APPARATUS AND METHOD FOR RADIALLY EXPANDING A WELLBORE CASING USING AN ADAPTIVE EXPANSION SYSTEM

APPAREIL ET PROCEDE PERMETTANT DE DILATER RADIALEMENT UN GAINAGE DE TROU DE FORAGE AU MOYEN D'UN SYSTEME DE DILATATION ADAPTATIF

English Abstract

An apparatus and method for radially expanding a wellbore (34) using an
adaptive expansion device (14).

French Abstract

La présente invention concerne un appareil et un procédé permettant de dilater radialement un gainage de trou de forage au moyen d'un système de dilatation adaptatif.

Claims

Claims

What is claimed is:

1. An apparatus for radially expanding and plastically deforming a tubular
member, comprising:
a support member; and
an.adaptive expansion device coupled to the support member for radially
expanding
and plastically deforming the tubular member, comprising:
a support structure coupled to the support member;
one or more expansion device segments for engaging the tubular member to
thereby radially expand and plastically deform the tubular member;
one or more adjustable spring elements coupled between the support
structure and one or more of the expansion device segments;
one or more adjustable damping elements coupled between the support
structure and one or more of the expansion device segments; and
one or more sensors for sensing operating conditions during the radial
expansion and plastic deformation of the tubular member by the
adaptive expansion device;
a controller operably coupled to the adjustable spring elements, the
adjustable damping elements, and the sensors; and
a user interface operably coupled to the controller for receiving user inputs;
wherein the controller is programmed to controllably adjust a spring rate of
one or more of the adjustable spring elements, and a damping rate of
one or more of the damping elements as a function of the operating
conditions sensed by the sensors and the user inputs.
2. A method of adaptively radially expanding a tubular member within a
wellbore, comprising:
inserting an adaptive expansion device into the tubular member;
radially expanding and plastically deforming the tubular member using the
adaptive
expansion device;
sensing one or more operating conditions during the radial expansion and
plastic
deformation of the tubular member; and
as a function of the sensed operating conditions, controllably adjusting a
spring rate
and a damping rate of the adaptive expansion device during the radial
expansion and plastic deformation of the tubular member.
3. A system for adaptively radially expanding a tubular member within a
wellbore, comprising:
means for inserting an adaptive expansion device into the tubular member;



35


means for radially expanding and plastically deforming the tubular member
using the
adaptive expansion device;
means for sensing one or more operating conditions during the radial expansion
and
plastic deformation of the tubular member; and
means for, as a function of the sensed operating conditions, controllably
adjusting a
spring rate and a damping rate of the adaptive expansion device during the
radial expansion and plastic deformation of the tubular member.
4. An apparatus for radially expanding and plastically deforming a tubular
member, comprising:
a support member; and
an adaptive expansion device coupled to the support member for radially
expanding
and plastically deforming the tubular member, comprising:
a support structure coupled to the support member;
one or more expansion device segments for engaging the tubular member to
thereby
radially expand and plastically deform the tubular member; and
one or more sensors for sensing operating conditions during the radial
expansion
and plastic deformation of the tubular member by the adaptive expansion
device; and
a controller operably coupled to the expansion device segments and the
sensors;
wherein the controller is programmed to controllably adjust a frequency
characteristic
of one or more of the expansion device segments as a function of the
operating conditions sensed by the sensors.
5. A method of adaptively radially expanding a tubular member within a
wellbore, comprising:
inserting an adaptive expansion device comprising one or more expansion device
segments for engaging and radially expanding and plastically deforming the
tubular member into the tubular member;
radially expanding and plastically deforming the tubular member using the
adaptive
expansion device;
sensing one or more operating conditions during the radial expansion and
plastic
deformation of the tubular member; and
as a function of the sensed operating conditions, controllably adjusting a
frequency
response characteristic of one or more of the expansion device segments
during the radial expansion and plastic deformation of the tubular member.
6. A system for adaptively radially expanding a tubular member within a
wellbore, comprising:
means for inserting an adaptive expansion device comprising one or more
expansion



36


device segments for engaging and radially expanding and plastically
deforming the tubular member into the tubular member;
means for radially expanding and plastically deforming the tubular member
using the
adaptive expansion device;
means for sensing one or more operating conditions during the radial expansion
and
plastic deformation of the tubular member; and
means for, as a function of the sensed operating conditions, controllably
adjusting a
frequency response characteristic of one or more of the expansion device
segments during the radial expansion and plastic deformation of the tubular
member.
7. An apparatus for radially expanding and plastically deforming overlapping
ends of first and second tubular members, comprising:
a support member; and
an adaptive expansion device coupled to the support member for radially
expanding
and plastically deforming the overlapping ends of the tubular members,
comprising:
a support structure coupled to the support member;
one or more expansion device segments for engaging the overlapping ends of the
tubular members to thereby radially expand and plastically deform the
overlapping ends of the tubular member; and
one or more sensors for sensing operating conditions during the radial
expansion
and plastic deformation of the overlapping ends of the tubular member by the
adaptive expansion device; and
a controller operably coupled to the expansion device segments and the
sensors;
wherein the controller is programmed to controllably adjust one or more
operational
characteristics of one or more of the expansion device segments as a
function of a sensing of the overlapping ends of the tubular members by one
or more of the sensors.
8. A method of adaptively radially expanding overlapping ends of tubular
members within a wellbore, comprising:
inserting an adaptive expansion device comprising one or more expansion device
segments for engaging and radially expanding and plastically deforming the
tubular member into the overlapping ends of the tubular members;
radially expanding and plastically deforming the overlapping ends of the
tubular
members using the adaptive expansion device;
sensing the overlapping ends of the tubular members during the radial
expansion
and plastic deformation of the overlapping ends of the tubular members; and



37


as a function of the sensing of the overlapping ends of the tubular members,
controllably adjusting an operational characteristic of one or more of the
expansion device segments during the radial expansion and plastic
deformation of the overlapping ends of the tubular members.
9. A system for adaptively radially expanding overlapping ends of tubular
members within a wellbore, comprising:
means for inserting an adaptive expansion device comprising one or more
expansion
device segments for engaging and radially expanding and plastically
deforming the tubular member into the overlapping ends of the tubular
members;
means for radially expanding and plastically deforming the overlapping ends of
the
tubular members using the adaptive expansion device;
means for sensing the overlapping ends of the tubular members during the
radial
expansion and plastic deformation of the overlapping ends of the tubular
members; and
means for, as a function of the sensing of the overlapping ends of the tubular
members, controllably adjusting an operational characteristic of one or more
of the expansion device segments during the radial expansion and plastic
deformation of the overlapping ends of the tubular members.
10. An apparatus for radially expanding and plastically deforming first and
second
tubular members coupled to one another by a threaded connection, comprising:
a support member; and
an adaptive expansion device coupled to the support member for radially
expanding
and plastically deforming the threaded connection, comprising:
a support structure coupled to the support member;
one or more expansion device segments for engaging the threaded connection to
thereby radially expand and plastically deform the threaded connection; and
one or more sensors for sensing operating conditions during the radial
expansion
and plastic deformation of the threaded connection by the adaptive expansion
device; and
a controller operably coupled to the expansion device segments and the
sensors;
wherein the controller is programmed to controllably adjust one or more
operational
characteristics of one or more of the expansion device segments as a
function of a sensing of the threaded connection by one or more of the
sensors.
11. A method of adaptively radially expanding tubular members coupled to one
another by a threaded connection within a wellbore, comprising:



38


inserting an adaptive expansion device comprising one or more expansion device
segments for engaging and radially expanding and plastically deforming the
tubular members proximate the threaded connection;
radially expanding and plastically deforming the threaded connection using the
adaptive expansion device;
sensing the threaded connection during the radial expansion and plastic
deformation
of the threaded connection; and
as a function of the sensing of the threaded connection, controllably
adjusting an
operational characteristic of one or more of the expansion device segments
during the radial expansion and plastic deformation of the threaded
connection.
12. A system for adaptively radially expanding tubular members coupled to one
another by a threaded connection within a wellbore, comprising:
means for inserting an adaptive expansion device comprising one or more
expansion
device segments for engaging and radially expanding and plastically
deforming the tubular members proximate the threaded connection;
means for radially expanding and plastically deforming the threaded connection
using
the adaptive expansion device;
means for sensing the threaded connection during the radial expansion and
plastic
deformation of the threaded connection; and
means for, as a function of the sensing of the threaded connection,
controllably
adjusting an operational characteristic of one or more of the expansion device
segments during the radial expansion and plastic deformation of the threaded
connection.
13. An apparatus for radially expanding and plastically deforming a tubular
member within a wellbore that traverses a subterranean formation, comprising:
a support member; and
an adaptive expansion device coupled to the support member for radially
expanding
and plastically deforming the tubular member and elastically deforming the
subterranean formation, comprising:
a support structure coupled to the support member;
one or more expansion device segments for engaging the threaded connection to
thereby radially expand and plastically deform the tubular member and
elastically deform the subterranean formation; and
one or more sensors for sensing operating conditions during the radial
expansion
and plastic deformation of the tubular member and the elastic deformation of
the subterranean formation; and



39


a controller operably coupled to the expansion device segments and the
sensors;
wherein the controller is programmed to controllably adjust one or more
operational
characteristics of one or more of the expansion device segments as a
function of a sensing of the subterranean formation by one or more of the
sensors.
14. A method of adaptively radially expanding a tubular member within a
wellbore
that traverses a subterranean formation, comprising:
inserting an adaptive expansion device comprising one or more expansion device
segments for engaging and radially expanding and plastically deforming the
tabular member and elastically deforming the subterranean formation within
the wellbore;
radially expanding and plastically deforming the tubular member and
elastically
deforming the subterranean formation using the adaptive expansion device;
sensing the subterranean formation during the radial expansion and plastic
deformation of the tubular member and the elastic deformation of the
subterranean formation; and
as a function of the sensing of the subterranean formation, controllably
adjusting an
operational characteristic of one or more of the expansion device segments
during the radial expansion and plastic deformation of the tubular member
and the elastic deformation of the subterranean formation.
15. A system for adaptively radially expanding a tubular member within a
wellbore
that traverses a subterranean formation, comprising:
means for inserting an adaptive expansion device comprising one or more
expansion
device segments for engaging and radially expanding and plastically
deforming the tubular member and elastically deforming the subterranean
formation within the wellbore;
means for radially expanding and plastically deforming the tubular member and
elastically deforming the subterranean formation using the adaptive
expansion device;
means for sensing the subterranean formation during the radial expansion and
plastic deformation of the tubular member and the elastic deformation of the
subterranean formation; and
means for, as a function of the sensing of the subterranean formation,
controllably
adjusting an operational characteristic of one or more of the expansion device
segments during the radial expansion and plastic deformation of the tubular
member and the elastic deformation of the subterranean formation.
16. An apparatus for radially expanding and plastically deforming a tubular



40


member, comprising:
a support member; and
an adaptive expansion device coupled to the support member for radially
expanding
and plastically deforming the tubular member, comprising:
a support structure coupled to the support member; and
one or more expansion device segments coupled to the support structure for
engaging the tubular member to thereby radially expand and plastically
deform the tubular member;
one or more sensors for sensing one or more operating conditions during the
radial
expansion and plastic deformation of the tubular member; and
a controller operably coupled to the expansion device segments and the
sensors;
and
wherein the controller is programmed to controllably adjust one or more of the
operational characteristics of one or more the expansion device segments as
a function of the operating conditions sensed by the sensors.
17. A method of adaptively radially expanding a tubular member within a
wellbore, comprising:
inserting an adaptive expansion device into the tubular member;
radially expanding and plastically deforming the tubular member using the
adaptive
expansion device;
sensing one or more operating conditions during the radial expansion and
plastic
deformation of the tubular member; and
as a function of the sensed operating conditions, controllably adjusting one
or more
of the operating characteristics of the adaptive expansion device during the
radial expansion and plastic deformation of the tubular member.
18. A system for adaptively radially expanding a tubular member within a
wellbore, comprising:
means for inserting an adaptive expansion device into the tubular member;
means for radially expanding and plastically deforming the tubular member
using the
adaptive expansion device;
means for sensing one or more operating conditions during the radial expansion
and
plastic deformation of the tubular member; and
means for, as a function of the sensed operating conditions, controllably
adjusting
one or more of the operating characteristics of the adaptive expansion device
during the radial expansion and plastic deformation of the tubular member.
19. The apparatus of claims 1, 4, 7, 10, 13, or 16, wherein one or more of the
expansion device segments comprise:



41


one or more expansion surfaces; and
an actuator coupled to the expansion surfaces.
20. The apparatus of claim 19, wherein the actuator comprises one or more
degrees of freedom.
21. The apparatus of claim 20, wherein the actuator comprises a plurality of
degrees of freedom.
22. The apparatus of claim 19, wherein the actuator comprises one or more
rotary actuators.
23. The apparatus of claims 1, 4, 7, 10, 13, or 16, wherein one or more of the
expansion device segments comprise:
one or more hydro-forming devices.
24. The method of claims 2, 5, 8, 11, 14, or 17, wherein radially expanding
and
plastically deforming the tubular member using the adaptive expansion device
comprises:
displacing the adaptive expansion device relative to the tubular member in the
longitudinal direction.
25. The method of claims 2, 5, 8, 11, 14, or 17, wherein radially expanding
and
plastically deforming the tubular member using the adaptive expansion device
comprises:
rotating the adaptive expansion device relative to the tubular member.
26. The method of claims 2, 5, 8, 11, 14, or 17, wherein radially expanding
and
plastically deforming the tubular member using the adaptive expansion device
comprises:
applying a pressurized fluid to the interior surface of the tubular member.
27. The system of claims 3, 6, 9, 12, 15, or 18, wherein the means for
radially
expanding and plastically deforming the tubular member using the adaptive
expansion
device comprises:
means for displacing the adaptive expansion device.
28. The system of claim 27, wherein the means for displacing the adaptive
expansion device comprises one or more degrees of freedom.
29. The system of claim 27, wherein the means for displacing the adaptive
expansion device comprises a plurality of degrees of freedom.
30. The system of claims 3, 6, 9, 12, 15, or 18, wherein the means for
radially
expanding and plastically deforming the tubular member using the adaptive
expansion
device comprises:
means for radially expanding and plastically deforming the tubular member
using a
hydro-forming device.



42


CLAIMS


24. The method of claims 2, 5, 8, 11, 14, or 17, wherein radially expanding
and
plastically deforming the tubular member using the adaptive expansion device
comprises:
displacing the adaptive expansion device relative to the tubular member in the
longitudinal direction.
25. The method of claims 2, 5, 8, 11, 14, or 17, wherein radially expanding
and
plastically deforming the tubular member using the adaptive expansion device
comprises:
rotating the adaptive expansion device relative to the tubular member.
26. The method of claims 2, 5, 8, 11, 14, or 17, wherein radially expanding
and
plastically deforming the tubular member using the adaptive expansion device
comprises:
applying a pressurized fluid to the interior surface of the tubular member.
27. The system of claims 3, 6, 9, 12, 15, or 18, wherein the means for
radially
expanding and plastically deforming the tubular member using the adaptive
expansion
device comprises:
means for displacing the adaptive expansion device.
28. The system of claim 27, wherein the means for displacing the adaptive
expansion device comprises one or more degrees of freedom.
29. The system of claim 27, wherein the means for displacing the adaptive
expansion device comprises a plurality of degrees of freedom.
34. The system of claims 3, 6, 9, 12, 15, or 18, wherein the means for
radially
expanding and plastically deforming the tubular member using the adaptive
expansion
device comprises:
means for radially expanding and plastically deforming the tubular member
using a
hydro-forming device.
31. The apparatus of claims 1, 4, 7, 10, 13, or 16, wherein one or more of the
expansion device segments comprise:
one or more expansion surfaces; and
an actuator coupled to the expansion surfaces;
wherein the actuator comprises a plurality of degrees of freedom;
wherein the actuator comprises one or more rotary actuators; and



43




wherein one or more of the expansion device segments comprise;
one or more hydro-forming devices.

32. ~The method of claims 2, 5, 8, 11, 14, or 17, wherein radially expanding
and
plastically deforming the tubular member using the adaptive expansion device
comprises:
displacing the adaptive expansion device relative to the tubular member in the
longitudinal direction;
wherein radially expanding and plastically deforming the tubular member using
the
adaptive expansion device comprises:
rotating the adaptive expansion device relative to the tubular member; and
wherein radially expanding and plastically deforming the tubular member using
the
adaptive expansion device comprises;
applying a pressurized fluid to the interior surface of the tubular member.

33. ~The system of claims 3, 6, 9, 12, 15, or 18, wherein the means for
radially
expanding and plastically deforming the tubular member using the adaptive
expansion
device comprises:
means for displacing the adaptive expansion device;
wherein the means for displacing the adaptive expansion device comprises a
plurality
of degrees of freedom; end
wherein the means for radially expanding and plastically deforming the tubular
member using the adaptive expansion device comprises:
means for radially expanding and plastically deforming the tubular member
using a
hydro-forming device.

44

Description

CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
APPARATUS AND METHOD FOR RADIALLY EXPANDING A WELLBORE CASING
USING AN ADAPTIVE EXPANSION SYSTEM
Cross Reference To Related Applications
[001 The present application claims the benefit of the filing date of U.S.
provisional patent
application serial no. 60/455,124, attorney docket no. 25791.241, filed on
Larch 17, 2003,
the disclosure of e~~hich is incorp~rated 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. 091454,139, 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 priority from provisional application 601121,907,
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 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 docleet 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



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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 yeas filed as
applicati~n serial n~.
09/679,907, attorney docket no. 25791.3~~.02, on 10/5/00, which claims
priority from
provisional patenfi application serial no. 60/159,082, attorney docket no.
25791.34, filed on
10/12/1999, (18) U.S. patent application serial no. 10/089,4.19, filed on
3/27/02, attorney
docket no. 25791.36.03, ~ehich claims priority from provisional patent
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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,
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11/22/02, attorney docket no. 25791.38.07, which claims priority from
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6/19/2000, (21) U.S.
provisional patent application serial no. 60/165,228, attorney docket no.
25791.39, filed on
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attorney docket
no. 25791.40, filed on 3/14/03, (23) PCT application US02/2477, filed on
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serial no. 10/311,412, filed on 12/12/02, attorney docket no. 25791.45.07,
which claims
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25791.45, filed on 7/28/2000, (25) U.S. patent application serial no. 10/,
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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 7128/2000, (26)
U.S. patent
application serial no. 10/322,947, filed on 1/22/03, attorney docket no.
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patent application serial no. 10/465,831, filed on 6/13/03, attorney docket
no. 25791.52.06,
2



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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,
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attorney docleet 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
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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.
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divisional application of U.S. Patent il~umber 6,497,289, which was filed as
U.S. Patent
Application serial no. 09/454,139, a~tfiorney docket no. 25791.03.02, filed on
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(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
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(35) PCT Application
US02/25608, attorney docket no. 25791.58.02, filed on 8/13/02, which claims
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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
3/1012000, which claims priority from provisional application 60/124~,04~2,
filed on 3/11/99,
(4.1) 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
3



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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 d~cket no. 25791.11.02,
filed on
3/10/2000, which claims priority fr~m provisional applicafiion 60/124,042,
filed on 3/11/99,
(44) PCT applicafii~n US 02/25727, filed ~n 8114/02, att~rney d~chet n~.
25791.67.03, ~,~hich
claims priority from U.S. provisional patenfi applicati~n serial no.
60/317,985, atfiorney d~cket
no. 25791.67, filed on 9/6/2001, and U.S. provisional patenfi application
serial no.
60/318,386, attorney dockefi no. 25791.67.02, filed on 9/10/2001, (4.5) PCT
applicafii~n US
02139.25, filed on 12/10/02, atfiorney docl:efi no. 25791.68.02, which claims
priority fr~m
U.S. provisional pafient applicafiion serial no. 60/343,674 , attorney docket
no. 25791.68,
filed on 12/27/2001, (46) U.S. ufiility pa~fienfi application serial no.
09/969,922, atfiorney docket
no. 25791.69, filed on 10/3/2001, which is a continuation-in-part application
of U.S. pafient
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 1013/2001, 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 1/9/03,
attorney docket 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.
pafienfi number
6,568,4.71, which was filed as pafient application serial no. 09/512,895,
atfiorney docket no.
25791.12.02, filed on 2/2~~/2000, which claims priority from provisional
applicafiion
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



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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,x.71, which was filed as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, ~~hich claims pri~rity from provisional
application
60/121,841, filed on 2/25/99, (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, ~ru~hich 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 2/26199,
(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, attornr~y 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



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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
4/16103, attorney
docleet no. 25791.89.02, ~,~hich claims priority from U.S. provisional patent
application serial
no. 60/383,917, attorney docleet 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 12110/02, 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. 101262,008, 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 6,4.97,289, which was filed as U.S.
Patent r4pplication
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



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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,
att~rney docket no. 25791.10q..02, which claims priority from U.S. pr~visional
patent
application serial n~. 50/380,14.7, attorney doclcc~t no. 25791.104, filed on
5/8/02, (77) PCT
application US 03/19993, filed on 8/24/03, attorney dockcet no. 25791.106.02,
which claims
priority from U.S. provisional patent application serial no. 60/397,284,
attorney docket no.
25791.108, filed on 7/19/02, (78) PCT application US 03/13787, filed on
5/5/03, attorney
d~cket n~. 25791.107.02, which claims priority from U.S. provisional patent
application
serial no. 80/387,486 , atfiorney 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 6,497,289, 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. 601412,544,
attorney docket no. 25791.121, filed on 9120/02, (90) PCT application US
03/24779, filed on
8/8/03, attorney docket no. 25791.125.02, which claims priority from U.S.
provisional patent
application serial no. 80/4.07,4q.2, attorney doclcc~t 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,
attorney docket no.
7



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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. 601412,371, 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 5,557,64.0, which was filed as patent
application serial
no. 09/588,946, attorney docket no. 25791.17.02, filed on 5/7/2000, which
claims priority
from provisional application 60/137,998, filed on 6/7/99, (96) U.S. patent
application serial
no. 10/624,84.2, 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 1215/02, (98) U.S. provisional patent application serial
no. 60/44.8,526,
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. 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.
10/436,4.67, attorney doclzet 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



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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 n~.
25791.277, filed ~n 4/17/03, (119) U.S. provisional patent applicadion serial
n~. GO/q~72,240,
attorney docleet no. 25791.286, filced 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 091440,338, 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. 25791.40.02, filed on 3/15/04, (124) PCT patent application serial no.
PCT/US04/ , attorney docket no. 25791.236.02, filed on 3/15/04, and (125) PCT
patent application serial number PCT/US04/ , attorney docket number
25791.253.02, filed on 3/11/2004, 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] 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
9



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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
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.
[~~~~ Thc~ present invention is directed to ~verc~ming one or m~re of the
limitations of thc~
existing pr~cedures for forming and/or repairing wellbore casings.
Summary of the Invention
[0~~~ According to one aspect of the present invention, an apparatus for
radially expanding
and plastically deforming a tubular member is provided that includes a support
member; and
an adaptive expansion device coupled to the suppork member for radially
expanding and
plastically deforming the tubular member that includes a support structure
coupled to the
support member; one or more expansion device segments for engaging the tubular
member
to thereby radially expand and plastically deform the tubular member; one or
more
adjustable spring elements coupled between the support structure and one or
more of the
expansion device segments; one or more adjustable damping elements coupled
between
the support structure and one or more of the expansion device segments; and
one or more
sensors for sensing operating conditions during the radial expansion and
plastic deformation
of the tubular member by the adaptive expansion device; a controller operably
coupled to the
adjustable spring elements, the adjustable damping elements, and the sensors;
and a user
interface operably coupled to the controller for receiving user inputs;
wherein the controller is
programmed to controllably adjust a spring rate of one or more of the
adjustable spring
elements, and a damping rate of one or more of the damping elements as a
function of the
operating conditions sensed by the sensors and the user inputs.
[007 According to another aspect of the present invention, a method of
adaptively radially
expanding a tubular member within a wellbore is provided that includes
inserting an adaptive
expansion device into the tubular member; radially expanding and plastically
deforming the
tubular member using the adaptive expansion device; sensing one or more
operating
conditions during the radial expansion and plastic deformation of the tubular
member; and as
a function of the sensed operating conditions, controllably adjusting a spring
rate and a
damping rate of the adaptive expansion device during the radial expansion and
plastic
deformation of fihe tubular member.
[0~~~ According to another aspect of the present invention, a system for
adaptively radially
expanding a tubular member within a wellbore is provided that includes means
for inserting
an adaptive expansion device into the tubular member; means for radially
ea~panding and
plastically deforming the tubular member using the adaptive expansion device;
means for
sensing one or more operating conditions during the radial expansion and
plastic



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
deformation of the tubular member; and means for, as a function of the sensed
operating
conditions, controllably adjusting a spring rate and a damping rate of the
adaptive expansion
device during the radial expansion and plastic deformation of the tubular
member.
[00~] According to another aspect of the present invention, an apparatus for
radially
expanding and plastically def~rming a tubular member is provided that includes
a support
member; and an adaptive ea;pansion device coupled to the support member f~r
radially
e~zpanding and plastically deformins~ the tubular member that includes a
supp~rt structure
coupled to fihe support member; one or more expansion device segments for
engaging the
tubular member t~ thereby radially expand and plastically deform the tubular
member; and
one or more sensors for sensing operating c~nditi~ns during the radial
eazpansion and plastic
deformation of the tubular member by the adaptive expansion device; and a
controller
operably coupled to the expansion device segments and the sensors; wherein the
controller
is programmed to controllably adjust a frequency characteristic of one or more
of the
expansion device segments as a function of the operating conditions sensed by
the sensors.
[0010] According to another aspect of the present invention, a method of
adaptively radially
expanding a tubular member within a wellbore is provided that includes
inserting an adaptive
expansion device comprising one or more expansion device segments for engaging
and
radially expanding and plastically deforming the tubular member into the
tubular member;
radially expanding and plastically deforming the tubular member using the
adaptive
expansion device; sensing one or more operating conditions during the radial
expansion and
plastic deformation of the tubular member; and as a function of the sensed
operating
conditions, controllably adjusting a frequency response characteristic of one
or more of the
expansion device segments during the radial expansion and plastic deformation
of the
tubular member.
[0011] According to another aspect of the present invention, a system for
adaptively radially
expanding a tubular member within a wellbore is provided that includes means
for inserting
an adaptive expansion device comprising one or more expansion device segments
for
engaging and radially expanding and plastically deforming the tubular member
into the
tubular member; means for radially expanding and plastically deforming the
tubular member
using the adaptive expansion device; means for sensing one or more operating
conditions
during the radial expansion and plastic deformation of the tubular member; and
means for,
as a function of the sensed operating conditions, controllably adjusting a
frequency response
characteristic of one or more of the expansion device segments during the
radial expansion
and plastic deformation of the tubular member.
[~~~ ~] According to another aspect of the present invention, an apparatus for
radially
expanding and plastically deforming overlapping ends of first and second
tubular members is
provided that includes a support member; and an adaptive expansion device
coupled to the
11



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
support member for radially expanding and plastically deforming the
overlapping ends of the
tubular members that includes a support structure coupled to the support
member; one or
more expansion device segments for engaging the overlapping ends of the
tubular members
to thereby radially expand and plastically deform the overlapping ends of the
tubular
member; and one or more sensors for sensing operating conditions during the
radial
expansion and plastic deformati~n ~f the overlapping ends of the tubular
member by the
adaptive expansion device; and a controller operably coupled to the ea~pansion
device
segments and the sensors; wherein the controller is programmed to controllably
adjust one
or more operational characteristics of one or more of the expansi~n device
segments as a
function of a sensing of the overlapping ends of the tubular members by one or
more of the
sensors.
[001~~ ~4ccording to another aspect of the present invention, a method of
adaptively radially
expanding overlapping ends of tubular members within a wellbore is provided
that includes
inserting an adaptive expansion device comprising one or more expansion device
segments
for engaging and radially expanding and plastically deforming the tubular
member into the
overlapping ends of the tubular members; radially expanding and plastically
deforming the
overlapping ends of the tubular members using the adaptive expansion device;
sensing the
overlapping ends of the tubular members during the radial expansion and
plastic
deformation of the overlapping ends of the tubular members; and as a function
of the
sensing of the overlapping ends of the tubular members, controllably adjusting
an
operational characteristic of one or more of the expansion device segments
during the radial
expansion and plastic deformation of the overlapping ends of the tubular
members.
[0014 According to another aspect of the present invention, a system for
adaptively radially
expanding overlapping ends of tubular members within a wellbore is provided
that includes
means for inserting an adaptive expansion device comprising one or more
expansion device
segments for engaging and radially expanding and plastically deforming the
tubular member
into the overlapping ends of the tubular members; means for radially expanding
and
plastically deforming the overlapping ends of the tubular members using the
adaptive
expansion device; means for sensing the overlapping ends of the tubular
members during
the radial expansion and plastic deformation of the overlapping ends of the
tubular
members; and means for, as a function of the sensing of the overlapping ends
of the tubular
members, controllably adjusting an operational characteristic of one or more
of the
expansion device segments during the radial expansion and plastic deformation
of the
overlapping ends of the tubular members.
[~01~~ According to another aspect of the present invention, an apparatus for
radially
expanding and plastically deforming first and second tubular members coupled
to one
another by a threaded connection is provided that includes a support member;
and an
12



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
adaptive expansion device coupled to the support member for radially expanding
and
plastically deforming the threaded connection that includes a support
structure coupled to
the support member; one or more expansion device segments for engaging the
threaded
connection to thereby radially expand and plastically deform the threaded
connection; and
one or more sensors for sensing operating conditions during the radial
expansion and plastic
deformafiion of the threaded connection by fihe adaptive e~cpansion device;
and a confiroller
operably coupled to the eezpansion device segments and the sensors; wherein
the controller
is programmed to controllably adjust one or more operational characteristics
of one or more
of the expansion device segments as a function of a sensing of the threaded
connection by
one or more of the sensors.
[001 ~] According to another aspect of the present invention, a method of
adaptively radially
expanding tubular members coupled to one another by a threaded connection
within a
wellbore is provided that includes inserting an adaptive expansion device
comprising one or
more expansion device segments for engaging and radially expanding and
plastically
deforming the tubular members proximate the threaded connection; radially
expanding and
plastically deforming the threaded connection using the adaptive expansion
device; sensing
the threaded connection during the radial expansion and plastic deformation of
the threaded
connection; and as a function of the sensing of the threaded connection,
controllably
adjusting an operational characteristic of one or more of the expansion device
segments
during the radial expansion and plastic deformation of the threaded
connection.
[0017) According to another aspect of the present invention, a system for
adaptively radially .
expanding tubular members coupled to one another by a threaded connection
within a
wellbore is provided that includes means for inserting an adaptive expansion
device
comprising one or more expansion device segments for engaging and radially
expanding
and plastically deforming the tubular members proximate the threaded
connection; means
for radially expanding and plastically deforming the threaded connection using
the adaptive
expansion device; means for sensing the threaded connection during the radial
expansion
and plastic deformation of the threaded connection; and means for, as a
function of the
sensing of the threaded connection, controllably adjusting an operational
characteristic of
one or more of the expansion device segments during the radial expansion and
plastic
deformation of the threaded connection.
[0010] According fio another aspect of the present invention, an apparatus for
radially
expanding and plastically defiorming a tubular member within a wellbore that
traverses a
subfierranean formation is provided that includes a support member; and an
adaptive
expansion device coupled fio fihe support member for ra~dially expanding and
plasfiically
deforming the tubular member and elastically deforming the subterranean
formation that
includes a support structure coupled to the support member; one or more
expansion device
13



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
segments for engaging the threaded connection to thereby radially expand and
plastically
deform the tubular member and elastically deform the subterranean formation;
and one or
more sensors for sensing operating conditions during the radial expansion and
plastic
deformation of the tubular member and the elastic deformation of the
subterranean
formation; and a controller operably coupled to the expansion device segments
and the
sensors; ~c,~herein the controller is programmed to controllably adjust one or
more operational
characteristics of one or more of the eazpansion device segments as a function
of a sensing
of the subterranean formation by one or more of the sensors.
[00~~] According to another aspect of the present invention, a method of
adaptively radially
eazpanding a tabular member within a wellbore that traverses a subterranean
formation is
provided that includes inserting an adaptive expansion device comprising one
or more
expansion device segments for engaging and radially expanding and plastically
deforming
the tubular member and elastically deforming the subterranean formation within
the wellbore;
radially expanding and plastically deforming the tubular member and
elastically deforming
the subterranean formation using the adaptive expansion device; sensing the
subterranean
formation during the radial expansion and plastic deformation of the tubular
member and the
elastic deformation of the subterranean formation; and as a function of the
sensing of the
subterranean formation, controllably adjusting an operational characteristic
of one or more of
the expansion device segments during the radial expansion and plastic
deformation of the
tubular member and the elastic deformation of the subterranean formation.
[0020] According to another aspect of the present invention, a system for
adaptively radially
expanding a tubular member within a wellbore that traverses a subterranean
formation is
provided that includes means for inserting an adaptive expansion device
comprising one or
more expansion device segments for engaging and radially expanding and
plastically
deforming the tubular member and elastically deforming the subterranean
formation within
the wellbore; means for radially expanding and plastically deforming the
tubular member and
elastically deforming the subterranean formation using the adaptive expansion
device;
means for sensing the subterranean formation during the radial expansion and
plastic
deformation of the tubular member and the elastic deformation of the
subterranean
formation; and means for, as a function of the sensing of the subterranean
formation,
controllably adjusting an operational characteristic of one or more of the
expansion device
segments during the radial expansion and plastic deformation of the tubular
member and the
elastic defiormation of the subterranean formation.
[002] According to another aspect of the present invention, an apparatus for
radially
expanding and plastically deforming a tubular member is provided that includes
a support
member; and an adaptive expansion device coupled to the support member for
radially
expanding and plastically deforming the tubular member that includes a support
structure
14



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
coupled to the support member; and one or more expansion device segments
coupled to the
support structure for engaging the tubular member to thereby radially expand
and plastically
deform the tubular member; one or more sensors for sensing one or more
operating
conditions during the radial expansion and plastic deformation of the tubular
member; and a
controller operably coupled to the expansion device segments and the sensors;
and wherein
the controller is programmed to controllably adjust one or more of the
operational
characteristics of one or more the eazpansion device segments as a function of
the operating
conditions sensed by the sensors.
[0022] According to another aspect of the present invention, a method of
adaptively radially
expanding a tubular member within a wellbore is provided that includes
inserting an adaptive
expansion device into the tubular member; radially expanding and plastically
deforming the
tubular member using the adaptive expansion device; sensing one or more
operating
conditions during the radial expansion and plastic deformation of the tubular
member; and as
a function of the sensed operating conditions, controllably adjusting one or
more of the
operating characteristics of the adaptive expansion device during the radial
expansion and
plastic deformation of the tubular member.
[0023] According to another aspect of the present invention, a system for
adaptively radially
expanding a tubular member within a wellbore is provided that includes means
for inserting
an adaptive expansion device into the tubular member; means for radially
expanding and
plastically deforming the tubular member using the adaptive expansion device;
means for
sensing one or more operating conditions during the radial expansion and
plastic
deformation of the tubular member; and means for, as a function of the sensed
operating
conditions, controllably adjusting one or more of the operating
characteristics of the adaptive
expansion device during the radial expansion and plastic deformation of the
tubular member.
Brief Description of the Drawings
[0024] Figs. 1 a and 1 b are fragmentary cross sectional illustrations of an
exemplary
embodiment of an adaptive system for radially expanding a tubular member.
[0025] Fig. 2 is a schematic illustration of an exemplary embodiment of the
adaptive
expansion device of the system of Figs. 1 a and 1 b.
[0026] Figs. 3a-3c are fragmentary cross sectional illustrations of exemplary
embodiments
of the operation of the adaptive system of Figs. 1 a and 1 b.
Detailed Description of the Illustrative Embodiments
[002] F~eferring to Figs. 1 a, 1 b, and ~, an adaptive system 10 for radially
expanding a
tubular member includes a support member 12 and an adaptive expansion device
14.. In
several exemplary embodiments, the system 10 may be used to radially expand
and
plastically deform a tubular member 16 by displacing the expansion device 14.
in the
longitudinal direction and/or by rotating the expansion device relative to the
tubular member.



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
[0028] In an exemplary embodiment, the adaptive expansion device 14 includes
one or
more expansion device segments 18 for engaging, and thereby radially expanding
and
plastically deforming the tubular member 16, that are coupled to an expansion
device
support structure 20 by one or more conventional adjustable spring elements 22
and one or
more conventional adjusfiable damping elements 24. In several exemplary
embodimenfis,
the adjustable spring elerrrenfis 22 and/or the adjusfiable damping elements
24. are be
provided as disclosed in one or more of the following: 1 ) U.S. Patent i~o.
6,431,284, 2) U.S.
Pafient No. 6,390,956, 3) U.S. Patent No. 6,296,533, 4) U.S. Pafient No.
6,237,889, 5) U.S.
Patenfi i~o. 6,220,089, G) U.S. Patent i~o. 6,159,289, 7) U.S. Patenfi I~o.
6,105,988, 8) U.S.
Patent i~o. G,065,7~.1, 9) U.S. Patent i~o. 6,062,324, 10) U.S. Pafient i~o.
6,035,954, 11) U.S.
Pafient No. 5,947,458, 12) U.S. Patent No. 5,875,567, 13) U.S. Patent No.
5,713,088, 14)
U.S. Pafient No. 5,603,574, 15) U.S. Pafient No. 5,364,565, 1G) 5,531,522, 17)
U.S. Patent
No. 5,464,197, 18) U.S. Patent No. 5,421,655, 19) U.S. Patent No. 5,201,392,
20) U.S.
Patent No. 5,169,129, 21) U.S. Patent No. 5,005,820, 22) U.S. Patent No.
4,984,632, 23)
U.S. Patent No. 4,862,995, 24) U.S. Patent No. 4,789,343, 25) U.S. Patent No.
4,657,280,
26) U.S. Patent No. 4,624,477, 27) U.S. Patent No. 4,575,058, 28) U.S. Patent
No.
4,566,717, 29) U.S. Patent No. 4,509,403, 30) U.S. Patent No. 4,277,045,
and/or 31) U.S.
Patent No. 4,071,104, the disclosures of which are incorporated herein by
reference.
[0029] In several exemplary embodiments, the expansion device segments 18
include, for
example, segments of a conventional expansion cone and/or conventional roller
expansion
elements and/or conventional hydro-forming elements. The expansion device
support
structure 20 is also coupled to the support member 12. The adjustable spring
and damping
elements, 22 and 24, are also operably coupled to a controller 26, and one or
more sensors
28 are also operably coupled to the controller 26 for reasons to be described.
A user
interface 28 may also be provided that is operably coupled to the controller
26. In several
exemplary embodiments, the controller 2G includes analog, digital, electronic,
and/or
hydraulic control elements that may or may not be positioned within the
adaptive expansion
device 14. In several alternative embodiments, the user interface 28 may
include a
conventional keyboard input device and/or a conventional display device and/or
a
conventional communication channel for linking the user interface to the
controller 26.
[0030] In an exemplary embodiment, during the operation of the system 10, the
controller 26
is programmed to adjust the spring rate of the adjusfiable spring elements 22
and/or the
damping rate of fihe adjustable damping elemenfis 24 as a function of one or
more operafiing
conditions thafi are sensed by the sensors 28. In several exemplary
embodiments, the
sensed operafiing condifiions may include the reaction forces of the tubular
member 1 G, the
operating pressure of fluidic materials within the system 10 and/or the
tubular member, the
16



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
rotational speed of the system, the longitudinal speed of the system, and/or
one or more
user defined inputs to the controller 26 provided via the user interface 28.
[0031] In an exemplary embodiment, at least one of the sensors 28 includes a
conventional
strain gauge that senses the reaction force of the tubular member 16 during
the radial
expansion and plastic deformation of the tubular member by the system 10. In
an exemplary
emb~c~iment, increases in the sensed reaction force causes the controller 28
tca increase ~r
decrease the spring rate of one or more of the adjustable spring elements 22
thereby
increasing or decreasing the stiffness of the corresponding expansion device
segments 18.
In this manner, the forces applied to the tubular member 16 may be increased
or decreased
for example, to provide increased or decreased radial expansion forces as a~
function of the
sensed reaction forces.
[0032] In an exemplary embodiment, at least one of the sensors 28 includes a
conventional
pressure sensor that senses the operating pressures of fluidic materials
within the system 10
and/or the tubular member 16 during the radial expansion and plastic
deformation of the
tubular member by the system 10. In an exemplary embodiment, the value of the
sensed
operating pressure causes the controller 26 to increase or decrease the spring
rate of one or
more of the adjustable spring elements 22 thereby increasing or decreasing the
stiffness of
the corresponding expansion device segments 18. In this manner, the forces
applied to the
tubular member 16 may be increased or decreased for example, to provide
increased or
decreased radial expansion forces as a function of the sensed operating
pressures.
[0033] In an exemplary embodiment, the controller 26 is programmed to
adaptively adjust
the spring rates of one or more of the adjustable spring elements 22 and/or
the damping rate
of one or more of the adjustable damping elements 24 to control the frequency
response of
one or more of the corresponding expansion device segments to provide, for
example, an
underdamped, a critically damped, or an overdamped frequency response. In this
manner,
the system 10 can provide an adaptive expansion system having user defined
operational
characteristics that may vary as a function of one or more sensed operating
conditions.
[0034] Referring to Fig. 3a, in an exemplary embodiment, the system 10 is used
to radially
expand and plastically deform the overlapping ends of tubular members, 16 and
30. In an
exemplary embodiment, during the radial expansion and plastic deformation of
the
overlapping ends of the tubular members, 16 and 30, the reaction forces of the
overlapping
ends of the tubular members, 16 and 30, are sensed by one or more of the
sensors 28, and,
ifi the sensed reaction forces increase, the spring rates of one or more of
the adjustable
spring elements 22 of the adaptive expansion device 14. are increased to
thereby increase
the radial expansion forces applied to the overlapping ends of the tubular
members. In this
manner, the system 10 can controllably adjust the radial expansion forces
applied to
overlapping tubulars thereby enhancing the radial expansion process. In an
alternative
17



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
embodiment, the location of the overlapped ends of the tubular members, 16 and
30, may be
input into the controller 26 using the user interface 28 to control the
initiation of the
adjustment of the spring rates of the adjustable spring elements 22 in
combination with, or in
the alternative to, the sensing of the reaction forces described above.
[~~3~] Referring to Fig. 3b, in an e~zemplary embodiment, the system 10 is
used to radially
eazpand and plastically deform a tubular member 18 that includes first and
second tubular
members, 18a and 16b, coupled to one another by a threaded connection 32. In
an
exemplary embodiment, during the radial expansion and plastic deformation of
the threaded
connection 32, the reaction forces of the threaded connection are sensed by
one or more of
the sensors 28, and, the spring rates and/or the damping rate of one or more
of the
adjustable spring elements 22 and/or adjustable damping elements 24~ of the
adaptive
expansion device 14. are adjusted to thereby minimize damage to the integrity
of the
threaded connection during the radial expansion process. For example, the
spring rates one
or more of the adjustable spring elements 22 may be reduced to minimize damage
to the
integrity of the threaded connection 32 during the radial expansion process
and/or the
damping rates of one or more of the adjustable damping elements 24 may be
increased to
minimize shock loading of the threaded connection during the radial expansion
process. In
an alternative embodiment, the location of the threaded connection 32 may be
input into the
controller 26 using the user interface 28 to control the initiation of the
adjustment of the
spring rates and/or damping rates of the adjustable spring elements 22 and/or
damping
elements 24 in combination with, or in the alternative to, the sensing of the
reaction forces
described above.
[0036] Referring to Fig. 3c, in an exemplary embodiment, the system 10 is used
to radially
expand and elastically deform a subterranean formation 34 during the radial
expansion and
plastic deformation of the tubular member 16. In an exemplary embodiment,
during the
radial expansion and plastic deformation of the tubular member 16 against the
subterranean
formation 34, the reaction forces of the formation 34 are sensed by one or
more of the
sensors 28, and the spring rates of one or more of the adjustable spring
elements 22 of the
adaptive expansion device 14 are increased to thereby increase the radial
expansion forces
applied to the formation. In this manner, the system 10 can controllably
adjust the radial
expansion forces applied to the formation 34 surrounding the tubular member 16
during the
radial expansion and plastic deformation of the tubular member. In an
alternative
embodiment, the location ofi the formation 34 may be input into the controller
26 using the
user infierface 28 to control the initiation of the adjustmenfi of the spring
rates of the
adjustable spring elements 22 in combination with, or in the alternative to,
the sensing of the
reaction forces described above.
18



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WO 2004/083591 PCT/US2004/008030
[0037] In several alternative embodiments, the exemplary embodiments of the
present
disclosure 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. 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 doclzet 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 50/119,611, filed on 2/11/99, (4) U.S.
patent no.
6,328,113, which was filed as U.S. Patent Application serial number
09/44.0,338, 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 priority
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 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 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
19



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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,q~19, 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 patenfi
application serial no. 60/159,033, attorney docks t no. 25791.37, filed on
10/12/1999, (20)
U.S. patent application serial no. 10/303,992, filed on 11/22/02, attorney
docleet 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.
601262,434, 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. 60/259,4.86, 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



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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 ill~amber
6,x.97,289, ~~hich was filed as U.S. Patent Application serial no.
091q.5~.,139, attorney docket
no. 25791.03.02, filed ~n 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, v~hich was filed as U.S. Patent Application serial no. 09/454.,139,
attorney docket
no. 25791.03.02, filed on 12/311999, 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. paterit 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 docl.et 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. 09/962,4.68, 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
21



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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. 60/318,380, attorney docket no. 25791.67.02, filed on
9/10/2001, (45)
PCT application US 02/394.25, filed on 12/10/02, attorney docket no.
25791.68.02, which
claims priority from U.S. pr~visi~nal patent application serial no.
60/343,67q. , attorney
docket no. 25791.88, filed on 12/27/2001, (~~5) 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 09/44.0,338, attorney docket number 25791.9.02, filed on 11/15/99,
which claims
priority fr~m provisional application 601108,558, 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 1/9/03,
attorney docket 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
doclcet no. 25791.77, filed on 2/15/02, which is a divisional of U.S. patent
number
6,568,4.71, which was filled as patent application serial no. 09/512,895,
attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
applicafiion
60/121,8q.1, filed on 2/28/99, (53) U.S. patent application serial no.
10/078,659, 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.
22



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
601121,841, 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. 091512,895,
attorney docket no.
25791.12.02, filed on 2124./2000, which claims priority from provisional
application
60/121,8.1, filed on 2/26/99, (55) U.S. patent application serial no.
10/~78,922, attorney
docleet n~. 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 docleet no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
60/121,8.1, filed on 2/26/99, (56) U.S. patent application serial no.
101078,921, 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, 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 doclcet 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.
23



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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. 601391,703, attorney docket no.
25791.90, filed on
6/26/02, (66) PCT application US 02/39418, filed on 12/10102, attorney docleet
n~.
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. 60/372,04.8, attorney docleet 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 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
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 q~/15/02, (75) U.S. provisional patent application serial no.
60/412,5q.2, 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
24



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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
docleet no. 25791.107.02, which claims priority from U.S. provisional patent
application
serial no. 80/387,486 , attorney d~cleet no. 25791.107, filed on 6/10/02, (79)
PCT applicati~n
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 6,497,289, 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 US
03/24779, 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,
attorney docket no.
25791.127, filed on 9120102, (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. 60/4.12,371, 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



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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. 80/~.31,18q~, att~rney
docket no.
25791.157, filed on 12/5/02, (98) U.S. provisional patent application serial
no. 60/4q.8,526,
attorney docket no. 25791.185, filed on 2118/03, (99) U.S. provisional patent
application
serial no. 60/q.61,539, attorney docket no. 25791.186, filed on 4/9103, (100)
U.S. provisional
patent application serial no. 60/4.62,750, attorney docket no. 25791.193,
filed on 4./1./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. 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. 091559,122,
attorney
docket no. 25791.23.02, filed on 4/26/2000, which claims priority from
provisional application
601131,106, 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. 60/4~61,09~., 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.
26



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
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 filr~d as U.S. Patent Applicati~n serial number 09/4.x.0,338, attorney
docket number
25791.9.02, filed on 11/15/99, ~~ahich claims priority from provisional
application 80/108,558,
filed on 11/18/98, (121) U.S. utility patent application serial no.
10/418,888, attorney docket
no. 25791.257, which was filed on 4/18103, as a division ofi U.S. utility
patent application
serial no. 09/523,488, attorney docket no. 25791.11.02, filed on 3/10/2000,
which claims
priority from provisional application 80/124,042, filed on 3/11/99, (122) PCT
patent
application serial no. PCT/US04/ , attorney docket no. 25791.238.02, filed on
2/26/2004, (123) PCT patent application serial number PCTlUS04/ , attorney
docket number 25791.40.02, filed on 3/15/04 , (124) PCT patent application
serial number PCT/US04/ , attorney docket number 25791.236.02, filed on
3/15/04, and (125) PCT patent application serial number PCT/US04/ , attorney
docket number 25791.253.02, filed on 3/11/2004, (125) conventional rotary
expansion tools
such as, for example, as described in U.S. 6,457,532 and/or WO 02/081863 A1,
or any one
of the commercially available rotary expansion tools available from
Weatherford
International, Inc., and/or (126) conventional hydro-forming methods and
tools, the
disclosures of which are incorporated herein by reference.
[0038 More generally, the operational characteristics of the adaptive
expansion device 14
may be determined as a function of empirical data regarding the tubular member
16
determined during a radial expansion testing procedure. For example, if a
certain spring rate
and/or damping rate, or range and/or variation in spring rate and/or damping
rate, for one or
more of the adjustable spring elements 22 and/or one or more of the adjustable
damping
elements 24 provide enhanced operational performance of the tubular member 16,
before,
during or after, a radial expansion and plastic deformation of the tubular
member, then the
preferred spring rate and/or damping rate, or the range and/or variation in
the spring rate
and/or damping rate, for one or more of the adjustable spring elements 22
and/or one or
more of the adjustable damping elements 24 may be programmed into the
controller 26 to
thereby provide enhanced radial expansion and plastic deformation of the
tubular member
using the adaptive expansion device 14..
[0039 An apparatus for radially expanding and plastically deforming a tubular
member has
been described that includes a support member; and an adaptive expansion
device coupled
to the support member for radially expanding and plastically deforming the
tubular member
that includes a support structure coupled to the support member; one or more
expansion
27



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
device segments for engaging the tubular member to thereby radially expand and
plastically
deform the tubular member; one or more adjustable spring elements coupled
between the
support structure and one or more of the expansion device segments; one or
more
adjustable damping elements coupled between the support structure and one or
more of the
expansion o~evice segments; and one or more sensors for sensing operating
conditions
during the radial e~;pansi~n and plastic deformation of the tubular member by
the adaptive
expansion device; a controller operably coupled to the adjustable spring
elements, the
adjustable damping elements, and the sensors; and a user interface operably
coupled to the
controller for receiving user inputs; wherein the controller is programmed to
controllably
adjust a spring rate of one or more of the adjustable spring elements, and a
damping rate of
one or more of the damping elements as a function of the operating conditions
sensed by
the sensors and the user inputs.
[0040] A method of adaptively radially expanding a tubular member within a
wellbore has
been described that includes inserting an adaptive expansion device into the
tubular
member; radially expanding and plastically deforming the tubular member using
the adaptive
expansion device; sensing one or more operating conditions during the radial
expansion: and
plastic deformation of the tubular member; and as a function of the sensed
operating
conditions, controllably adjusting a spring rate and a damping rate of the
adaptive expansion
device during the radial expansion and plastic deformation of the tubular
member.
[0041] A system for adaptively radially expanding a tubular member within a
wellbore has
been described that includes means for inserting an adaptive expansion device
into the
tubular member; means for radially expanding and plastically deforming the
tubular member
using the adaptive expansion device; means for sensing one or more operating
conditions
during the radial expansion and plastic deformation of the tubular member; and
means for,
as a function of the sensed operating conditions, controllably adjusting a
spring rate and a
damping rate of the adaptive expansion device during the radial expansion and
plastic
deformation of the tubular member.
[0042] An apparatus for radially expanding and plastically deforming a tubular
member has
been described that includes a support member; and an adaptive expansion
device coupled
to the support member for radially expanding and plastically deforming the
tubular member
that includes a support structure coupled to the support member; one or more
expansion
device segments for engaging the tubular member to thereby radially expand and
plastically
deform the tubular member; and one or more sensors for sensing operating
conditions
during the radial expansion and plastic defiormation of the tubular member by
the adaptive
e~;pansion device; and a controller operably coupled to the expansion device
segments and
the sensors; wherein the controller is programmed to controllably adjust a
frequency
characteristic of one or more of the expansion device segments as a function
of the
28



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
operating conditions sensed by the sensors.
[0043 A method of adaptively radially expanding a tubular member within a
wellbore has
been described that includes inserting an adaptive expansion device comprising
one or more
expansion device segments for engaging and radially expanding and plastically
deforming
the tubular member into the tubular member; radially expanding and plastically
deforming
the tubular member using the adaptivr~ expansion device; sensing one or more
operating
conditions during the radial expansion and plastic deformation of the tubular
member; and as
a function of the sensed operating conditions, controllably adjusting a
frequency response
characteristic of one or more of the expansion device segments during the
radial expansion
and plastic deformation of the tubular member.
[0044 A system for adaptively radially expanding a tubular member within a
wellbore has
been described that includes means for inserting an adaptive expansion device
comprising
one or more expansion device segments for engaging and radially expanding and
plastically
deforming the tubular member into the tubular member; means for radially
expanding and
plastically deforming the tubular member using the adaptive expansion device;
means for
sensing one or more operating conditions during the radial expansion and
plastic
deformation of the tubular member; and means for, as a function of the sensed
operating
conditions, controllably adjusting a frequency response characteristic of one
or more of the
expansion device segments during the radial expansion and plastic deformation
of the
tubular member.
(0045 An apparatus for radially expanding and plastically deforming
overlapping ends of
first and second tubular members has been described that includes a support
member; and
an adaptive expansion device coupled to the support member for radially
expanding and
plastically deforming the overlapping ends of the tubular members that
includes a support
structure coupled to the support member; one or more expansion device segments
for
engaging the overlapping ends of the tubular members to thereby radially
expand and
plastically deform the overlapping ends of the tubular member; and one or more
sensors for
sensing operating conditions during the radial expansion and plastic
deformation of the
overlapping ends of the tubular member by the adaptive expansion device; and a
controller
operably coupled to the expansion device segments and the sensors; wherein the
controller
is programmed to controllably adjust one or more operational characteristics
of one or more
of the expansion device segments as a function of a sensing of the overlapping
ends of the
tubular members by one or more of the sensors.
[0046 A method of adaptively radially expanding overlapping ends of tubular
members
within a wellbore has been described that includes inserting an adaptive
expansion device
comprising one or more expansion device segments for engaging and radially
expanding
and plastically deforming the tubular member into the overlapping ends of the
tubular
29



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
members; radially expanding and plastically deforming the overlapping ends of
the tubular
members using the adaptive expansion device; sensing the overlapping ends of
the tubular
members during the radial expansion and plastic deformation of the overlapping
ends of the
tubular members; and as a function of the sensing of the overlapping ends of
the tubular
members, controllably adjusting an operational characteristic of one or more
of the
e~zpansion device segments during the radial e~~pansion and plastic
deformati~n of the
overlapping ends of the tubular members.
[004] A system for adaptively radially expanding overlapping ends of tubular
members
within a wellbore has been described that includes means for inserting an
adaptive
expansi~n device comprising one or more expansion device segments for engaging
and
radially expanding and plastically deforming the tubular member into the
overlapping ends of
the tubular members; means for radially expanding and plastically deforming
the overlapping
ends of the tubular members using the adaptive expansion device; means for
sensing the
overlapping ends of the tubular members during the radial expansion and
plastic
deformation of the overlapping ends of the tubular members; and means for, as
a function of
the sensing of the overlapping ends of the tubular members, controllably
adjusting an
operational characteristic of one or more of the expansion device segments
during the radial
expansion and plastic deformation of the overlapping ends of the tubular
members.
[0048] An apparatus for radially expanding and plastically deforming first and
second tubular
members coupled to one another by a threaded connection has been described
that
includes a support member; and an adaptive expansion device coupled to the
support
member for radially expanding and plastically deforming the threaded
connection that
includes a support structure coupled to the support member; one or more
expansion device
segments for engaging the threaded connection to thereby radially expand and
plastically
deform the threaded connection; and one or more sensors for sensing operating
conditions
during the radial expansion and plastic deformation of the threaded connection
by the
adaptive expansion device; and a controller operably coupled to the expansion
device
segments and the sensors; wherein the controller is programmed to controllably
adjust one
or more operational characteristics of one or more of the expansion device
segments as a
function of a sensing of the threaded connection by one or more of the
sensors.
[0049] A method of adaptively radially expanding tubular members coupled to
one another
by a threaded connection within a wellbore has been described that includes
inserting an
adaptive expansion device comprising one or more expansion device segments for
engaging
and radially expanding and plastically deforming the tubular members proximate
the
threaded connection; radially eazpanding and plastically deforming the
threaded connection
using the adaptive expansion device; sensing the threaded connection during
the radial
expansion and plastic deformation of the threaded connection; and as a
function of the



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
sensing of the threaded connection, controllably adjusting an operational
characteristic of
one or more of the expansion device segments during the radial expansion and
plastic
deformation of the threaded connection.
[0050] A system for adaptively radially expanding tubular members coupled to
one another
by a threaded connection within a wellbore has been described that includes
means for
inserting an adaptive expansion c9evice comprising one or more e~cpansion
dr~vice segments
for engaging and radially e~zpanding and plastically deforming the tubular
members
proxcimate the threaded connection; means for radially expanding and
plastically deforming
the threaded connection using the adaptive expansion device; means for sensing
the
threaded connection during the radial ea~pa~nsion and plastic defiormation of
the threaded
connection; and means for, as a function of the sensing of the threaded
connection,
controllably adjusting an operational characteristic of one or more of the
expansion device
segments during the radial expansion and plastic deformation of the threaded
connection.
[0051] An apparatus for radially expanding and plastically deforming a tubular
member
within a wellbore that traverses a subterranean formation has been described
that includes a
support member; and an adaptive expansion device coupled to the support member
for
radially expanding and plastically deforming the tubular member and
elastically deforming
the subterranean formation that includes a support structure coupled to the
support member;
one or more expansion device segments for engaging the threaded connection to
thereby
radially expand and plastically deform the tubular member and elastically
deform the
subterranean formation; and one or more sensors for sensing operating
conditions during
the radial expansion and plastic deformation of the tubular member and the
elastic
deformation of the subterranean formation; and a controller operably coupled
to the
expansion device segments and the sensors; wherein the controller is
programmed to
controllably adjust one or more operational characteristics of one or more of
the expansion
device segments as a function of a sensing of the subterranean formation by
one or more of
the sensors.
[0052] A method of adaptively radially expanding a tubular member within a
wellbore that
traverses a subterranean formation has been described that includes inserting
an adaptive
expansion device comprising one or more expansion device segments for engaging
and
radially expanding and plastically deforming the tubular member and
elastically deforming
the subterranean formation within the wellbore; radially expanding and
plastically deforming
the tubular member and elastically deforming the subterranean formation using
the adaptive
expansion device; sensing the subterranean formation during the radial
expansion and
plastic defiormation of the tubular member and the elastic deformation of the
subterranean
formation; and as a function of the sensing of the subterranean formation,
controllably
adjusting an operational characteristic of one or more of the expansion device
segments
31



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
during the radial expansion and plastic deformation of the tubular member and
the elastic
deformation of the subterranean formation.
[0053] A system for adaptively radially expanding a tubular member within a
wellbore that
traverses a subterranean formation has been described that includes means for
inserting an
adaptive expansion device comprising one or more e~~pansion device segments
for engaging
and radially e~zpanding and plastically deforming the trab~alar member and
elastically
deforming the subterranean formation within the wellbore; means for radially
expanding and
plastically deforming the tubular member and elastically deforming the
subterranean
formation using the adaptive expansion device; means for sensing the
subterranean
formation during the radial expansion and plastic deformation of the tubular
member and the
elastic deformation of the subterranean formation; and means for, as a
function of the
sensing of the subterranean formation, controllably adjusting an operational
characteristic of
one or more of the expansion device segments during the radial expansion and
plastic
deformation of the tubular member and the elastic deformation of the
subterranean
formation.
[0054] An apparatus for radially expanding and plastically deforming a tubular
member has
been described that includes a support member; and an adaptive expansion
device coupled
to the support member for radially expanding and plastically deforming the
tubular member
that includes a support structure coupled to the support member; and one or
more
expansion device segments coupled to the support structure for engaging the
tubular
member to thereby radially expand and plastically deform the tubular member;
one or more
sensors for sensing one or more operating conditions during the radial
expansion and plastic
deformation of the tubular member; and a controller operably coupled to the
expansion
device segments and the sensors; and wherein the controller is programmed to
controllably
adjust one or more of the operational characteristics of one or more the
expansion device
segments as a function of the operating conditions sensed by the sensors.
[0055] A method of adaptively radially expanding a tubular member within a
wellbore has
been described that includes inserting an adaptive expansion device into the
tubular
member; radially expanding and plastically deforming the tubular member using
the adaptive
expansion device; sensing one or more operating conditions during the radial
expansion and
plastic deformation of the tubular member; and as a function of the sensed
operating
conditions, controllably adjusting one or more of the operating
characteristics of the adaptive
expansion device during the radial expansion and plastic deformation of the
tubular member.
[0055] A system for adaptively radially expanding a tubular member within a
wellbore has
been described that includes means for inserting an adaptive expansion device
into the
tubular member; means for radially expanding and plastically deforming the
tubular member
using the adaptive expansion device; means for sensing one or more operating
conditions
32



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
during the radial expansion and plastic deformation of the tubular member; and
means for,
as a function of the sensed operating conditions, controllably adjusting one
or more of the
operating characteristics of the adaptive expansion device during the radial
expansion and
plastic deformation of the tubular member.
[005e] In several exemplary embodiments, one or more of the expansion device
segments
includes one or more eazpansion surfaces; and an actuator coupled to the
ea<pansion
surfaces. In an eazemplary embodiment, the actuator includes one or more
degrees of
freedom. In an exemplary embodiment, the actuator includes a plurality of
degrees of
freedom. In an exemplary embodiment, the actuator includes one or more rotary
actuators.
In a~n exemplary embodiment, one or more ofi the expansion device segments
include one or
more hydro-forming devices.
[0055] In several exemplary embodiments, radially expanding and plastically
deforming the
tubular member using the adaptive expansion device includes displacing the
adaptive
expansion device relative to the tubular member in the longitudinal direction.
In several
exemplary embodiments, radially expanding and plastically deforming the
tubular member
using the adaptive expansion device includes rotating the adaptive expansion
device relative
to the tubular member. In an exemplary embodiment, radially expanding and
plastically
deforming the tubular member using the adaptive expansion device includes
applying a
pressurized fluid to the interior surface of the tubular member. In several
exemplary
embodiments, the means for radially expanding and plastically deforming the
tubular
member using the adaptive expansion device includes means for displacing the
adaptive
expansion device. In several exemplary embodiments, the means for displacing
the
adaptive expansion device includes one or more degrees of freedom. In several
exemplary
embodiments, the means for displacing the adaptive expansion device includes a
plurality of
degrees of freedom. In several exemplary embodiments, the means for radially
expanding
and plastically deforming the tubular member using the adaptive expansion
device includes
means for radially expanding and plastically deforming the tubular member
using a hydro-
forming device.
[0059] 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, one or more of the tubular members, 16 and 30, may be slotted,
perforated, or
otherwise include one or more radial passages. In addition, the adaptive
expansion device
~4~ may be displaced in the longitudinal direction and/or rotated relative to
the tubular
member ~ 6 during the radial expansion and plastic deformation of the tubular
member.
[0060] Although illustrative embodiments of the invention have been shown and
described,
a wide range of modification, changes and substitution is contemplated in the
foregoing
33



CA 02518453 2005-09-07
WO 2004/083591 PCT/US2004/008030
disclosure. In some instances, some features of the present invention maybe
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.
34

Representative Drawing