed on
2/24/2000, which claims priority from provisional application 60/121,907,
filed on 2/26199, (9)
U.S. patent number 6,557,640, which was filed as patent application serial no.
09/588,946,
attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from
provisional
application 60/137,998, filed on 6/7/99, (10) U.S. patent application serial
no. 09/981,916,
attorney docket no. 25791.18, filed on 10/18/01 as a continuation-in-part
application of U.S.
patent no. 6,328,113, which was filed as U.S. Patent Application serial number
09/440,338,
attorney docket number 25791.9.02, filed on 11/15/99, which claims priority
from provisional
application 60/108,558, filed on 11/16/98, (11) U.S. patent number 6,604,763,
which was
filed as application serial no. 09/559,122, attorney docket no. 25791.23.02,
filed on
4/26/2000, which claims priority from provisional application 60/131,106,
filed on 4/26/99,
(12) U.S. patent application serial no. 10/030,593, attorney docket no.
25791.25.08, filed on
1/8/02, which claims priority from provisional application 60/146,203, filed
on 7/29/99, (13)
U.S. provisional patent application serial no. 60/143,039, attorney docket no.
25791.26, filed
1
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on 7/9/99, (14) U.S. patent application serial no. 10/111,982, attorney docket
no.
25791.27.08, filed on 4/30/02, which claims priority from provisional patent
application serial
no. 60/162,671, attorney docket no. 25791.27, filed on 11/1/1999, (15) U.S.
provisional
patent application serial no. 60/154,047, attorney docket no. 25791.29, filed
on 9/16/1999,
(16) U.S. provisional patent application serial no. 60/438,828, attorney
docket no. 25791.31,
filed on 1/9/03, (17) U.S. patent number 6,564,875, which was filed as
application serial no.
09/679,907, attorney docket no. 25791.34.02, on 10/5/00, which claims priority
from
provisional patent application serial no. 60/159,082, attorney docket no.
25791.34, filed on
10/12/1999, (18) U.S. patent application serial no. 10/089,419, filed on
3/27/02, attorney
docket no. 25791.36.03, which claims priority from provisional patent
application serial no.
60/159,039, attorney docket no. 25791.36, filed on 10/12/1999, (19) U.S.
patent application
serial no. 091679,906, filed on 10/5/00, attorney docket no. 25791.37.02,
which claims
priority from provisional patent application serial no. 60/159,033, attorney
docket no.
25791.37, filed on 10/12/1999, (20) U.S. patent application serial no.
10/303,992, filed on
11/22/02, attorney docket no. 25791.38.07, which claims priority from
provisional patent
application serial no. 60/212,359, attorney docket no. 25791.38, filed on
6/19/2000, (21) U.S.
provisional patent application serial no. 60/165,228, attorney docket no.
25791.39, filed on
11/12/1999, (22) U.S. provisional patent application serial no. 60/455,051,
attorney docket
no. 25791.40, filed on 3/14/03, (23) PCT application US02/2477, filed on
6/26/02, attorney
docket no. 25791.44.02, which claims priority from U.S. provisional patent
application serial
no. 60/303,711, attorney docket no. 25791.44, filed on 7/6/01, (24) U.S.
patent application
serial no. 10/311,412, filed on 12/12/02, attorney docket no. 25791.45.07,
which claims
priority from provisional patent application serial no. 60/221,443, attorney
docket no.
25791.45, filed on 7/28/2000, (25) U.S. patent application serial no. 10/,
filed on 12/18/02,
attorney docket no. 25791.46.07, which claims priority from provisional patent
application
serial no. 60/221,645, attorney docket no. 25791.46, filed on 7/28/2000, (26)
U.S. patent
application serial no. 10/322,947, filed on 1/22/03, attorney docket no.
25791.47.03, which
claims priority from provisional patent application serial no. 60/233,638,
attorney docket no.
25791.47, filed on 9/18/2000, (27) U.S. patent application serial no.
10/406,648, filed on
3/31/03, attorney docket no. 25791.48.06, which claims priority from
provisional patent
application serial no. 60/237,334, attorney docket no. 25791.48, filed on
10/2/2000, (28) PCT
application US02/04353, filed on 2/14/02, attorney docket no. 25791.50.02,
which claims
priority from U.S. provisional patent application serial no. 60/270,007,
attorney docket no.
25791.50, filed on 2/20/2001, (29) U.S. patent application serial no.
10/465,835, filed on
6/13/03, attorney docket no. 25791.51.06, which claims priority from
provisional patent
application serial no. 60/262,434, attorney docket no. 25791.51, filed on
1/17/2001, (30) U.S.
patent application serial no. 10/465,831, filed on 6/13/03, attorney docket
no. 25791.52.06,
2
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which claims priority from U.S. provisional patent application serial no.
60/259,486, attorney
docket no. 25791.52, filed on 1/3/2001, (31) U.S. provisional patent
application serial no.
60/452,303, filed on 3/5/03, attorney docket no. 25791.53, (32) U.S. patent
number
6,470,966, which was filed as patent application serial number 09/850,093,
filed on 5/7/01,
attorney docket no. 25791.55, as a divisional application of U.S. Patent
Number 6,497,289,
which was filed as U.S. Patent Application serial no. 09/454,139, attorney
docket no.
25791.03.02, filed on 12/3/1999, which claims priority from provisional
application
60/111,293, filed on 12/7/98, (33) U.S. patent number 6,561,227, which was
filed as patent
application serial number 09/852,026 , filed on 5/9/01, attorney docket no.
25791.56, as a
divisional application of U.S. Patent Number 6,497,289, which was filed as
U.S. Patent
Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on
12/3/1999, which
claims priority from provisional application 60/111,293, filed on 12/7/98,
(34) U.S. patent
application serial number 09/852,027, filed on 5/9/01, attorney docket no.
25791.57, as a
divisional application of U.S. Patent Number 6,497,289, which was filed as
U.S. Patent
Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on
12/3/1999, which
claims priority from provisional application 60/111,293! filed on 12/7/98,
(35) PCT Application
US02125608, attorney docket no. 25791.58.02, filed on 8/13/02, which claims
priority from
provisional application 60/318,021, filed on 9/7/01, attorney docket no.
25791.58, (36) PCT
Application US02/24399, attorney docket no. 25791.59.02, filed on 8/1/02,
which claims
priority from U.S. provisional patent application serial no. 60/313,453,
attorney docket no.
25791.59, filed on 8/20/2001, (37) PCT Application US02/29856, attorney docket
no.
25791.60.02, filed on 9/19/02, which claims priority from U.S. provisional
patent application
serial no. 60/326,886, attorney docket no. 25791.60, filed on 10/3/2001, (38)
PCT
Application US02/20256, attorney docket no. 25791.61.02, filed on 6/26/02,
which claims
priority from U.S. provisional patent application serial no. 60/303,740,
attorney docket no.
25791.61, filed on 7/6/2001, (39) U.S. patent application serial no.
09/962,469, filed on
9/25/01, attorney docket no. 25791.62, which is a divisional of U.S. patent
application serial
no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which
claims priority
from provisional application 60/124,042, filed on 3/11/99, (40) U.S. patent
application serial
no. 09/962,470, filed on 9/25/01, attorney docket no. 25791.63, which is a
divisional of U.S.
patent application serial no. 09/523,468, attorney docket no. 25791.11.02,
filed on
3/10/2000, which claims priority from provisional application 60/124,042,
filed on 3/11/99,
(41) U.S. patent application serial no. 09/962,471, filed on 9/25/01, attorney
docket no.
25791.64, which is a divisional of U.S. patent application serial no.
091523,468, attorney
docket no. 25791.11.02, filed on 3/10/2000, which claims priority from
provisional application
60/124,042, filed on 3/11/99, (42) U.S, patent application serial no.
09/962,467, filed on
9/25/01, attorney docket no. 25791.65, which is a divisional of U.S. patent
application serial
3
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no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which
claims priority
from provisional application 60/124,042, filed on 3/11/99, (43) U.S. patent
application serial
no. 09/962,468, filed on 9/25/01, attorney docket no. 25791.66, which is a
divisional of U.S.
patent application serial no. 09/523,468, attorney docket no. 25791.11.02,
filed on
3/10/2000, which claims priority from provisional application 60/124,042,
filed on 3/11/99,
(44) PCT application US 02/25727, filed on 8/14/02, attorney docket no.
25791.67.03, which
claims priority from U.S. provisional patent application serial no.
60/317,985, attorney docket
no. 25791.67, filed on 9/6/2001, and U.S. provisional patent application
serial no.
60/318,386, attorney docket no. 25791.67.02, filed on 9/10/2001, (45) PCT
application US
02/39425, filed on 12/10/02, attorney docket no. 25791.68.02, which claims
priority from
U.S. provisional patent application serial no. 60/343,674 , attorney docket
no. 25791.68,
filed on 12/27/2001, (46) U.S. utility patent application serial no.
09/969,922, attorney docket
no. 25791.69, filed on 10/3/2001, which is a continuation-in-part application
of U.S. patent
no. 6,328,113, which was filed as U.S. Patent Application serial number
09/440,338,
attorney docket number 25791.9.02, filed on 11/15/99, which claims priority
from provisional
application 60/108,558, filed on 11/16/98, (47) U.S. utility patent
application serial no.
10/516,467, attorney doclcet no. 25791.70, filed on 12/10/01, which is a
continuation
application of U.S. utility patent application serial no. 09/969,922, attorney
docket no.
25791.69, filed on 10/3/2001, which is a continuation-in-park application of
U.S. patent no.
6,328,113, which was filed as U.S. Patent Application serial number
09/440,338, attorney
docket number 25791.9.02, filed on 11/15/99, which claims priority from
provisional
application 60/108,558, filed on 11/16/98, (48) PCT application US 03/00609,
filed on 1/9/03,
attorney docleet no. 25791.71.02, which claims priority from U.S. provisional
patent
application serial no. 60/357,372 , attorney docket no. 25791.71, filed on
2/15/02, (49) U.S.
patent application serial no. 10/074,703, attorney docket no. 25791.74, filed
on 2/12/02,
which is a divisional of U.S. patent number 6,568,471, which was filed as
patent application
serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000,
which claims
priority from provisional application 60/121,841, filed on 2/26/99, (50) U.S.
patent application
serial no. 10/074,244, attorney docket no. 25791.75, filed on 2/12/02, which
is a divisional of
U.S. patent number 6,568,471, which was filed as patent application serial no.
09/512,895,
attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority
from provisional
application 60/121,841, filed on 2/26/99, (51) U.S. patent application serial
no. 10/076,660,
attorney docket no. 25791.76, filed on 2/15/02, which is a divisional of U.S.
patent number
6,568,471, which was filed as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,841, filed on 2/26/99, (52) U.S. patent application serial no.
10/076,661, attorney
docket no. 25791.77, filed on 2/15/02, which is a divisional of U.S. patent
number
4
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6,568,471, which was filed as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,841, filed on 2/26/99, (53) U.S. patent application serial no.
10/076,659, attorney
docket no. 25791.78, filed on 2/15/02, which is a divisional of U.S. patent
number
6,568,471, which was filed as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,841, filed on 2/26/99, (54) U.S. patent application serial no.
10/078,928, attorney
docket no. 25791.79, filed on 2/20/02, which is a divisional of U.S. patent
number
6,568,471, which was filed as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,841, filed on 2/26/99, (55) U.S. patent application serial no.
10/078,922, attorney
docket no. 25791.80, filed on 2/20/02, which is a divisional of U.S. patent
number
6,568,471, which was filed as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,841, filed on 2/26/99, (56) U.S. patent application serial no.
10/078,921, attorney
docket no. 25791.81, filed on 2/20/02, which is a divisional of U.S. patent
number
6,568,471, which was filed as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,841, filed on 2/26/99, (57) U.S. patent application serial no.
10/261,928, attorney
docket no. 25791.82, filed on 10/1/02, which is a divisional of U.S. patent
number
6,557,640, which was filed as patent application serial no. 09/588,946,
attorney docket no.
25791.17.02, filed on 6/7/2000, which claims priority from provisional
application 60/137,998,
filed on 6/7/99, (58) U.S. patent application serial no. 10/079,276 , attorney
docket no.
25791.83, filed on 2/20/02, which is a divisional of U.S. patent number
6,568,471, which was
filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on
2124/2000, which claims priority from provisional application 60/121,841,
filed on 2/26/99,
(59) U.S. patent application serial no. 10/262,009, attorney docket no.
25791.84, filed on
10/1/02, which is a divisional of U.S. patent number 6,557,640, which was
filed as patent
application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on
6/7/2000, which
claims priority from provisional application 60/137,998, filed on 6/7/99, (60)
U.S. patent
application serial no. 10/092,481, attorney docket no. 25791.85, filed on
3/7/02, which is a
divisional of U.S. patent number 6,568,471, which was filed as patent
application serial no.
09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims
priority from
provisional application 60/121,841, filed on 2/26/99, (61) U.S. patent
application serial no.
10/261,926, attorney docket no. 25791.86, filed on 10/1/02, which is a
divisional of U.S.
patent number 6,557,640, which was filed as patent application serial no.
09/588,946,
attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from
provisional
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application 60/137,998, filed on 6/7/99, (62) PCT application US 02/36157,
filed on 11/12/02,
attorney docket no. 25791.87.02, which claims priority from U.S. provisional
patent
application serial no. 60/338,996, attorney docket no. 25791.87, filed on
11/12/01, (63) PCT
application US 02/36267, filed on 11/12/02, attorney docket no. 25791.88.02,
which claims
priority from U.S. provisional patent application serial no. 60/339,013,
attorney docket no.
25791.88, filed on 11/12/01, (64) PCT application US 03/11765, filed on
4/16/03, attorney
docket no. 25791.89.02, which claims priority from U.S. provisional patent
application serial
no. 60/383,917, attorney docket no. 25791.89, filed on 5/29/02, (65) PCT
application US
03/15020, filed on 5/12/03, attorney docket no. 25791.90.02, which claims
priority from U.S.
provisional patent application serial no. 60/391,703, attorney docket no.
25791.90, filed on
6/26/02, (66) PCT application US 02/39418, filed on 12/10/02, attorney docket
no.
25791.92.02, which claims priority from U.S. provisional patent application
serial no.
60/346,309, attorney docket no. 25791.92, filed on 1/7/02, (67) PCT
application US
03/06544, filed on 3/4/03, attorney docket no. 25791.93.02, which claims
priority from U.S.
provisional patent application serial no. 60/372,048, attorney docket no.
25791.93, filed on
4/12/02, (68) U.S. patent application serial no. 10/331,718, attorney docket
no. 25791.94,
filed on 12/30/02, which is a divisional U.S. patent application serial no.
09/679,906, filed on
10/5/00, attorney docket no. 25791.37.02, which claims priority from
provisional patent
application serial no. 60/159,033, attorney docket no. 25791.37, filed on
10/12/1999, (69)
PCT application US 03/04837, filed on 2/29/03, attorney docket no.
25791.95.02, which
claims priority from U.S. provisional patent application serial no.
60/363,829, attorney
docket no. 25791.95, filed on 3/13/02, (70) U.S. patent application serial no.
10/261,927,
attorney docleet no. 25791.97, filed on 10/1/02, which is a divisional of U.S.
patent number
6,557,640, which was filed as patent application serial no. 09/588,946,
attorney docket no.
25791.17.02, filed on 6/7/2000, which claims priority from provisional
application 60/137,998,
filed on 6/7/99, (71) U.S. patent application serial no. 10/262,008, attorney
docket no.
25791.98, filed on 10/1/02, which is a divisional of U.S. patent number
6,557,640, which was
filed as patent application serial no. 09/588,946, attorney docket no.
25791.17.02, filed on
6/7/2000, which claims priority from provisional application 60/137,998, filed
on 6/7/99, (72)
U.S. patent application serial no. 10/261,925, attorney docket no. 25791.99,
filed on
10/1/02, which is a divisional of U.S. patent number 6,557,640, which was
filed as patent
application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on
6/7/2000, which
claims priority from provisional application 60/137,998, filed on 6/7/99, (73)
U.S. patent
application serial no. 10/199,524, attorney docket no. 25791.100, filed on
7/19/02, which is
a continuation of U.S. Patent Number 6,497,289, which was filed as U.S. Patent
Application
serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999,
which claims
priority from provisional application 60/111,293, filed on 12/7/98, (74) PCT
application US
6
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03/10144, filed on 3/28/03, attorney docket no. 25791.101.02, which claims
priority from
U.S. provisional patent application serial no. 60/372,632, attorney docket no.
25791.101,
filed on 4/15/02, (75) U.S. provisional patent application serial no.
60/412,542, attorney
docket no. 25791.102, filed on 9/20/02, (76) PCT application US 03/14153,
filed on 5/6/03,
attorney docket no. 25791.104.02, which claims priority from U.S. provisional
patent
application serial no. 60/380,147, attorney docket no. 25791.104, filed on
5/6/02, (77) PCT
application US 03/19993, filed on 6/24/03, attorney docket no. 25791.106.02,
which claims
priority from U.S. provisional patent application serial no. 60/397,284,
attorney docket no.
25791.106, filed on 7/19/02, (78) PCT application US 03/13787, filed on
5/5/03, attorney
docket no. 25791.107.02, which claims priority from U.S. provisional patent
application
serial no. 60/387,486 , attorney docket no. 25791.107, filed on 6/10/02, (79)
PCT application
US 03/18530, filed on 6/11/03, attorney docket no. 25791.108.02, which claims
priority from
U.S. provisional patent application serial no. 60/387,961, attorney docket no.
25791.108,
filed on 6/12102, (80) PCT application US 03/20694, filed on 7/1/03, attorney
docket no.
25791.110.02, which claims priority from U.S. provisional patent application
serial no.
60/398,061, attorney docket no. 25791.110, filed on 7/24/02, (81) PCT
application US
03/20870, filed on 7/2/03, attorney docket no. 25791.111.02, which claims
priority from U.S.
provisional patent application serial no. 60/399,240, attorney docket no.
25791.111, filed on
7/29/02, (82) U.S. provisional patent application serial no. 60/412,487,
attorney docket no.
25791.112, filed on 9/20/02, (83} U.S. provisional patent application serial
no. 60/412,488,
attorney docket no. 25791.114, filed on 9/20/02, (84) U.S. patent application
serial no.
10/280,356, attorney docket no. 25791.115, filed on 10/25/02, which is a
continuation of
U.S. patent number 6,470,966, which was filed as patent application serial
number
09/850,093, filed on 5/7/01, attorney docket no. 25791.55, as a divisional
application of U.S.
Patent Number 6,497,289, which was filed as U.S. Patent Application serial no.
09/454,139,
attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority
from provisional
application 60/111,293, filed on 12/7/98, (85) U.S. provisional patent
application serial no.
60/412,177, attorney docket no. 25791.117, filed on 9/20/02, (86) U.S.
provisional patent
application serial no. 60/412,653, attorney docket no. 25791.118, filed on
9/20/02, (87) U.S.
provisional patent application serial no. 60/405,610, attorney docket no.
25791.119, filed on
8/23/02, (88) U.S. provisional patent application serial no. 60/405,394,
attorney docket no.
25791.120, filed on 8/23/02, (89) U.S. provisional patent application serial
no. 60/412,544,
attorney docket no. 25791.121, filed on 9/20/02, (90) PCT application
PCT/US03/24779,
filed on 8/8/03, attorney docket no. 25791.125.02, which claims priority from
U.S.
provisional patent application serial no. 60/407,442, attorney docket no.
25791.125, filed on
8/30/02, (91) U.S. provisional patent application serial no. 60/423,363,
attorney docket no.
25791.126, filed on 12/10/02, (92) U.S. provisional patent application serial
no. 60/412,196,
7
CA 02517524 2005-08-26
WO 2004/083594 PCT/US2004/008171
attorney docket no. 25791.127, filed on 9/20/02, (93) U.S. provisional patent
application
serial no. 60/412,187, attorney docket no. 25791.128, filed on 9/20/02, (94)
U.S. provisional
patent application serial no. 60/412,371, attorney docket no. 25791.129, filed
on 9/20/02,
(95) U.S. patent application serial no. 10/382,325, attorney docket no.
25791.145, filed on
3/5/03, which is a continuation of U.S. patent number 6,557,640, which was
filed as patent
application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on
6/7/2000, which
claims priority from provisional application 60/137,998, filed on 6/7/99, (96)
U.S. patent
application serial no. 10/624,842, attorney docket no. 25791.151, filed on
7/22/03, which is
a divisional of U.S. patent application serial no. 09/502,350, attorney docket
no. 25791.8.02,
filed on 2/10!2000, which claims priority from provisional application
60/119,611, filed on
2/11/99, (97) U.S. provisional patent application serial no. 60/431,184,
attorney docket no.
25791.157, filed on 12/5/02, (98) U.S. provisional patent application serial
no. 60/448,526,
attorney docket no. 25791.185, filed on 2/18/03, (99) U.S. provisional patent
application
serial no. 60/461,539, attorney docket no. 25791.186, filed on 4/9/03, (100)
U.S. provisional
patenfi application serial no. 60/462,750, attorney docket no. 25791.193,
filed on 4/14/03,
(101) U.S. provisional patent application serial no. 60/436,106, attorney
docket no.
25791.200, filed on 12/23/02, (102) U.S. provisional patent application serial
no. 60/442,942,
attorney docket no. 25791.213, filed on 1/27/03, (103) U.S. provisional patent
application
serial no. 60/442,938, attorney docket no. 25791.225, filed on 1/27/03, (104)
U.S. provisional
patent application serial no. 60/418,687, atfiorney docket no. 25791.228,
filed on 4/18/03,
(105) U.S. provisional patent application serial no. 60/454,896, attorney
docket no.
25791.236, filed on 3/14/03, (106) U.S. provisional patent application serial
no. 60/450,504,
attorney docket no. 25791.238, filed on 2/26/03, (107) U.S. provisional patent
application
serial no. 60/451,152, attorney docket no. 25791.239, filed on 3/9/03, (108)
U.S. provisional
patent application serial no. 60/455,124, attorney docket no. 25791.241, filed
on 3/17/03,
(109) U.S. provisional patent application serial no. 60/453,678, attorney
docket no.
25791.253, filed on 3/11/03, (110) U.S. patent application serial no.
10/421,682, attorney
docket no. 25791.256, filed on 4/23/03, which is a continuation of U.S. patent
application
serial no. 091523,468, attorney docket no. 25791.11.02, filed on 3/10/2000,
which claims
priority from provisional application 60/124,042, filed on 3/11/99, (111) U.S.
provisional
patent application serial no. 60/457,965, attorney docket no. 25791.260, filed
on 3/27/03,
(112) U.S. provisional patent application serial no. 60/455,718, attorney
docket no.
25791.262, filed on 3/18/03, (113) U.S. patent number 6,550,821, which was
filed as patent
application serial no. 09/811,734, filed on 3/19/01, (114) U.S. patent
application serial no.
10/436,467, attorney docket no. 25791.268, filed on 5/12/03, which is a
continuation of U.S.
patent number 6,604,763, which was filed as application serial no. 09/559,122,
attorney
docket no. 25791.23.02, filed on 4/26/2000, which claims priority from
provisional application
8
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WO 2004/083594 PCT/US2004/008171
60/131,106, filed on 4/26/99, (115) U.S. provisional patent application serial
no. 60/459,776,
attorney docket no. 25791.270, filed on 4/2/03, (116) U.S, provisional patent
application
serial no. 60/461,094, attorney docket no. 25791.272, filed on 4/8/03, (117)
U.S. provisional
patent application serial no. 60/461,038, attorney docket no. 25791.273, filed
on 4/7/03,
(118) U.S. provisional patent application serial no. 60/463,586, attorney
docket no.
25791.277, filed on 4/17/03, (119) U.S. provisional patent application serial
no. 60/472,240,
attorney docket no. 25791.286, filed on 5/20/03, (120) U.S. patent application
serial no.
10/619,285, attorney docket no. 25791.292, filed on 7/14/03, which is a
continuation-in-part
of U.S. utility patent application serial no. 09/969,922, attorney docket no.
25791.69, filed on
10/3/2001, which is a continuation-in-part application of U.S. patent no.
6,328,113, which
was filed as U.S. Patent Application serial number 09/440,338, attorney docket
number
25791.9.02, filed on 11/15/99, which claims priority from provisional
application 60/108,558,
filed on 11/16/98, (121) U.S. utility patent application serial no.
10/418,688, attorney docket
no. 25791.257, which was filed on 4/18/03, as a division of U.S. utility
patent application
serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000,
which claims
priority from provisional application 60/124,042, filed on 3/11/99, (122) PCT
patent
application serial no. , attorney docket no. 25791.238.02, filed on ,
(123) PCT patent application serial no. , attorney docket no. 25791.253.02,
filed
on , and (124) PCT patent application serial no. , attorney docket no.
25791.40.02, filed on , the disclosures of which are incorporated herein by
reference.
I~ackgr~und ~f the Invenfi~n
[~~3~ This invention relates generally to oil and gas exploration, and in
particular to forming
and repairing wellbore casings to facilitate oil and gas ea~ploration.
[004) Conventionally, when a wellbore is created, a number of casings are
installed in the
borehole to prevent collapse of the borehole wall and to prevent undesired
outflow of drilling
fluid into the formation or inflow of fluid from the formation into the
borehole. The borehole is
drilled in intervals whereby a casing which is to be installed in a lower
borehole interval is
lowered through a previously installed casing of an upper borehole interval.
As a
consequence of this procedure the casing of the lower interval is of smaller
diameter than
the casing of the upper interval. Thus, the casings are in a nested
arrangement with casing
diameters decreasing in downward direction. Cement annuli are provided between
the outer
surfaces of the casings and the borehole wall to seal the casings from the
borehole wall. As
a consequence of this nested arrangement a relatively large borehole diameter
is required at
the upper part of the wellbore. Such a large borehole diameter involves
increased costs due
to heavy casing handling equipment, large drill bits and increased volumes of
drilling fluid
and drill cuttings. Moreover, increased drilling rig time is involved due to
required cement
9
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WO 2004/083594 PCT/US2004/008171
pumping, cement hardening, required equipment changes due to large variations
in hole
diameters drilled in the course of the well, and the large volume of cuttings
drilled and
removed.
[005] The present invention is directed to overcoming one or more of the
limitations of the
existing procedures for forming and/or repairing wellbore casings.
Summary of the Invention
[006] According to one aspect of the present invention, an apparatus for
radially expanding
and plastically deforming a tubular member is provided that includes a tubular
support
member defining a first passage, a tubular expansion cone defining a second
passage
coupled to the tubular support member, a fluid driven motor coupled to the
tubular expansion
cone comprising an inlet, and a rotary expansion device coupled to the output
shaft of the
fluid driven motor. The first passage is operably coupled to the second
passage, and the
second passage is operably coupled to the inlet of the fluid driven motor.
[007] According to another aspect of the present invention, an apparatus for
radially
expanding and plastically deforming a tubular member is provided that includes
a first
expansion device for controllably straining the tubular member, and a second
expansion
device coupled to the first expansion device for controllably stressing the
tubular member.
[009] According to another aspect of the present invention, a method of
radially expanding
and plastically deforming a tubular member is provided that includes
controllably straining
the tubular member, and then controllably stressing the tubular member.
[009] According to another aspect of the present invention, an apparatus for
radially
expanding and plastically deforming a tubular member is provided that includes
means for
confirollably straining the tubular member, and means for controllably
stressing the tubular
member after controllably straining the tubular member.
[0010] According to another aspect of the present invention, an apparatus for
radially
expanding and plastically deforming a tubular member is provided that includes
a first
expansion device for radially expanding the tubular member, and a second
expansion device
coupled to the first expansion device for further radially expanding the
tubular member.
[0011] According to another aspect of the present invention, a method of
radially expanding
and plastically deforming a tubular member is provided that includes radially
expanding a
portion of the tubular member, and then further radially expanding the portion
of the tubular
member.
[0012] According to another aspect of the present invention, a system for
radially expanding
and plastically deforming a tubular member is provided that includes means for
radially
expanding a portion of the tubular member, and means for then further radially
expanding
the portion of the tubular member.
[0013] According to another aspect of the present invention, a method of
radially expanding
CA 02517524 2005-08-26
WO 2004/083594 PCT/US2004/008171
and plastically deforming a tubular member is provided that includes
controllably stressing
the tubular member; and then controllably straining the tubular member.
[0014] According to another aspect of the present invention, an apparatus for
radially
expanding and plastically deforming a tubular member is provided that includes
means for
controllably stressing the tubular member; and means for controllably
straining the tubular
member after controllably stressing the tubular member.
Brief Description of the Drawings
[0015] Fig. 1 is a fragmentary cross sectional ,illustration of an exemplary
embodiment of an
apparatus for radially expanding a tubular member.
Detailed Description of the Illustrative Embodiments
(0016] Referring to Fig. 1, an exemplary embodiment of an apparatus 100 for
radially
expanding a tubular member includes a tubular support member 102 that defines
a passage
102x. An end of an expansion mandrel 104 that defines a passage 104x, a
chamber 104b,
and a passage 104c is coupled to an end of the tubular support member 102 that
includes a
tapered outer surface 104d.
[0017] A conventional mud motor 106 is positioned within the chamber 104b of
the mandrel
104 that includes an rotable output shaft 106a that extends out of the
mandrel. In an
exemplary embodiment, the inlet of the mud motor 106 is fluidicly coupled to
the passage
104a of the mandrel, and the outlet of the mud motor is fluidicly coupled to
the passage 104c
of the mandrel. In this manner, the mud motor 106 may be operated to rotate
the shaft 106a
upon pumping fluidic materials into and through the mud motor. A conventional
rotary
expansion tool 108 is coupled to an end of the shaft 106a that may be any
number of
conventional commercially available rotary expansion devices such as, for
example, the
rotary expansion devices commercially available from V\leatherford
International or as
described in one or more of the following: IJ.S. 6,457,532 and/orlNO 02/081863
A1, the
disclosures of which are incorporated herein by reference. In an exemplary
embodiment,
the rotary expansion tool 108 includes one or more circumferentially and/or
axially spaced
apart roller expansion elements 108x.
[0018] The mandrel 104, the mud motor 106, and the rotary expansion tool 108
are housed
within a tubular launcher assembly 110 that includes a shoe 110a, a tubular
section 110b,
and a tapered tubular section 110c. In an exemplary embodiment, the tubular
section 110b
of the tubular launcher assembly 110 mates with the mandrel 104 and the rotary
expansion
tool 108. An end of an expandable tubular 112 is coupled to the tapered
tubular section
110c of the launcher assembly 110. In an exemplary embodiment, one or more cup
seals
114 are coupled to the exterior of the tubular support 102 for sealingly
engaging the interior
surface of the expandable tubular member 112.
[0019] In an exemplary embodiment, the apparatus is initially positioned
within a borehole
11
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WO 2004/083594 PCT/US2004/008171
116 that traverses a subterranean formation 118. Fluidic materials 120 are
then injected into
the apparatus 100 through the passages, 102a and 104a. The fluidic materials
120 are then
conveyed into and through the mud motor 106 and out of the mandrel 104 through
the
passage 104c. As a result, the mud motor 106 is operated to thereby rotate the
shaft 106a
and the rotary expansion tool 108. Also, as a result, the interior portion of
the launcher 110
below the mandrel 104 is pressurized thereby causing the mandrel, mud motor
106, and the
rotary expansion tool 108 to be displaced upwardly relative to the launcher
110.
[0020 The upward displacement of the mandrel 104, mud motor 106, and rotary
expansion
tool 108 then radially expands and plastically deforms at least the tubular
section 110b and
the tapered tubular section 110c of the launcher 110 and the expandable
tubular member
112. In an exemplary embodiment, the tapered surface 104d of the expansion
mandrel 104
provides the majority of the radial expansion and plastic deformation of the
tapered tubular
section 110c of the launcher 110 and the expandable tubular member 112. In an
exemplary
embodiment, the outside diameter of the rotary expansion tool 108 is
adjustable and thereby
permits the rotary expansion tool 108 to radially expand and plastically
deform the
expandable tubular member 112 into intimate contact with the walls of the
borehole 114. As
a result, the formation surrounding the expandable tubular member 112 may be
compressed
and, after the completion of the radial expansion and plastic deformation of
the expandable
tubular member, held in compression. In an exemplary embodiment, during the
operation ofi
the apparafius 100, the expansion mandrel 104 applies radial forces to
contiguous
circumferential interior surfaces of the tubular launcher assembly 110 and/or
the expandable
tubular member 112, and the rotary expansion tool 108 applies radial forces to
discrete
noncontiguous interior surfaces of the tubular launcher assembly and/or the
expandable
tubular member.
[0021) ~uring the operation of the apparatus 100, in an exemplary embodiment,
the
expansion mandrel 104 provides a strain controlled radial expansion process,
and the rotary
expansion tool 108 provides a stress controlled radial expansion process. For
example, the
final inside diameter of the expandable tubular member 112 provided by
operation of the
expansion mandrel 104 is controlled by the shape and geometry of the expansion
mandrel
and should be constant. However, the final inside diameter of the expandable
tubular
member provided by operation of the rotary expansion tool 108 may, or may not,
be constant
depending upon the shape of the wellbore 116. In particular, the amount of
strain of the
expandable tubular member 112 provided by the rotary expansion tool 108 is not
controlled.
Rather, the amount of stress applied to the expandable tubular member 112 by
the rotary
expansion tool 108 is controlled by controlling the compliance of the roller
expansion
elements 108a. Consequently, in an exemplary embodiment, the operation of the
rotary
expansion tool 108 will cause the outside diameter of the expandable tubular
member 112 to
12
CA 02517524 2005-08-26
WO 2004/083594 PCT/US2004/008171
engage and thereby match the inside diametrical shape of the wellbore 116. A
strain
controlled radial expansion process is typically capable of providing more
radial expansion
and plastic deformation than a stress controlled radial expansion process.
However, a
stress controlled radial expansion process is typically more capable of
expanding a tubular
member into engagement with an irregularly shaped wellbore 116. Consequently,
the
combination of a strain controlled expansion process with a stress controlled
expansion
process provides the benefits of both in one radial expansion process.
[0022] In several alternative embodiments, during the operation of the
apparatus 100, the
tubular support member 102, mandrel 104, and/or mud motor 106 are also rotated
during the
radial expansion and plastic deformation of the expandable tubular member 112.
In several
alternative embodiments, during the operation of the apparatus 100, the rotary
expansion
tool 108 is not rotated relative to the mandrel 104.
[0023] In an alternative embodiment, the expansion mandrel 104 is pulled
upwardly relative
to the tubular member 112 in combination with, or in substitution for, the
injection of the
fluidic material 120 during at least a portion of the radial expansion and
plastic deformation
of the tubular member.
[0024] In several exemplary embodiments, the interface between the expansion
mandrel
104 and the tubular launcher assembly 110 and/or the expandable tubular member
112 is
not fluid tight. As a result, the annulus defined between the cup seals 114
and the
expansion mandrel 104 within the expandable tubular member 112 is pressurized
such that
the resulting axial force applied to the cup seals pulls the expansion mandrel
104 and the
rotary expansion device 108 through the tubular launcher assembly 110 and/or
the
expandable tubular member 112.
[0025] In several alternative embodiments, the order and/or orientation of the
expansion
mandrel 104 and/or rotary expansion tool 108 may be reversed.
[0026] In several alternative embodiments, a conventional hydro-forming device
may be
substituted for, or used in addition to, the expansion mandrel 104.
[0027] In several alternative embodiments, the expansion mandrel 104 and/or
the rotary
expansion tool 108 are adjustable in size.
[0028] In several alternative embodiments, a conventional rotary expansion
tool such as, for
example, as described in U.S. 6,457,532 and/or WO 02/081863 A1, the
disclosures of which
are incorporated herein by reference, or any one of the commercially available
rotary
expansion tools available from Weatherford International, Inc. may be
substituted for, or
used in combination with, the expansion mandrel 104.
[0029] In several alternative embodiments, the exemplary embodiments of Fig. 1
are
implemented using the methods and/or apparatus disclosed one or more of the
following: (1)
U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application
serial no.
13
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WO 2004/083594 PCT/US2004/008171
09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims
priority from
provisional application 60/111,293, filed on 12/7/98, (2) U.S. patent
application serial no.
09/510,913, attorney docket no. 25791.7.02, filed on 2/23/2000, which claims
priority from
provisional application 60/121,702, filed on 2/25/99, (3) U.S. patent
application serial no.
09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, which claims
priority from
provisional application 60/119,611, filed on 2/11/99, (4) U.S. patent no.
6,328,113, which
was filed as U.S. Patent Application serial number 09/440,338, attorney docket
number
25791.9.02, filed on 11/15/99, which claims priority from provisional
application 60/108,558,
filed on 11/16/98, (5) U.S. patent application serial no. 10/169,434, attorney
docket no.
25791.10.04, filed on 7/1/02, which claims priority from provisional
application 60/183,546,
filed on 2/18/00, (6) U.S. patent application serial no. 09/523,468, attorney
docket no.
25791.11.02, filed on 3/10/2000, which claims priority from provisional
application
60/124,042, filed on 3/11/99, (7) U.S. patent number 6,568,471, which was
filed as patent
application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on
2/24/2000, which
claims priority from provisional application 60/121,841, filed on 2/26/99, (8)
U.S. patent
number 6,575,240, which was filed as patent application serial no. 09/511,941,
attorney
docket no. 25791.16.02, filed on 2/24/2000, which claims priorifiy from
provisional application
60/121,907, filed on 2/26/99, (9) U.S. patent number 6,557,640, which was
filed as patent
application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on
6/7/2000, which
claims priority from provisional application 60/137,998, filed on 6/7/99, (10)
U.S. patent
application serial no. 09/981,916, attorney docket no. 25791.18, filed on
10/18/01 as a
continuation-in-part application ~f U.S. patent no. 6,328,113, which was filed
as U.S. Patent
Application serial number 09/440,338, attorney docket number 25791.9.02, filed
on
11/15/99, which claims priority from provisional application 60/108,558, filed
on 11/16/98,
(11) U.S. pafient number 6,604,763, which was filed as application serial no.
09/559,122,
attorney docket no. 25791.23.02, filed on 4/26/2000, which claims priority
from provisional
application 60/131,106, filed on 4/26/99, (12) U.S. patent application serial
no. 10/030,593,
attorney docket no. 25791.25.08, filed on 1/8/02, which claims priority from
provisional
application 60/146,203, filed on 7129/99, (13) U.S. provisional patent
application serial no.
60/143,039, attorney docket no. 25791.26, filed on 7/9/99, (14) U.S. patent
application serial
no. 10/111,982, attorney docket no. 25791.27.08, filed on 4/30/02, which
claims priority from
provisional patent application serial no. 60/162,671, attorney docket no.
25791.27, filed on
11/1/1999, (15) U.S. provisional patent application serial no. 60/154,047,
attorney docket no.
25791.29, filed on 9/16/1999, (16) U.S. provisional patent application serial
no. 60/438,828,
attorney docket no. 25791.31, filed on 1/9/03, (17) U.S. patent number
6,564,875, which was
filed as application serial no. 09/679,907, attorney docket no. 25791.34.02,
on 10/5/00,
which claims priority from provisional patent application serial no.
60/159,082, attorney
14
CA 02517524 2005-08-26
WO 2004/083594 PCT/US2004/008171
docket no. 25791.34, filed on 10/12/1999, (18) U.S. patent application serial
no. 10/089,419,
filed on 3/27/02, attorney docket no. 25791.36.03, which claims priority from
provisional
patent application serial no. 60/159,039, attorney docket no. 25791.36, filed
on 10/12/1999,
(19) U.S. patent application serial no. 09/679,906, filed on 10/5/00, attorney
docket no.
25791.37.02, which claims priority from provisional patent application serial
no. 60/159,033,
attorney docket no. 25791.37, filed on 10/12/1999, (20) U.S. patent
application serial no.
10/303,992, filed on 11/22/02, attorney docket no. 25791.38.07, which claims
priority from
provisional patent application serial no. 60/212,359, attorney docket no.
25791.38, filed on
6/19/2000, (21) U.S. provisional patent application serial no. 60/165,228,
attorney docket no.
25791.39, filed on 11/12/1999, (22) U.S. provisional patent application serial
no. 60/455,051,
attorney docket no. 25791.40, filed on 3/14/03, (23) PCT application
US02/2477, filed on
6/26/02, attorney docket no. 25791.44.02, which claims priority from U.S.
provisional patent
application serial no. 60/303,711, attorney docket no. 25791.44, filed on
7/6/01, (24) U.S.
patent application serial no. 10/311,412, filed on 12/12/02, attorney docket
no. 25791.45.07,
which claims priority from provisional patent application serial no.
60/221,443, attorney
docket no. 25791.45, filed on 7/28/2000, (25) U.S. patent application serial
no. 10/, filed on
12/18/02, attorney docket no. 25791.46.07, which claims priority from
provisional patent
application serial no. 60/221,645, attorney docket no. 25791.46, filed on
7/28/2000, (26) U.S.
patent application serial no. 10/322,947, filed on 1/22/03, attorney docket
no. 25791.47.03,
which claims priority from provisional patent application serial no.
60/233,638, attorney
docket no. 25791.47, filed on 9/18/2000, (27) U.S. patent application serial
no. 10/406,648,
filed on 3/31/03, attorney docket no. 25791.48.06, which claims priority from
provisional
patent application serial no. 60/237,334, attorney docket no. 25791.48, filed
on 10/2/2000,
(28) PCT application US02/04353, filed on 2/14/02, attorney docket no.
25791.50.02, which
claims priority from U.S. provisional patent application serial no.
60/270,007, attorney docket
no. 25791.50, filed on 2/20/2001, (29) U.S. patent application serial no.
10/465,835, filed on
6/13/03, attorney docket no. 25791.51.06, which claims priority from
provisional patent
application serial no. 60/262,434, attorney docket no. 25791.51, filed on
1/17/2001, (30) U.S.
patent application serial no. 10/465,831, filed on 6/13/03, attorney docket
no. 25791.52.06,
which claims priority from U.S. provisional patent application serial no.
60/259,486, attorney
docket no. 25791.52, filed on 1/3/2001, (31) U.S. provisional patent
application serial no.
60/452,303, filed on 3/5/03, attorney docket no. 25791.53, (32) U.S. patent
number
6,470,966, which was filed as patent application serial number 09/850,093,
filed on 5/7/01,
attorney docket no. 25791.55, as a divisional application of U.S. Patent
Number 6,497,289,
which was filed as U.S. Patent Application serial no. 09/454,139, attorney
docket no.
25791.03.02, filed on 12/3/1999, which claims priority from provisional
application
601111,293, filed on 12/7/98, (33) U.S. patent number 6,561,227, which was
filed as patent
CA 02517524 2005-08-26
WO 2004/083594 PCT/US2004/008171
application serial number 09/852,026 , filed on 5/9/01, attorney docket no.
25791.56, as a
divisional application of U.S. Patent Number 6,497,289, which was filed as
U.S. Patent
Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on
12/3/1999, which
claims priority from provisional application 60/111,293, filed on 12/7/98,
(34) U.S. patent
application serial number 09/852,027, filed on 5/9/01, attorney docket no.
25791.57, as a
divisional application of U.S. Patent Number 6,497,289, which was filed as
U.S. Patent
Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on
12/3/1999, which
claims priority from provisional application 60/111,293, filed on 12/7/98,
(35) PCT Application
US02/25608, attorney docket no. 25791.58.02, filed on 8/13/02, which claims
priority from
provisional application 60/318,021, filed on 9/7/01, attorney docket no.
25791.58, (36) PCT
Application US02/24399, attorney docket no. 25791.59.02, filed on 8/1/02,
which claims
priority from U.S. provisional patent application serial no. 60/313,453,
attorney docket no.
25791.59, filed on 8/20/2001, (37) PCT Application US02/29856, attorney docket
no.
25791.60.02, filed on 9/19/02, which claims priority from U.S. provisional
patent application
serial no. 60/326,886, attorney docket no. 25791.60, filed on 10/3/2001, (38)'
PCT
Application US02/20256, attorney docket no. 25791.61.02, filed on 6/26/02,
which claims
priority from U.S. provisional patent application serial no. 60/303,740,
attorney docket no.
25791.61, filed on 7/6/2001, (39) U.S. patent application serial no.
09/962,469, filed on
9/25/01, attorney docket no. 25791.62, which is a divisional of U.S. patent
application serial
no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which
claims priority
from provisional application 60/124,042, filed on 3/11/99, (40) U.S. patent
application serial
no. 09/962,470, filed on 9/25/01, attorney docket no. 25791.63, which is a
divisional of U.S.
patent application serial no. 09/523,468, attorney docket no. 25791.11.02,
filed on
3/10/2000, which claims priority from provisional application 60/124,042,
filed on 3/11/99,
(41) U.S. patent application serial no. 09/962,471, filed on 9/25/01, attorney
docket no.
25791.64, which is a divisional of U.S. patent application serial no.
09/523,468, attorney
docket no. 25791.11.02, filed on 3/10/2000, which claims priority from
provisional application
60/124,042, filed on 3/11/99, (42) U.S. patent application serial no.
09/962,467, filed on
9/25/01, attorney docket no. 25791.65, which is a divisional of U.S. patent
application serial
no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which
claims priority
from provisional application 60/124,042, filed on 3/11/99, (43) U.S. patent
application serial
no. 09/962,468, filed on 9/25/01, attorney docket no. 25791.66, which is a
divisional of U.S.
patent application serial no. 09/523,468, attorney docket no. 25791.11.02,
filed on
3/10/2000, which claims priority from provisional application 60/124,042,
filed on 3/11/99,
(44) PCT application US 02/25727, filed on 8/14/02, attorney docket no.
25791.67.03, which
claims priority from U.S. provisional patent application serial no.
60/317,985, attorney docket
no. 25791.67, filed on 9/6/2001, and U.S. provisional patent application
serial no.
16
CA 02517524 2005-08-26
WO 2004/083594 PCT/US2004/008171
60/318,386, attorney docket no. 25791.67.02, filed on 9/10/2001, (45) PCT
application US
02/39425, filed on 12/10/02, attorney docket no. 25791.68.02, which claims
priority from
U.S. provisional patent application serial no. 60/343,674 , attorney docket
no. 25791.68,
filed on 12/27/2001, (46) U.S. utility patent application serial no.
09/969,922, attorney docket
no. 25791.69, filed on 10/3/2001, which is a continuation-in-part application
of U.S. patent
no. 6,328,113, which was filed as U.S. Patent Application serial number
09/440,338,
attorney docket number 25791.9.02, filed on 11/15/99, which claims priority
from provisional
application 60/108,558, filed on 11/16/98, (47) U.S. utility patent
application serial no.
10/516,467, attorney docket no. 25791.70, filed on 12/10/01, which is a
continuation
application of U.S. utility patent application serial no. 09/969,922, attorney
docket no.
25791.69, filed on 10/3/2001, which is a continuation-in-part application of
U.S. patent no.
6,328,113, which was filed as U.S. Patent Application serial number
09/440,338, attorney
docket number 25791.9.02, filed on 11/15/99, which claims priority from
provisional
application 60/108,558, filed on 11/16/98, (48) PCT application US 03/00609,
filed on 119/03,
attorney docket no. 25791.71.02, which claims priority from U.S. provisional
patent
application serial no. 601357,372 , attorney docket no. 25791.71, filed on
2/15/02, (49) U.S.
patent application serial no. 10/074,703, attorney docket no. 25791.74, filed
on 2/12/02,
which is a divisional of U.S. patent number 6,568,471, which was filed as
patent application
serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000,
which claims
priority from provisional application 60/121,841, filed on 2/26/99, (50) U.S.
patent application
serial no. 10/074,244, attorney docket no. 25791.75, filed on 2/12/02, which
is a divisional of
U.S. patent number 6,568,471, which was filed as patent application serial no.
09/512,895,
attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority
from provisional
application 60/121,841, filed on 2/26/99, (51) U.S. patent application serial
no. 10/076,660,
attorney docket no. 25791.76, filed on 2/15/02, which is a divisional of U.S.
patent number
6,568,471, which was filed as patenfi application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,841, filed on 2/26199, (52) U.S. patent application serial no.
10/076,661, attorney
docket no. 25791.77, filed on 2/15102, which is a divisional of U.S. patent
number
6,568,471, which was filed as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,841, filed on 2/26/99, (53) U.S. patent application serial no.
10/076,659, attorney
docket no. 25791.78, filed on 2/15/02, which is a divisional of U.S. patent
number
6,568,471, which was filed as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,841, filed on 2/26/99, (54) U.S. patent application serial no.
10/078,928, attorney
docket no. 25791.79, filed on 2/20/02, which is a divisional of U.S. patent
number
17
CA 02517524 2005-08-26
WO 2004/083594 PCT/US2004/008171
6,568,471, which was filed as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,841, filed on 2/26/99, (55) U.S. patent application serial no.
10/078,922, attorney
docket no. 25791.80, filed on 2/20/02, which is a divisional of U.S. patent
number
6,568,471, which was filed as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,841, filed on 2/26/99, (56) U.S. patent application serial no.
10/078,921, attorney
docket no. 25791.81, filed on 2/20/02, which is a divisional of U.S. patent
number
6,568,471, which was filed as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,841, filed on 2/26/99, (57) U.S. patent application serial no.
10/261,928, attorney
docket no. 25791.82, filed on 10/1/02, which is a divisional of U.S. patent
number
6,557,640, which was filed as patent application serial no. 09/588,946,
attorney docket no.
25791.17.02, filed on 6/7/2000, which claims priority from provisional
application 60/137,998,
filed on 6/7/99, (58) U.S. patent application serial no. 10/079,276 , attorney
docket no.
25791.83, filed on 2/20/02, which is a divisional of U.S. patent number
6,568,471, which was
filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on
2/24/2000, which claims priority from provisional application 60/121,841,
filed on 2/26/99,
(59) U.S. patent application serial no. 10/262,009, attorney docket no.
25791.84, filed4 on
10/1/02, which is a divisional of U.S. patent number 6,557,640, which was
filed as patent
application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on
6/7/2000, which
claims priority from provisional application 60/137,998, filed on 6/7/99, (60)
U.S. patent
application serial no. 10/092,q.81, attorney docket no. 25791.85, filed on
3/7/02, which is a
divisional of U.S. patent number 6,588,471, which was filed as patent
application serial no.
09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims
priority from
provisional application 60/121,841, filed on 2/26/99, (61) U.S. patent
application serial no.
10/261,926, attorney docket no. 25791.86, filed on 10/1/02, which is a
divisional of U.S.
patent number 6,557,640, which was filed as patent application serial no.
09/588,946,
attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from
provisional
application 60/137,998, filed on 6/7/99, (62) PCT application US 02/36157,
filed on 11/12/02,
attorney docket no. 25791.87.02, which claims priority from U.S. provisional
patent
application serial no. 60/338,996, attorney docket no. 25791.87, filed on
11/12/01, (63) PCT
application US 02/36267, filed on 11/12/02, attorney docket no. 25791.88.02,
which claims
priority from U.S. provisional patent application serial no. 60/339,013,
attorney docket no.
25791.88, filed on 11/12/01, (64) PCT application US 03/11765, filed on
4/16/03, attorney
docket no. 25791.89.02, which claims priority from U.S. provisional patent
application serial
no. 60/383,917, attorney docket no. 25791.89, filed on 5/29/02, (65) PCT
application US
18
CA 02517524 2005-08-26
WO 2004/083594 PCT/US2004/008171
03/15020, filed on 5/12/03, attorney docket no. 25791.90.02, which claims
priority from U.S.
provisional patent application serial no. 60/391,703, attorney docket no.
25791.90, filed on
6/26/02, (66) PCT application US 02/39418, filed on 12/10/02, attorney docket
no.
25791.92.02, which claims priority from U.S. provisional patent application
serial no.
60/346,309, attorney docket no. 25791.92, filed on 1/7/02, (67) PCT
application US
03/06544, filed on 3/4/03, attorney docket no. 25791.93.02, which claims
priority from U.S.
provisional patent application serial no. 60/372,048, attorney docket no.
25791.93, filed on
4/12/02, (68) U.S. patent application serial no. 10/331,718, attorney docket
no. 25791.94,
filed on 12/30/02, which is a divisional U.S. patent application serial no.
09/679,906, filed on
10/5/00, attorney docket no. 25791.37.02, which claims priority from
provisional patent
application serial no. 60/159,033, attorney docket no. 25791.37, filed on
10/12/1999, (69)
PCT application US 03/04837, filed on 2/29/03, attorney docket no.
25791.95.02, which
claims priority from U.S. provisional patent application serial no.
60/363,829, attorney
docket no. 25791.95, filed on 3/13/02, (70) U.S. patent application serial no.
10/261,927,
attorney docket no. 25791.97, filed on 10/1/02, which is a divisional of U.S.
patent number
6,557,640, which was filed as patent application serial no. 09/588,946,
attorney docket no.
25791.17.02, filed on 6/7/2000, which claims priority from provisional
application 60/137,998,
filed on 6/7/99, (71) U.S. patent application serial no. 10/262,008, attorney
docket no.
25791.98, filed on 10/1/02, which is a divisional of U.S. patent number
6,557,640, which was
filed as patent application serial no. 09/588,946, attorney docket no.
25791.17.02, filed on
6/7/2000, which claims priority from provisional application 60/137,998, filed
on 6/7/99, (72)
U.S. patent application serial no. 10/261,925, attorney doclcet no. 25791.99,
filed on
10/1/02, which is a divisional of U.S. patent number 6,557,6q~0, which was
filed as patent
application serial no. 09/588,946, attorney doclcet no. 25791.17.02, filed on
6/7/2000, which
claims priority from provisional application 60/137,998, filed on 6/7/99, (73)
U.S. patent
application serial no. 10/199,524, attorney docket no. 25791.100, filed on
7/19/02, which is
a continuation of U.S. Patenfi Number 6,497,289, which was filed as U.S.
Patent Application
serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 1213/1999,
which claims
priority from provisional application 60/111,293, filed on 12/7/98, (74) PCT
application US
03110144, filed on 3/28/03, attorney docket no. 25791.101.02, which claims
priority from
U.S. provisional patent application serial no. 60/372,632, attorney docket no.
25791.101,
filed on 4/15/02, (75) U.S. provisional patent application serial no.
60/412,542, attorney
docket no. 25791.102, filed on 9/20/02, (76) PCT application US 03/14153,
filed on 5/6/03,
attorney docket no. 25791.104.02, which claims priority from U.S. provisional
patent
application serial no. 60/380,147, attorney docket no. 25791.104, filed on
5/6/02, (77) PCT
application US 03/19993, filed on 6/24/03, attorney docket no. 25791.106.02,
which claims
priority from U.S. provisional patent application serial no. 60/397,284,
attorney docket no.
19
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WO 2004/083594 PCT/US2004/008171
25791.106, filed on 7/19/02, (78) PCT application US 03/13787, filed on
5/5/03, attorney
docket no. 25791.107.02, which claims priority from U.S. provisional patent
application
serial no. 60/387,486 , attorney docket no. 25791.107, filed on 6/10/02, (79)
PCT application
US 03/18530, filed on 6/11/03, attorney docket no. 25791.108.02, which claims
priority from
U.S. provisional patent application serial no. 60/387,961, attorney docket no.
25791.108,
filed on 6/12/02, (80) PCT application US 03/20694, filed on 7/1/03, attorney
docket no.
25791.110.02, which claims priority from U.S. provisional patent application
serial no.
60/398,061, attorney docket no. 25791.110, filed on 7/24/02, (81) PCT
application US
03/20870, filed on 7/2/03, attorney docket no. 25791.111.02, which claims
priority from U.S.
provisional patent application serial no. 60/399,240, attorney docket no.
25791.111, filed on
7/29/02, (82) U.S. provisional patent application serial no. 60/412,487,
attorney docket no.
25791.112, filed on 9/20/02, (83) U.S. provisional patent application serial
no. 60/412,488,
attorney docket no. 25791.114, filed on 9/20/02, (84) U.S. patent application
serial no.
10/280,356, attorney docket no. 25791.115, filed on 10/25/02, which is a
continuation of
U.S. patent number 6,470,966, which was filed as patent application serial
number
09/850,093, filed on 5/7/01, attorney docket no. 25791.55, as a divisional
application of U.S.
Patent Number 6,4.97,289, which was filed as U.S. Patent Application serial
no. 09/4.54,139,
attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority
from provisional
application 60/111,293, filed on 12/7/98, (85) U.S. provisional patent
application serial no.
60/412,177, attorney docket no. 25791.117, filed on 9/20/02, (86) U.S.
provisional patent
application serial no. 60/412,653, attorney docket no. 25791.118, filed on
9/20/02, (87) U.S.
provisional patent application serial no. 60/405,610, attorney doclcet no.
25791.119, filed on
8/23/02, (88) U.S. pro~aisional patent application serial no. 60/405,394,
attorney docket no.
25791.120, filed on 8/23/02, (89) U.S. provisional patent application serial
no. 60/412,544,
attorney docket no. 25791.121, filed on 9/20102, (90) PCT application
PCT/US03/24779,
filed on 8/8/03, attorney docket no. 25791.125.02, which claims priority from
U.S.
provisional patent application serial no. 60/407,442, attorney docket no.
25791.125, filed on
8/30/02, (91) U.S. provisional patent application serial no. 601423,363,
attorney docket no.
25791.126, filed on 12/10/02, (92) U.S. provisional patent application serial
no. 60/412,196,
attorney docket no. 25791.127, filed on 9/20/02, (93) U.S. provisional patent
application
serial no. 60/412,187, attorney docket no. 25791.128, filed on 9/20/02, (94)
U.S. provisional
patent application serial no. 60/412,371, attorney docket no. 25791.129, filed
on 9/20/02,
(95) U.S. patent application serial no. 10/382,325, attorney docket no.
25791.145, filed on
3/5/03, which is a continuation of U.S. patent number 6,557,640, which was
filed as patent
application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on
6/7/2000, which
claims priority from provisional application 60/137,998, filed on 6/7/99, (96)
U:S. patent
application serial no. 10/624,842, attorney docket no. 25791.151, filed on
7/22/03, which is
CA 02517524 2005-08-26
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a divisional of U.S. patent application serial no. 09/502,350, attorney docket
no. 25791.8.02,
filed on 2/10/2000, which claims priority from provisional application
60/119,611, filed on
2/11/99, (97) U.S. provisional patent application serial no. 60/431,184,
attorney docket no.
25791.157, filed on 12/5/02, (98) U.S. provisional patent application serial
no. 60/448,526,
attorney docket no. 25791.185, filed on 2/18/03, (99) U.S. provisional patent
application
serial no. 60/461,539, attorney docket no. 25791.186, filed on 4/9/03, (100)
U.S. provisional
patent application serial no. 60/462,750, attorney docket no. 25791.193, filed
on 4/14/03,
(101) U.S. provisional patent application serial no. 60/436,106, attorney
docket no.
25791.200, filed on 12/23/02, (102) U.S. provisional patent application serial
no. 60/442,942,
attorney docket no. 25791.213, filed on 1/27/03, (103) U.S. provisional patent
application
serial no. 60/442,938, attorney docket no. 25791.225, filed on 1/27/03, (104)
U.S. provisional
patent application serial no. 60/418,687, attorney docket no. 25791.228, filed
on 4/18/03,
(105) U.S. provisional patent application serial no. 60/454,896, attorney
docket no.
25791.236, filed on 3/14/03, (106) U.S. provisional patent application serial
no. 60/450,504,
attorney docket no. 25791.238, filed on 2/26/03, (107) U.S. provisional patent
application
serial no. 60/451,152, attorney docket no. 25791.239, filed on 3/9/03, (108)
U.S. provisional
patent application serial no. 60/455,124, attorney docket no. 25791.241, filed
on 3/17/03,
(109) U.S. provisional patent application serial no. 60/453,678, attorney
docket no.
25791.253, filed on 3/11/03, (110) U.S. patent application serial no.
10/421,682, attorney
docket no. 25791.256, filed on 4/23/03, which is a continuation of U.S. patent
application
serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000,
which claims
priority from provisional application 60/124,042, filed on 3/11/99, (111) U.S.
provisional
patent application serial no. 601457,965, attorney docket no. 25791.260, filed
on 3/27/03,
(112) U.S. provisional patent application serial no. 60/455,718, attorney
docket no.
25791.262, filed on 3/18/03, (113) U.S. patent number 6,550,821, which was
filed as patent
application serial no. 09/811,734, filed on 3/19/01, (114) U.S. patent
application serial no.
10/436,467, attorney docket no. 25791.268, filed on 5/12/03, which is a
continuation of U.S.
patent number 6,604,763, which was filed as application serial no. 091559,122,
attorney
docket no. 25791.23.02, filed on 4/26/2000, which claims priority from
provisional application
60/131,106, filed on 4/26199, (115) U.S. provisional patent application serial
no. 60/459,776,
attorney docket no. 25791.270, filed on 4/2/03, (116) U.S. provisional patent
application
serial no. 60/461,094, attorney docket no. 25791.272, filed on 4/8/03, (117)
U.S. provisional
patent application serial no. 60/461,038, attorney docket no. 25791.273, filed
on 4/7/03,
(118) U.S. provisional patent application serial no. 60/463,586, attorney
docket no.
25791.277, filed on 4/17/03, (119) U.S. provisional patent application serial
no. 60/472,240,
attorney docket no. 25791.286, filed on 5/20/03, (120) U.S. patent application
serial no.
10/619,285, attorney docket no. 25791.292, filed on 7/14/03, which is a
continuation-in-part
21
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of U.S. utility patent application serial no. 09/969,922, attorney docket no.
25791.69, filed on
10/3/2001, which is a continuation-in-part application of U.S. patent no.
6,328,113, which
was filed as U.S. Patent Application serial number 09/440,338, attorney docket
number
25791.9.02, filed on 11/15/99, which claims priority from provisional
application 60/108,558,
filed on 11/16/98, (121) U.S. utility patent application serial no.
10/418,688, attorney docket
no. 25791.257, which was filed on 4/18/03, as a division of U.S. utility
patent application
serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000,
which claims
priority from provisional application 60/124,042, filed on 3/11/99, (122) PCT
patent
application serial no. PCT/US04/ , attorney docket no. 25791.238.02, filed on
2/26/04, (123) PCT patent application serial no. PCT/US04/ , attorney docket
no.
25791.253.02, filed on 3/11/04, and (124) PCT patent application serial no.
PCT/US04/ , attorney docket no. 25791.40.02, filed on 3/15/04, the disclosures
of
which are incorporated herein by reference.
[0030] An apparatus for radially expanding and plastically deforming a tubular
member has
been described that includes a tubular support member defining a first
passage, a tubular
expansion cone defining a second passage coupled to the tubular support
member, a fluid
driven motor coupled to the tubular expansion cone comprising an inlet, and a
rotary
expansion device coupled to the output shaft of the fluid driven motor. The
first passage is
operably coupled to the second passage, and the second passage is operably
coupled to
the inlefi of the fluid driven motor.
[0031] An apparatus for radially expanding and plastically deforming a tubular
member has
been described that includes a first expansion device for controllably
straining the tubular
member, and a second ea~pansion device coupled to the first expansion device
for
controllably stressing the tubular member. In an exemplary embodiment, the
apparatus
further includes a motor coupled to the first expansion device for rotating
the second
expansion device relative to the first expansion device.
[0032] A method of radially expanding and plastically deforming a tubular
member has been
described that includes controllably straining the tubular member, and then
controllably
stressing the tubular member.
[0033] An apparatus for radially expanding and plastically deforming a tubular
member has
been described that includes means for controllably straining the tubular
member, and
means for controllably stressing the tubular member after controllably
straining the tubular
member.
[0034] An apparatus for radially expanding and plastically deforming a tubular
member has
been described that includes a first expansion device for radially expanding
the tubular
member, and a second expansion device coupled to the first expansion device
for further
radially expanding the tubular member. In an exemplary embodiment, the
apparatus further
22
CA 02517524 2005-08-26
WO 2004/083594 PCT/US2004/008171
includes a motor coupled to the first expansion device for rotating the second
expansion
device relative to the first expansion device.
[0035] A method of radially expanding and plastically deforming a tubular
member has been
described that includes radially expanding a portion of the tubular member,
and then further
radially expanding the portion of the tubular member. In an exemplary
embodiment, radially
expanding the portion of the tubular member includes applying forces to a
continuous
circumferential portion of the interior surface of the tubular member. In an
exemplary
embodiment, further radially expanding the portion of the tubular member
includes applying
forces to one or more discrete portions of the interior surface of the tubular
member.
[0036] A system for radially expanding and plastically deforming a tubular
member has been
described that includes means for radially expanding a portion of the tubular
member, and
means for then further radially expanding the portion of the tubular member.
In an
exemplary embodiment, the means for radially expanding the portion of the
tubular member
includes means for applying forces to a continuous circumferential portion of
the interior
surface of the tubular member. In an exemplary embodiment, the means for
further radially
expanding the portion of the tubular member includes means for applying forces
to one or
more discrete portions of the interior surface of the tubular member.
[0037] A method of radially expanding and plastically deforming a tubular
member has been
described that includes controllably stressing the tubular member; and then
controllably
straining the tubular member.
[0038] An apparatus for radially expanding and plastically deforming a tubular
member has
been described that includes means for controllably stressing the tubular
member; and
means f~r controllably straining the tubular member afier controllably
stressing the tubular
member.
[0039] 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 teachings of the present disclosure may incorporate one or
more features
or operational aspects of conventional hydro-forming tools.
[0040] 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. In 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.
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