A METHOD OF RADIALLY EXPANDING AND PLASTICALLY DEFORMING TUBULAR MEMBERS

PROCEDE D'EXPANSION RADIALE ET DE DEFORMATION PLASTIQUE D'ELEMENTS TUBULAIRES

English Abstract

A method of radially expanding and plastically deforming a tubular assembly
comprising a first tubular member, a second tubular member, and a mechanical
coupling for coupling the first tubular member to the second tubular member,
the method comprising placing the mechanical coupling in tension; and then
radially expanding and plastically deforming the mechanical coupling. It is
emphasized that this abstract is provided to comply with the rules requiring
an abstract to allow a searcher or other reader to quickly ascertain the
subject matter of the technical disclosure; and is submitted with the
understanding that it will not be used to interpret or limit the scope or
meaning of the claims under 37 CFR 1.72.

French Abstract

L'invention concerne un procédé d'expansion radiale et de déformation plastique d'un élément tubulaire constitué d'un premier élément tubulaire, d'un deuxième élément tubulaire et d'un raccord mécanique destiné à raccorder le premier élément tubulaire au deuxième élément tubulaire. Ce procédé consiste à mettre le raccord mécanique en tension, puis à procéder à l'expansion radiale et à la déformation plastique de ce raccord.

Claims

30

CLAIMS

What is claimed is:

1. A method of creating a casing in a borehole located in a subterranean
formation,
comprising:
installing the casing in the borehole, the casing comprising a frst tubular
member, a
second tubular member, and a threaded connection coupling the frst tubular
member to the second tubular member;
radially expanding and plastically deforming at least a portion of the first
tubular
member,
radially expanding and plastically deforming at least a portion of the second
tubular
member; and
then radially expanding and plastically deforming the threaded connection;
wherein the radially expanded portion of the first tubular member is not part
of the
threaded connection; and
wherein the radially expanded portion of the second tubular member is not part
of the
threaded connection.
2. The method of claim 1, wherein radially expanding and plastically deforming
at least a
portion of the first tubular member comprises radially expanding and
plastically deforming the
portion with an expandable expansion device.
3. The method of claim 1, wherein radially expanding and plastically deforming
at least a
portion of the second tubular member comprises radially expanding and
plastically deforming
the portion with an expandable expansion device.
4. The method of claim 1, wherein radially expanding and plastically deforming
the
threaded connection comprises radially expanding and plastically deforming the
connection
with an expansion cone.
5. The method of claim 1, wherein radially expanding and plastically deforming
at least a
portion of the first tubular member comprises radially expanding and
plastically deforming the
portion with a first expansion device, and wherein radially expanding and
plastically deforming the threaded connection comprises radially expanding and
plastically
deforming the connection with a second


31

6. The method of claim 1, wherein radially expanding and plastically deforming
at least a
portion of the first tubular member and radially expanding and plastically
deforming at least a
portion of the second tubular member comprises placing the threaded connection
in tension.
7. The method of claim 1, wherein radially expanding and plastically deforming
at least a
portion of the first tubular member comprises radially expanding and
plastically deforming the
portion into engagement with at least one of a pre-existing structure and the
borehole.
8. The method of claim 1, wherein radially expanding and plastically deforming
at least a
portion of the second tubular member comprises radially expanding and
plastically deforming
the portion into engagement with at least one of a pre-existing structure and
the borehole.
9. A method of creating a casing in a borehole located in a subterranean
formation,
comprising:
installing the casing in the borehole, the casing comprising a frst tubular
member, a
second tubular member, and a threaded connection coupling the frst tubular
member to the second tubular member;
placing a first expansion device and a second expansion device in the casing;
radially expanding and plastically deforming at least a portion of the first
tubular member and at least a portion of the second tubular member with the
first expansion device; and
then radially expanding and plastically deforming the threaded connection with
the
second expansion device;
wherein the radially expanded portion of the first tubular member is not part
of the
threaded connection; and
wherein the radially expanded portion of the second tubular member is not part
of the
threaded connection.
10. The method of claim 9, wherein the radially expanding and plastically
deforming the
threaded connection is done after radially expanding and plastically deforming
at least a
portion of the first tubular member and at least a portion of the second
tubular member.
11. The method of claim 9, wherein the first expansion device is expandable.
12. The method of claim 9, wherein the first expansion device includes
rotating elements.


32

13. A method of creating a casing in a borehole located in a subterranean
formation,
comprising:
installing the casing in the borehole, the casing comprising a first tubular
member, a
second tubular member, and a third tubular member, a frst threaded
connection coupling the first tubular member to the second tubular member,
and a second threaded connection coupling the second tubular member to the
third tubular member;
radially expanding and plastically deforming at least a portion of the first
tubular
member and at least a portion of the second tubular member,
then radially expanding and plastically deforming the first threaded
connection;
radially expanding and plastically deforming at least a portion of the third
tubular
member; and
then radially expanding and plastically deforming the second threaded
connection;
wherein the radially expanded portion of the first tubular member is not part
of the first
threaded connection;
wherein the radially expanded portion of the second tubular member is not part
of the
first threaded connection; and
wherein the radially expanded portion of the third tubular member is not part
of the
second threaded connection.
14. The method of claim 13, wherein radially expanding and plastically
deforming at least
a portion of the first tubular member comprises radially expanding and
plastically deforming
the portion with an expandable expansion device.
15. The method of claim 13, wherein radially expanding and plastically
deforming at least
a portion of the second tubular member comprises radially expanding and
plastically
deforming the portion with an expandable expansion device.
16. The method of claim 13, wherein radially expanding and plastically
deforming at least
a portion of the third tubular member comprises radially expanding and
plastically deforming
the portion with an expandable expansion device.
17- The method of claim 13, wherein radially expanding and plastically
deforming the first
threaded connection comprises radially expanding and plastically deforming the
connection
with an expansion cone.


33

18. The method of claim 13, wherein radially expanding and plastically
deforming the
second threaded connection comprises radially expanding and plastically
deforming the
connection with an expansion cone.
19. The method of claim 13, wherein radially expanding and plastically
deforming at least
a portion of the first tubular member comprises radially expanding and
plastically deforming
the portion with a first expansion device, and wherein radially expanding and
plastically
deforming the first threaded connection comprises radially expanding and
plastically
deforming the connection with a second expansion device.
20. The method of claim 13, wherein radially expanding and plastically
deforming at least
a portion of the first tubular member and at least a portion of the second
tubular member
further comprises placing the first threaded connection in tension.
21. The method of claim 13, wherein radially expanding and plastically
deforming at least
a portion of the first tubular member and at least a portion of the second
tubular member
further comprises a tensional force on the first threaded connection.
22. The method of claim 13, wherein radially expanding and plastically
deforming at least
a portion of the first tubular member comprises radially expanding and
plastically deforming
the portion into engagement with at least one of a pre-existing structure and
the borehole.
23. The method of claim 13, wherein radially expanding and plastically
deforming at least
a portion of the second tubular member comprises radially expanding and
plastically
deforming the portion into engagement with at least one of a pre-existing
structure and the
borehole.
24. The method of claim 13, wherein radially expanding and plastically
deforming at least
a portion of the third tubular member comprises radially expanding and
plastically deforming
the portion into engagement with at least one of a pre-existing structure and
the borehole.
25. An expanded casing in a borehole located in a subterranean formation,
comprising:
a first tubular member, a second tubular member, and a threaded connection
coupling the first tubular member to the second tubular member, the casing
produced by the process of:
installing the casing in the borehole;


34

radially expanding and plastically deforming at least a portion of the first
tubular member;
radially expanding and plastically deforming at least a portion of the second
tubular member; and
then radially expanding and plastically deforming the threaded connection;
wherein the radially expanded portion of the first tubular member is not part
of the
threaded connection; and
wherein the radially expanded portion of the second tubular member is not part
of the
threaded connection.
26. The casing of claim 25, wherein radially expanding and plastically
deforming at least
a portion of the first tubular member comprises radially expanding and
plastically deforming
the portion with an expandable expansion device.
27. The casing of claim 25, wherein radially expanding and plastically
deforming at least
a portion of the second tubular member comprises radially expanding and
plastically
deforming the portion with an expandable expansion device.
28. The casing of claim 25, wherein radially expanding and plastically
deforming the
threaded connection comprises radially expanding and plastically deforming the
connection
with an expansion cone.
29. The casing of claim 25, wherein radially expanding and plastically
deforming at least
a portion of the first tubular member comprises radially expanding and
plastically deforming
the portion with a first expansion device, and wherein radially expanding and
plastically
deforming the threaded connection comprises radially expanding and plastically
deforming
the connection with a second expansion device.
30. The casing of claim 25, wherein radially expanding and plastically
deforming at least
a portion of the first tubular member and radially expanding and plastically
deforming at least
a portion of the second tubular member comprises placing the threaded
connection in
tension.
31. The casing of claim 25, wherein radially expanding and plastically
deforming at least
a portion of the first tubular member comprises radially expanding and
plastically deforming
the portion into engagement with at least one of a pre-existing structure and
the borehole.


35

32. The casing of claim 25, wherein radially expanding and plastically
deforming at least
a portion of the second tubular member comprises radially expanding and
plastically
deforming the portion into engagement with at least one of a pre-existing
structure and the
borehole.
33. A method of radially expanding and plastically deforming a tubular
assembly comprising
a first tubular member, a second tubular member, and a mechanical coupling for
coupling the
first tubular member to the second tubular member, the method comprising:
placing the mechanical coupling in tension; and
then radially expanding and plastically deforming the tubular assembly,
wherein the mechanical coupling is maintained in tension during the radial
expansion
and plastic deformation of the tubular assembly.
34. The method of claim 33, wherein the mechanical coupling comprises a
threaded
connection.
35. The method of claim 34, wherein the threaded connection comprises a pin
and a box
member.
36. A method of radially expanding and plastically deforming a tubular
assembly comprising
a first tubular member, a second tubular member, and a mechanical coupling for
coupling the
first tubular member to the second tubular member, the method comprising:
placing the mechanical coupling in tension; and
then radially expanding and plastically deforming the mechanical coupling;
wherein the mechanical coupling is maintained in tension during the radial
expansion
and plastic deformation of the mechanical coupling.
37. The method of claim 36, wherein the mechanical coupling comprises a
threaded
connection.
38. The method of claim 37, wherein the threaded connection comprises a pin
and a box
member.
39. The method of claim 36, wherein the placing comprises engaging at least
one out of
the first tubular member in the second tubular member with a pre-existing
structure.
40. The method of claim 39, wherein the pre-existing structure comprises a
borehole.



36

41. A system for creating a casing in a borehole located in a subterranean
formation,
comprising:
means for installing the casing in the borehole, the casing comprising a frst
tubular
member, a second tubular member, and a threaded connection coupling the
first tubular member to the second tubular member;
means for radially expanding and plastically deforming at least a portion of
the first
tubular member,
means for radially expanding and plastically deforming at least a portion of
the
second tubular member; and
means for then radially expanding and plastically deforming the threaded
connection;
wherein the radially expanded portion of the first tubular member is not part
of the
threaded connection; and
wherein the radially expanded portion of the second tubular member is not part
of the
threaded connection.
42. The system of claim 41, wherein means for radially expanding and
plastically
deforming at least a portion of the first tubular member comprises means for
radially
expanding and plastically deforming the portion with an expandable expansion
device.
43. The system of claim 41, wherein means for radially expanding and
plastically
deforming at least a portion of the second tubular member comprises means for
radially
expanding and plastically deforming the portion with an expandable expansion
device.
44. The system of claim 41, wherein means for radially expanding and
plastically
deforming the threaded connection comprises means for radially expanding and
plastically
deforming the connection with an expansion cone.
45. The system of claim 41, wherein means for radially expanding and
plastically
deforming at least a portion of the first tubular member comprises means for
radially
expanding and plastically deforming the portion with a first expansion device,
and wherein
radially expanding and means for plastically deforming the threaded connection
comprises
radially expanding and plastically deforming the connection with a second
expansion device.
46. The system of claim 41, wherein means for radially expanding and
plastically
deforming at least a portion of the first tubular member and radially
expanding and plastically


37

deforming at least a portion of the second tubular member comprises means for
placing the
threaded connection in tension.
47. The system of claim 41, wherein means for radially expanding and
plastically
deforming at least a portion of the first tubular member comprises means for
radially
expanding and plastically deforming the portion into engagement with at least
one of a pre-
existing structure and the borehole.
48. The system of claim 41, wherein means for radially expanding and
plastically
deforming at least a portion of the second tubular member comprises means for
radially
expanding and plastically deforming the portion into engagement with at least
one of a pre-
existing structure and the borehole.
49. A system for creating a casing in a borehole located in a subterranean
formation,
comprising:
means for installing the casing in the borehole, the casing comprising a frst
tubular
member, a second tubular member, and a threaded connection coupling the
first tubular member to the second tubular member;
means for placing a first expansion device and a second expansion device in
the
casing;
means for radially expanding and plastically deforming at least a portion of
the first
tubular member and at least a portion of the second tubular member with the
first expansion device; and
means for then radially expanding and plastically deforming the threaded
connection
with the second expansion device;
wherein the radially expanded portion of the first tubular member is not part
of the
threaded connection; and
wherein the radially expanded portion of the second tubular member is not part
of the
threaded connection.
50. The system of claim 49, wherein the means for radially expanding and
plastically
deforming the threaded connection is done after means for radially expanding
and plastically
deforming at least a portion of the first tubular member and at least a
portion of the second
tubular member.
51. The system of claim 49, wherein the first expansion device is expandable.


38

52. The system of claim 49, wherein the first expansion device includes
rotating elements.
53. A system for creating a casing in a borehole located in a subterranean
formation,
comprising:
means for installing the casing in the borehole, the casing comprising a frst
tubular
member, a second tubular member, and a third tubular member, a frst
threaded connection coupling the first tubular member to the second tubular
member, and a second threaded connection coupling the second tubular
member to the third tubular member;
means for radially expanding and plastically deforming at least a portion of
the first
tubular member and at least a portion of the second tubular member;
then means for radially expanding and plastically deforming the first threaded
connection;
means for radially expanding and plastically deforming at least a portion of
the third
tubular member, and
then means for radially expanding and plastically deforming the second
threaded
connection;
wherein the radially expanded portion of the first tubular member is not part
of the first
threaded connection;
wherein the radially expanded portion of the second tubular member is not part
of the
first threaded connection; and
wherein the radially expanded portion of the third tubular member is not part
of the
second threaded connection.
54. The system of claim 53, wherein means for radially expanding and
plastically
deforming at least a portion of the first tubular member comprises radially
expanding and
plastically deforming the portion with an expandable expansion device.
55. The system of claim 53, wherein means for radially expanding and
plastically
deforming at least a portion of the second tubular member comprises means for
radially
expanding and plastically deforming the portion with an expandable expansion
device.
56. The system of claim 53, wherein means for radially expanding and
plastically
deforming at least a portion of the third tubular member comprises means for
radially
expanding and plastically deforming the portion with an expandable expansion
device.


39

57. The system of claim 53, wherein means for radially expanding and
plastically
deforming the first threaded connection comprises means for radially expanding
and
plastically deforming the connection with an expansion cone.
58. The system of claim 53, wherein means for radially expanding and
plastically
deforming the second threaded connection comprises means for radially
expanding and
plastically deforming the connection with an expansion cone.
59. The system of claim 53, wherein means for radially expanding and
plastically
deforming at least a portion of the first tubular member comprises means for
radially
expanding and plastically deforming the portion with a first expansion device,
and wherein
means for radially expanding and plastically deforming the first threaded
connection
comprises means for radially expanding and plastically deforming the
connection with a
second expansion device.
60. The system of claim 53, wherein means for radially expanding and
plastically
deforming at least a portion of the first tubular member and at least a
portion of the second
tubular member further comprises means for placing the first threaded
connection in tension.
61. The system of claim 53, wherein means for radially expanding and
plastically
deforming at least a portion of the first tubular member and at least a
portion of the second
tubular member further comprises means for applying a tensional force on the
first threaded
connection.
62. The system of claim 53, wherein means for radially expanding and
plastically
deforming at least a portion of the first tubular member comprises means for
radially
expanding and plastically deforming the portion into engagement with at least
one of a pre-
existing structure and the borehole.
63. The system of claim 53, wherein means for radially expanding and
plastically
deforming at least a portion of the second tubular member comprises means for
radially
expanding and plastically deforming the portion into engagement with at least
one of a pre-
existing structure and the borehole.
64. The system of claim 53, wherein means for radially expanding and
plastically
deforming at least a portion of the third tubular member comprises means for
radially



40

expanding and plastically deforming the portion into engagement with at least
one of a pre-
existing structure and the borehole.

65. A system for radially expanding and plastically deforming a tubular
assembly comprising
a first tubular member, a second tubular member, and a mechanical coupling for
coupling the
first tubular member to the second tubular member, the method comprising:
means for placing the mechanical coupling in tension;
then means for radially expanding and plastically deforming the tubular
assembly,
and
means for maintaining the mechanical coupling in tension during the radial
expansion
and plastic deformation of the tubular assembly.

66. The system of claim 65, wherein the mechanical coupling comprises a
threaded
connection.

67. The system of claim 66, wherein the threaded connection comprises a pin
and a box
member.

68. A system for radially expanding and plastically deforming a tubular
assembly comprising
a first tubular member, a second tubular member, and a mechanical coupling for
coupling the
first tubular member to the second tubular member, the method comprising:
means for placing the mechanical coupling in tension;
then means for radially expanding and plastically deforming the mechanical
coupling;
and
means for maintaining the mechanical coupling in tension during the radial
expansion
and plastic deformation of the mechanical coupling.

69. The system of claim 68, wherein the mechanical coupling comprises a
threaded
connection.

70. The system of claim 69, wherein the threaded connection comprises a pin
and a box
member.

71. The system of claim 68, wherein the means for placing comprises means for
engaging at least one out of the first tubular member in the second tubular
member with a
pre-existing structure.




41

72. The system of claim 71, wherein the pre-existing structure comprises a
borehole.

73. An apparatus, comprising:
a wellbore that traverses a subterranean formation; and
a wellbore casing positioned within and coupled to the wellbore;
wherein at least a portion of the wellbore casing is in tension; and
wherein the wellbore casing is radially expanded and plastically deformed into
connection with a plurality of spaced apart portions of the wellbore.

74. The apparatus of claim 73, wherein an upper portion of the wellbore casing
is radially
expanded and plastically deformed and coupled to the wellbore; and wherein a
lower portion
of the wellbore casing, spaced apart from the upper portion, is radially
expanded and
plastically deformed and coupled to the wellbore.

75. The apparatus of claim 74, wherein an intermediate portion of the wellbore
casing.
between the upper and lower portions, is not radially expanded and plastically
deformed.

76. The apparatus of claim 73, wherein the wellbore casing comprises a
plurality of
wellbore casings coupled to one another end to end; and wherein one or more of
the
couplings are in tension.

77. The apparatus of claim 76, wherein one or more of the couplings comprise
threaded
connections.

78. A method of creating a casing in a borehole located in a subterranean
formation,
comprising:
installing the casing in the borehole, the casing comprising a frst tubular
member, a
second tubular member, and a threaded connection coupling the frst tubular
member to the second tubular member;
radially expanding and plastically deforming at least a portion of the first
tubular
member;
radially expanding and plastically deforming at least a portion of the second
tubular
member; and
then radially expanding and plastically deforming the threaded connection;
wherein the radially expanded portion of the first tubular member is spaced
apart from
the threaded connection;




42

wherein the radially expanded portion of the second tubular member is spaced
apart
from the threaded connection;
wherein radially expanding and plastically deforming at least a portion of the
first
tubular member comprises radially expanding and plastically deforming the
portion with an expandable expansion device;
wherein radially expanding and plastically deforming at least a portion of the
second
tubular member comprises radially expanding and plastically deforming the
portion with an expandable expansion device;
wherein radially expanding and plastically deforming the threaded connection
comprises radially expanding and plastically deforming the connection with an
expansion cone; and
wherein radially expanding and plastically deforming at least a portion of the
first
tubular member and radially expanding and plastically deforming at least a
portion of the second tubular member comprises placing the threaded
connection in tension.

79. The method of claim 78, wherein radially expanding and plastically
deforming at least a
portion of the first tubular member comprises radially expanding and
plastically deforming the
portion Into engagement with an outer structure; and wherein radially
expanding and
plastically deforming at least a portion of the second tubular member
comprises radially
expanding and plastically deforming the portion into engagement with the outer
structure.

80. The method of claim 79, wherein the outer structure comprises a
preexisting wellbore
casing.

81. A method of creating a casing in a borehole located in a subterranean
formation,
comprising:
installing the casing in the borehole, the casing comprising a frst tubular
member, a
second tubular member, and a threaded connection coupling the first tubular
member to the second tubular member;
radially expanding and plastically deforming at least a portion of the first
tubular
member;
radially expanding and plastically deforming at least a portion of the second
tubular
member; and
then radially expanding and plastically deforming the threaded connection;
wherein the radially expanded portion of the first tubular member is spaced
apart form
the threaded connection;




43

wherein the radially expanded portion of the second tubular member is spaced
apart
from the threaded connection;
wherein radially expanding and plastically deforming at least a portion of the
first
tubular member comprises radially expanding and plastically deforming the
portion with a first expansion device,
wherein radially expanding and plastically deforming the threaded connection
comprises radially expanding and plastically deforming the connection with a
second expansion device; and
wherein radially expanding and plastically deforming at least a portion of the
first
tubular member and radially expanding and plastically deforming at least a
portion of the second tubular member comprises placing the threaded
connection in tension.

82. The method of claim 81, wherein radially expanding and plastically
deforming at least a
portion of the first tubular member comprises radially expanding and
plastically deforming the
portion into engagement with an outer structure; and wherein radially
expanding and
plastically deforming at least a portion of the second tubular member
comprises radially
expanding and plastically deforming the portion into engagement with the outer
structure.

83. The method of claim 82, wherein the outer structure comprises a
preexisting wellbore
casing.

Description

CA 02536623 2006-02-22
WO 2005/021921 PCT/US2004/028423
A METH~~ ~F RA~IALLI' E?~PAN~ING AN~ PLASTI~ALL1P ~EF~RMING
TUEULAR MEMSERS
Cross Reference To Related Applications
[00~] This application claims the benefit of the filing dates of: 1 ) U.S.
provisional patent
application serial number 60/499,576, attorney docket number 25791.215, filed
on September 2,
2003, the disclosure of which is incorporated herein by reference.
[002] The present application is related to the following: (1 ) U.S. Patent
Number 6,497,289,
which was filed as U.S. Patent Application serial no. 09/454,139, attorney
docket no.
25791.03.02, filed on 12/3/1999, which claims priority from provisional
application 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 2110/2000, 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 601108,558, 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 2124/2000, 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 7/29/99, (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.
1



CA 02536623 2006-02-22
WO 2005/021921 PCT/US2004/028423
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 number6,564,875, which was filed as application
serial no. 09/679,907,
attorney docket no. 25791.34.02, on 10/5/00, which claims priority from
provisional patent
application serial no. 60/159,082, attorney docket no. 25791.34, filed on
10/12/1999, (18) U.S.
patent application serial no. 10/089,419, filed on 3/27/02, attorney docket
no. 25791.36.03,
which claims priority from provisional patent application serial no.
60/159,039, attorney docket
no. 25791.36, filed on 10/12/1999, (19) U.S. patent application serial no.
09/679,906, filed on
10/5/00, attorney docket no. 25791.37.02, which claims priority from
provisional patent
application serial no. 60/159,033, attorney docket no. 25791.37, filed on
10/12/1999, (20) U.S.
patent application serial no. 10/303,992, filed on 11/22/02, attorney docket
no. 25791.38.07,
which claims priority from provisional patent application serial no.
60/212,359, attorney docket
no. 25791.38, filed on 6/19/2000, (21 ) U.S. provisional patent application
serial no. 60/165,228,
attorney docket no. 25791.39, filed on 11/12/1999, (22) U.S. provisional
patent application serial
no. 60/455,051, attorney docket no. 25791.40, filed on 3/14/03, (23) PCT
application US02/2477,
filed on 6/26/02, attorney docket no. 25791.44.02, which claims priority from
U.S. provisional
patent application serial no. 60/303,711, attorney docket no. 25791.44, filed
on 7/6/01, (24) U.S.
patent application serial no. 10/311,412, filed on 12/12/02, attorney docket
no. 25791.45.07,
which claims priority from provisional patent application serial no.
601221,443, attorney docket
no. 25791.45, filed on 7/28/2000, (25) U.S. patent application serial no. 10/,
filed on 12/18102,
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 10/212000, (28) PCT application
US02/04353, filed on
2/14/02, attorney docket no. 25791.50.02, which claims priority from U.S.
provisional patent
application serial no. 60/270,007, attorney docket no. 25791.50, filed on
2/20/2001, (29) U.S.
patent application serial no. 10/465,835, filed on 6/13/03, attorney docket
no. 25791.51.06,
which claims priority from provisional patent application serial no.
60/262,434, attorney docket
no. 25791.51, filed on 1 /17/2001, (30) U.S. patent application serial no.
10/465,831, filed on
6/13/03, attorney docket no. 25791.52.06, which claims priority from U.S.
provisional patent
application serial no. 60/259,486, attorney docket no. 25791.52, filed on
1/3/2001, (31) U.S.
provisional patent application serial no. 60/452,303, filed on 3/5/03,
attorney docket no.
2



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25791.53, (32) U.S. patent number 6,470,966, which was filed as patent
application serial
number 09/850,093, filed on 5!7/01, attorney docket no. 25791.55, as a
divisional application of
U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application
serial no. 09/454,139,
attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority
from provisional
application 60/111,293, filed on 12/7/98, (33) U.S. patent number 6,561,227,
which was filed as
patent application serial number 09/852,026 , filed on 5/9/01, attorney docket
no. 25791.56, as a
divisional application of U.S. Patent Number 6,497,289, which was filed as
U.S. Patent
Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on
12/311999, which
claims priority from provisional application 60/111,293, filed on 12/7/98,
(34) U.S. patent
application serial number 09/852,027, filed on 5/9/01, attorney docket no.
25791.57, as a
divisional application of U.S. Patent Number 6,497,289, which was filed as
U.S. Patent
Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on
12/3/1999, which
claims priority from provisional application 60/111,293, filed on 12/7/98,
(35) PCT Application
US02/25608, attorney docket no. 25791.58.02, filed on 8/13/02, which claims
priority from
provisional application 60/318,021, filed on 9/7!01, attorney docket no.
25791.58, (36) PCT
Application US02/24399, attorney docket no. 25791.59.02, filed on 8/1 /02,
which claims priority
from U.S. provisional patent application serial no. 60/313,453, attorney
docket no. 25791.59,
filed on 8/20/2001, (37) PCT Application US02/29856, attorney docket no.
25791.60.02, filed on
9/19/02, which claims priority from U.S. provisional patent, application
serial no. 60/326,886,
attorney docket no. 25791.60, filed on 10/3/2001, (38) PCT Application
US02/20256, attorney
docket no. 25791.61.02, filed on 6/26/02, which claims priority from U.S.
provisional patent
application serial no. 60/303,740, attorney docket no. 25791.61, filed on
7/6/2001, (39) U.S.
patent application serial no. 09/962,469, filed on 9/25/01, attorney docket
no. 25791.62, which is
a divisional of U.S. patent application serial no. 09/523,468, attorney docket
no. 25791.11.02,
filed on 3/10/2000, which claims priority from provisional application
60/124,042, filed on 3/11/99,
(40) U.S. patent application serial no. 09!962,470, filed on 9/25/01, attorney
docket no.
25791.63, which is a divisional of U.S. patent application serial no.
09/523,468, attorney docket
no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional
application
60/124,042, filed on 3/11/99, (41 ) U.S. patent application serial no.
09/962,471, filed on 9/25/01,
attorney docket no. 25791.64, which is a divisional of U.S. patent application
serial no.
09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims
priority from
provisional application 60/124,042, filed on 3/11/99, (42) U.S. patent
application serial no.
09/962,467, filed on 9/25/01, attorney docket no. 25791.65, which is a
divisional of U.S. patent
application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on
3/10/2000, which
claims priority from provisional application 60/124,042, filed on 3/11/99,
(43) U.S. patent
application serial no. 09/962,468, filed on 9/25/01, attorney docket no.
25791.66, which is a
divisional of U.S. patent application serial no. 09!523,468, attorney docket
no. 25791.11.02, filed
3



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on 3/10/2000, which claims priority from provisional application 60/124,04.2,
fled on 3/11/99, (44)
PCT application US 02/25727, filed on 8/14/02, attorney docket no.
25791.67.03, which claims
priority from U.S. provisional patent application serial no. 60/317,985,
attorney docket no.
25791.67, filed on 9/6/2001, and U.S. provisional patent application serial
no. 60/318,386,
attorney docket no. 25791.67.02, filed on 9/10/2001, (45) PCT application US
02/39425, filed on
12/10102, attorney docket no. 25791.68.02, which claims priority from U.S.
provisional patent
application serial no. 60/343,674 , attorney docket no. 25791.68, filed on
12/27/2001, (46) U.S.
utility patent application serial no. 09/969,922, attorney docket no.
25791.69, filed on 10/3/2001,
which is a continuation-in-part application of U.S. patent no. 6,328,113,
which was filed as U.S.
Patent Application serial number 09/440,338, attorney docket number
25791.9.02, filed on
11/15/99, which claims priority from provisional application 60/108,558, filed
on 11/16/98, (47)
U.S. utility patent application serial no. 10/516,467, attorney docket no.
25791.70, filed on
12/10/01, which is a continuation application of U.S. utility patent
application serial no.
09/969,922, attorney docket no. 25791.69, filed on 10/3/2001, which is a
continuation-in-part
application of U.S. patent no. 6,328,113, which was filed as U.S. Patent
Application serial
number 09/440,338, attorney docket number 25791.9.02, filed on 11 /15/99,
which claims priority
from provisional application 60/108,558, filed on 11/16/98, (48) PCT
application US 03/00609,
filed on 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 docket no. 25791.77,
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, (53) U.S. patent
application serial no.
10/076,659, attorney docket no. 25791.78, filed on 2/15/02, which is a
divisional of U.S. patent
number 6,568,471, which was filed as patent application serial no. 09/512,895,
attorney docket
no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional
application
4



CA 02536623 2006-02-22
WO 2005/021921 PCT/US2004/028423
60/121,841, filed on 2/26/99, (54) U.S. patent application serial no.
10/078,928, attorney docket
no. 25791.79, filed on 2/20/02, which is a divisional of U.S. patent number
6,568,471, which was
filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on
2/24/2000, which claims priority from provisional application 60/121,841,
filed on 2/26/99, (55)
U.S. patent application serial no. 10/078,922, attorney docket no. 25791.80,
filed on 2120/02,
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 isa 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
6/712000, 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 docket no. 25791.17.02, filed on 6/7/2000, which claims
priority from
provisional application 60/137,998, filed on 6/7/99, (62) PCT application US
02/36157, filed on
11/12/02, attorney docket no. 25791.87.02, which claims priority from U.S.
provisional patent
application serial no. 60/338,996, attorney docket no. 25791.87, filed on
11/12/01, (63) PCT
application US 02/36267, filed on 11112/02, attorney docket no. 25791.88.02,
which claims
priority from U.S. provisional patent application serial no. 60/339,013,
attorney docket no.
25791.88, filed on 11/12/01, (64) PCT application US 03/11765, filed on
4/16/03, attorney docket
no. 25791.89.02, which claims priority from U.S. provisional patent
application serial no.
60/383,917, attorney docket no. 25791.89, filed on 5/29/02, (65) PCT
application US 03/15020,



CA 02536623 2006-02-22
WO 2005/021921 PCT/US2004/028423
filed on 5/12/03, attorney docket no. 25791.90.02, which claims priority from
U.S. provisional
patent application serial no. 60/391,703, attorney docket no. 25791.90, filed
on 6/26/02, (66)
PCT application US 02/39418, filed on 12/10/02, attorney docket no.
25791.92.02, which claims
priority from U.S. provisional patent application serial no. 60/346,309,
attorney docket no.
25791.92, filed on 1/7/02, (67) PCT application US 03/06544, filed on 3/4/03,
attorney docket no.
25791.93.02, which claims priority from U.S. provisional patent application
serial no.
60/372,048, attorney docket no. 25791.93, filed on 4/12/02, (68) U.S. patent
application serial
no. 10/331,718, attorney docket no. 25791.94, filed on 12/30/02, which is a
divisional U.S.
patent application serial no. 09/679,906, filed on 10/5/00, attorney docket
no. 25791.37.02,
which claims priority from provisional patent application serial no.
60/159,033, attorney docket
no. 25791.37, filed on 10/12/1999, (69) PCT application US 03/04837, filed on
2/29/03, attorney
docket no. 25791.95.02, which claims priority from U.S. provisional patent
application serial no.
60/363,829, attorney docket no. 25791.95, filed on 3/13/02, (70) U.S. patent
application serial
no. 10/261,927, attorney docket no. 25791.97, filed on 10/1/02, which is a
divisional of U.S.
patent number 6,557,640, which was filed as patent application serial no.
09/588,946, attorney
docket no. 25791.17.02, filed on 6/7/2000, which claims priority from
provisional application
60/137,998, filed on 6/7/99, (71 ) U.S. patent application serial no.
10/262,008, attorney docket
no. 25791.98, filed on 10/1 /02, which is a divisional of U.S. patent number
6,557,640, which was
filed as patent application serial no. 09/588,946, attorney docket no.
25791.17.02, filed on
6/7/2000, which claims priority from provisional application 60/137,998, filed
on 6/7/99, (72) U.S.
patent application serial no.10/261,925, attorney docket no. 25791.99, filed
on 1011 /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 4/15/02, (75)
U.S. provisional
patent application serial no. 60/412,542, attorney docket no. 25791.102, filed
on 9/20/02, (76)
PCT application US 03/14153, filed on 5/6/03, attorney docket no.
25791.104.02, which claims
priority from U.S. provisional patent application serial no. 60/380,147,
attorney docket no.
25791.104, filed on 5/6/02, (77) PCT application US 03/19993, filed on
6/24/03, attorney docket
no. 25791.106.02, which claims priority from U.S. provisional patent
application serial no.
60/397,284, attorney docket no. 25791.106, filed on 7/19/02, (78) PCT
application US 03/13787,
filed on 5/5/03, attorney docket no. 25791.107.02, which claims priority from
U.S. provisional
6



CA 02536623 2006-02-22
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patent application serial no. 60/387,486 , attorney docket no. 25791.107,
filed on 6/10/02, (79)
PCT application US 03/18530, filed on 6/11 /03, attorney docket no.
25791.108.02, which claims
priority from U.S. provisional patent application serial no. 60/387,961,
attorney docket no.
25791.108, filed on 6!12/02, (80) PCT application US 03/20694, filed on 7/1
/03, attorney docket
no. 25791.110.02, which claims priority from U.S. provisional patent
application serial no.
60/398,061, attorney docket no. 25791.110, filed on 7/24102, (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
9120/02, (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. 601412,196, attorney docket no. 25791.127, filed on 9/20102, (93) U.S.
provisional patent
application serial no. 60/412,187, attorney docket no. 25791.128, filed on
9/20/02, (94) U.S.
provisional patent application serial no. 60/412,371, attorney docket no.
25791.129, filed on
9/20/02, (95) U.S. patent application serial no. 10/382,325, attorney docket
no. 25791.145, filed
on 3/5/03, which is a continuation of U.S. patent number 6,557,640, which was
filed as patent
application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on
6/7/2000, which
claims priority from provisional application 60/137,998, filed on 6/7/99, (96)
U.S. patent
application serial no. 10/624,842, attorney docket no. 25791.151, filed on
7/22/03, which is a
divisional of U.S. patent application serial no. 09/502,350, attorney docket
no. 25791.8.02, filed
on 2/10/2000, which claims priority from provisional application 60/119,611,
filed on 2!11/99, (97)
U.S. provisional patent application serial no. 60/431,184, attorney docket no.
25791.157, filed on
7



CA 02536623 2006-02-22
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12/5/02, (98) U.S. provisional patent application serial no. 601448,526,
atfiorney 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
2/26103, (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. 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, (115) U.S. provisional patent application serial
no. 60/459,776,
attorney docket no. 25791.270, filed on 4/2/03, (116) U.S. provisional patent
application serial
no. 60/461,094, attorney docket no. 25791.272, filed on 4/8/03, (117) U.S.
provisional patent
application serial no. 60/461,038, attorney docket no. 25791.273, filed on
4/7/03, (118) U.S.
provisional patent application serial no. 60/463,586, attorney docket no.
25791.277, filed on
4/17/03, (119) U.S. provisional patent application serial no. 60/472,240,
attorney docket no.
25791.286, filed on 5/20/03, (120) U.S. patent application serial no.
10/619,285, attorney docket
no. 25791.292, filed on 7/14/03, which is a continuation-in-part of U.S.
utility patent application
serial no. 09/969,922, attorney docket no. 25791.69, filed on 10/3/2001, which
is a continuation-
in-part application of U.S. patent no. 6,328,113, which was filed as U.S.
Patent Application serial
number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which
claims priority
from provisional application 60/108,558, filed on 11/16/98, (121) U.S.
provisional patent
8



CA 02536623 2006-02-22
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application serial no. 60/472,240, attorney docket no. 25791.236, filed on
5/20/03. The
disclosures of all of which (01-121 ) are herein incorporated by reference in
their entirety.
Field of the Invention
[003] This invention relates to expandable tubular members, and in particular
to a method of
expanding tubular members.
Background
[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 a smaller diameter than the casing of
the upper interval.
Thus, the casings are in a nested arrangement with casing diameters decreasing
in a downward
direction. Cement annuli may be provided between the outer surfaces of the
casings and the
borehole wall to seal the casings from the borehole wall. As a consequence of
this nested
arrangement a relatively large borehole diameter is required at the upper part
of the wellbore.
Such a large borehole diameter involves increased costs due to heavy casing
handling
a
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.
[005] In order to avoid the nested arrangement of casing as discussed above,
wellbore casings
may be formed in the wellbore by radially expanding and plastically deforming
tubular members
in the borehole. These tubular members are often coupled to one another by
threaded
connections. The threaded engagement between properly secured tubular members
in a
conventional casing joint is effective in maintaining a secure mechanical
connection that holds
the string together and effectively seals the internal casing area from the
formation wellbore
environment. When the casing string and connection are enlarged radially, a
conventional
connection changes dimensionally in a way that can prevent the engaged
components of the
connection from properly engaging and sealing. The radial expansion of a
conventional
connection may weaken or otherwise damage the connection sufficiently to
permit mechanical
separation or leakage in the connection.
[006] Furthermore, if a first tubular member is connected to a second tubular
member, and
then radially expanded and plastically deformed while the connection between
the first tubular
member and the second tubular member is in compression, the connection may
fail during
and/or after the radial expansion and plastic deformation.
[007] What is needed is a new method and apparatus to expand a tubular
connection.
9



CA 02536623 2006-02-22
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brief Description of the Drawings
[008] Fig. 1 is a sectional view through a borehole illustrating a string of
casing run in a
borehole prior to being radially expanded and plastically deformed.
[009] Fig. 2 is a sectional view through a borehole illustrating a string of
casing that has been
partially radially expanded and plastically deformed.
(0010] Fig. 3 is a sectional view through a borehole illustrating a string of
casing that has been
radially expanded and plastically deformed.
[0011] Fig. 4 is a sectional view through a borehole illustrating a string of
casing being radially
expanded and plastically deformed with an expansion device.
[0012] Fig. 5 is a sectional view through a borehole illustrating a partially
expanded string of
casing and an expandable expansion device.
[0013] Fig. 6 is a sectional view through a borehole illustrating a string of
casing being radially
expanded and plastically deformed with two expansion devices.
Detailed Description
[0014] Referring to Fig. 1, there is illustrated a subterranean formation 8,
and a borehole 10
positioned in the subterranean formation. As a first step, a string of casing
12 is positioned
within the borehole 10. The string of casing 12 includes a first tubular
member 14 and a second
tubular member 16. The first tubular member 14 and the second tubular member
16 are
connected by a conventional mechanical connection 18, for example a
conventional threaded
connection.
[0015] Referring to Fig. 2, a second step is illustrated where a portion of
the first tubular member
14 above the connection 18 has been radially expanded and plastically deformed
into
engagement with the borehole 10, and a portion of the second tubular member 16
below the
connection 18 has been radially expanded and plastically deformed into
engagement with the
borehole 10. The connection 18 has not been radially expanded and plastically
deformed.
[0016] The connection 18 is shown in tension. The first tubular member 14 is
exerting a force
on the connection 18 in the direction of an arrow 20. The second tubular
member 16 is exerting
a force on the connection 18 in the direction of an arrow 22.
[0017] It is understood that the connection 18 is in tension because as a
portion of the first
tubular member 14 is expanded and plastically deformed in a radial direction
into engagement
with the borehole 10, that portion contracts in an axial direction due to
Poisson's ratio, and exerts
a tensional force on the connection. Alternatively, the connection 18 is in
tension because as a
portion of the second tubular member 16 is expanded and plastically deformed
in a radial
direction into engagement with the borehole 10, that portion contracts in an
axial direction due to
Poisson's ratio, and exerts a tensional force on the connection. It is
understood that both the
first tubular member 14 and the second tubular member 16 are held stationary,
for example by
being expanded into engagement with the borehole 10, in order for the
connection 18 to be in



CA 02536623 2006-02-22
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tension. If either the first tubular member 14 or the second tubular member 16
were not held
stationary, there would be no tensional force in the connection 18, because
the tubular members
would move in the direction of the tensional force to relieve the force.
[0018] Referring to Fig. 3, a third step is illustrated where the string of
casing 12 has been
radially expanded and plastically deformed within the borehole 10. The first
tubular member 14
and the second tubular member 16 were radially expanded and plastically
deformed into
engagement with the borehole 10, as shown in Fig. 2, and then the connection
18 was radially
expanded and plastically deformed, as shown in Fig. 3.
[0019] Referring to Fig. 4, there is illustrated a first part of a technique
of radiallyexpanding and
plastically deforming the string of casing 12 of Fig. 1. An expansion device
22 is used to radially
expand and plastically deform portions of the string of casing 12.
[0020] It is understood that suitable expansion devices for the expansion
device 22 include
conventional expansion devices adjustable between a small diameter
configuration and a large
diameter configuration. It is also understood that when the expansion device
22 is in the small
diameter configuration, the expansion device can fit through the unexpended
connection 18, as
shown in Figs. 1 and 2; and when the expansion device is in the large diameter
configuration,
the expansion device can expand a portion of the first tubular member 14,
second tubular
member 16, and/or the connection 18, as shown in Figs. 2 and 3.
[0021] Referring again to Fig. 4, a first part of the technique is illustrated
where a portion of the
second tubular member 16 below the connection 18 is being radially expanded
and plastically
deformed by the expansion device 22. The expansion device 22 is shown in the
large diameter
configuration. The expansion device 22 is mounted to a support number 23. It
is understood
that an area 24 under the expansion device 22 may be pressurized to force the
expansion
device towards the connection 18 and the first tubular member 14.
Alternatively, the expansion
device 22 may be pulled by the support member 23 towards the connection 18 and
the first
tubular member 14.
[0022] It is understood that the expansion device 22 may be lowered through
the string of casing
12 in the small diameter configuration, then the expansion device may be
expanded to the large
diameter configuration, and used to expand a portion of the second tubular
member 16.
Alternatively, the expansion device 22 may start in the large diameter
configuration, and the
string of casing 12 may be placed over the support number 23, so that the
expansion device is at
the bottom of the string of casing, then the expansion device can be pulled
through the second
tubular member 16 to radially expand and plastically deform the second tubular
member.
[0023] Referring to Fig. 5, a second part of the technique is illustrated
where the expansion
device 22 is in a small diameter configuration moving through the connection
18. It is
understood that the expansion device 22 may be used to radially expand and
plastically deform
a portion of the second tubular member 16 while in a large diameter
configuration during the first
11



CA 02536623 2006-02-22
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part of the technique as illustrated in Fig. 4, then be collapsed into a small
diameter configuration
and be pulled through the connection 18 by the support number 23, during the
second part of the
technique as illustrated in Fig. 5.
[0024] It is also understood that after being pulled through the connection 18
and into the first
tubular member 14, the expansion device 22 may be re-expanded into the large
diameter
configuration and used to radially expand and plastically deform a portion of
the first tubular
member 14, during a third part of the technique.
[0025] After a portion of the second tubular member 16 and a portion of the
first tubular member
14 have been radially expanded and plastically deformed with the expansion
device 22 in the
above described manner, the connection 18 may be radially expanded and
plastically deformed
with the expansion device 22 or with another expansion device (not shown),
during a fourth part
of the technique.
[0026] Referring to Fig. 6, there is illustrated a second technique of
radially expanding and
plastically deforming the string of casing 12 of Fig. 1. A portion of the
string of casing 12 is
radially expanded and plastically performed with a first expansion device 26
and a second
expansion device 28. The first expansion device 26 is mounted on a support
member 34. The
second expansion device 28 is connected to the first expansion device 26 in a
conventional
manner by a connecting device 30.
[0027] It is understood that the first expansion device 26 is expandable
between a small
diameter configuration and a large diameter configuration, while the second
expansion device 28
may or may not be expandable between a small diameter configuration and a
large diameter
configuration.
[0028] In operation, during a first part of the second technique, the first
expansion device 26 is
used to radially expand and plastically deform a portion of the second tubular
member 16 while
in a large diameter configuration. During a second part of the second
technique, the first
expansion device 26 is then retracted into a small diameter configuration and
moved through the
connection 18. During a third part of the second technique, the first
expansion device 26 is
expanded into a large diameter configuration and used to radially expand and
plastically deform
a portion of the first tubular member 14, after moving through the connection
18.
[0029] The second expansion device 28 is pulled by the connecting device 30
behind the first
expansion device 26. It is understood that the second expansion device 28 has
a fixed
diameter. Alternatively, the second expansion device 28 is movable between a
first small
diameter configuration and a second large diameter configuration.
[0030] After the first expansion device 26 has radially expanded and
plastically deformed a
portion of the second tubular member 16 and a portion of the first tubular
member 14 during the
third part of the second technique, during a fourth part the second expansion
device 28 is pulled
through the connection 18 by the connecting device 30, and the second
expansion device
12



CA 02536623 2006-02-22
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radially expands and plastically deforms the connection. After moving the
first expansion device
26 and the second expansion device 23 through the string of casing 12 (shown
in Fig. 6) using
the second technique, the string of casing may look like the string of casing
12 as illustrated in
Fig. 3.
[003] It is understood that the first expansion device 26 and the second
expansion device 213
may be moved through the string of casing 12 by pulling them with the support
member 34.
Alternatively, the first expansion device 26 and the second expansion device
23 are moved
through the string of casing 12 by pressurizing an area 32 under the second
expansion device,
which pushes the second expansion device, the connecting device 30, and the
first expansion
device.
[0032] In one embodiment, there is disclosed a method of creating a casing in
a borehole
located in a subterranean formation, comprising installing the casing in the
borehole, the casing
comprising a first tubular member, a second tubular member, and a conventional
threaded
connection coupling the first tubular member to the second tubular member;
radially expanding
and plastically deforming at least a portion of the first tubular member;
radially expanding and
plastically deforming at least a portion of the second tubular member; and
then radially
expanding and plastically deforming the conventional threaded connection. In
another
embodiment, the radially expanding and plastically deforming at least a
portion of the first tubular
member comprises radially expanding and plastically deforming the portion with
an expandable
expansion device. In another embodiment, the radially expanding and
plastically deforming at
least a portion of the second tubular member comprises radially expanding and
plastically
deforming the portion with an expandable expansion device. In another
embodiment, the radially
expanding and plastically deforming the conventional threaded connection
comprises radially
expanding and plastically deforming the connection with an expansion cone. In
another
embodiment, the radially expanding and plastically deforming at least a
portion of the first tubular
member comprises radially expanding and plastically deforming the portion with
a first expansion
device, and wherein radially expanding and plastically deforming the
conventional threaded
connection comprises radially expanding and plastically deforming the
connection with a second
expansion device. In another embodiment, the radially expanding and
plastically deforming at
least a portion of the first tubular member and radially expanding and
plastically deforming at
least a portion of the second tubular member comprises placing the
conventional threaded
connection in tension. In another embodiment, the radially expanding and
plastically deforming
at least a portion of the first tubular member comprises radially expanding
and plastically
deforming the portion into engagement with at least one of a pre-existing
structure and the
borehole. In another embodiment, the radially expanding and plastically
deforming at least a
portion of the second tubular member comprises radially expanding and
plastically deforming the
portion into engagement with at least one of a pre-existing structure and the
borehole.
13



CA 02536623 2006-02-22
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[0033] In one embodiment, there is disclosed a method of creating a casing in
a borehole
located in a subterranean formation, comprising installing the casing in the
borehole, the casing
comprising a first tubular member, a second tubular member, and a conventional
threaded
connection coupling the first tubular member to the second tubular member;
placing a first
expansion device and a second expansion device in the casing; radially
expanding and
plastically deforming at least a portion of the first tubular member and at
least a portion of the
second tubular member with the first expansion device; and radially expanding
and plastically
deforming the conventional threaded connection with the second expansion
device. In another
embodiment, the radially expanding and plastically deforming the conventional
threaded
connection is done after radially expanding and plastically deforming at least
a portion of the first
tubular member and at least a portion of the second tubular member. In another
embodiment,
the first expansion device is expandable. In another embodiment, the first
expansion device
includes rotating elements.
[0034] In one embodiment, there is disclosed a method of creating a casing in
a borehole
located in a subterranean formation, comprising installing the casing in the
borehole, the casing
comprising a first tubular member, a second tubular member, and a third
tubular member, a first
conventional threaded connection coupling the first tubular member to the
second tubular
member, and a second conventional threaded connection coupling the second
tubular member
to the third tubular member; radially expanding and plastically deforming at
least a portion of the
first tubular member and at least a portion of the second tubular member; then
radially
expanding and plastically deforming the first conventional threaded
connection; radially
expanding and plastically deforming at least a portion of the third tubular
member; and then
radially expanding and plastically deforming the second conventional threaded
connection. In
another embodiment, the radially expanding and plastically deforming at least
a portion of the
first tubular member comprises radially expanding and plastically deforming
the portion with an
expandable expansion device. In another embodiment, the radially expanding and
plastically
deforming at least a portion of the second tubular member comprises radially
expanding and
plastically deforming the portion with an expandable expansion device. In
another embodiment,
the radially expanding and plastically deforming at least a portion of the
third tubular member
comprises radially expanding and plastically deforming the portion with an
expandable
expansion device. In another embodiment, the radially expanding and
plastically deforming the
first conventional threaded connection comprises radially expanding and
plastically deforming
the connection with an expansion cone. In another embodiment, the radially
expanding and
plastically deforming the second conventional threaded connection comprises
radially expanding
and plastically deforming the connection with an expansion cone. In another
embodiment, the
radially expanding and plastically deforming at least a portion of the first
tubular member
comprises radially expanding and plastically deforming the portion with a
first expansion device,
14



CA 02536623 2006-02-22
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and wherein radially expanding and plastically deforming the first
conventional threaded
connection comprises radially expanding and plastically deforming the
connection with a second
expansion device. In another embodiment, the radially expanding and
plastically deforming at
least a portion of the first tubular member and at least a portion of the
second tubular member
further comprises placing the first conventional threaded connection in
tension. In another
embodiment, the radially expanding and plastically deforming at least a
portion of the first tubular
member and at least a portion of the second tubular member further comprises a
tensional force
on the first conventional threaded connection. In another embodiment, the
radially expanding
and plastically deforming at least a portion of the first tubular member
comprises radially
expanding and plastically deforming the portion into engagement with at least
one of a pre-
existing structure and the borehole. In another embodiment, the radially
expanding and
plastically deforming at least a portion of the second tubular member
comprises radially
expanding and plastically deforming the portion into engagement with at least
one of a pre-
existing structure and the borehole. In another embodiment, the radially
expanding and
plastically deforming at least a portion of the third tubular member comprises
radially expanding
and plastically deforming the portion into engagement with at least one of a
pre-existing structure
and the borehole.
[0035] In one embodiment, there is disclosed an expanded casing in a borehole
located in a
subterranean formation, comprising a first tubular member, a second tubular
member, and a
conventional threaded connection coupling the first tubular member to the
second tubular
member, the casing produced by the process of installing the casing in the
borehole; radially
expanding and plastically deforming at least a portion of the first tubular
member; radially
expanding and plastically deforming at least a portion of the second tubular
member; and then
radially expanding and plastically deforming the conventional threaded
connection. In another
embodiment, the radially expanding and plastically deforming at least a
portion of the first tubular
member comprises radially expanding and plastically deforming the portion with
an expandable
expansion device. In another embodiment, the radially expanding and
plastically deforming at
least a portion of the second tubular member comprises radially expanding and
plastically
deforming the portion with an expandable expansion device. In another
embodiment, the radially
expanding and plastically deforming the conventional threaded connection
comprises radially
expanding and plastically deforming the connection with an expansion cone. In
another
embodiment, the radially expanding and plastically deforming at least a
portion of the first tubular
member comprises radially expanding and plastically deforming the portion with
a first expansion
device, and wherein radially expanding and plastically deforming the
conventional threaded
connection comprises radially expanding and plastically deforming the
connection with a second
expansion device. In another embodiment, the radially expanding and
plastically deforming at
least a portion of the first tubular member and radially expanding and
plastically deforming at



CA 02536623 2006-02-22
WO 2005/021921 PCT/US2004/028423
least a portion of the second tubular member comprises placing the
conventional threaded
connection in tension. In another embodiment, the radially expanding and
plastically deforming
at least a portion of the first tubular member comprises radially expanding
and plastically
deforming the portion into engagement with at least one of a pre-existing
structure and the
borehole. In another embodiment, radially expanding and plastically deforming
at least a portion
of the second tubular member comprises radially expanding and plastically
deforming the portion
into engagement with at least one of a pre-existing structure and the
borehole.
[0036] In one embodiment, there is disclosed a method of radially expanding
and plastically
deforming a tubular assembly comprising a first tubular member, a second
tubular member, and
a mechanical coupling for coupling the first tubular member to the second
tubular member, the
method comprising placing the mechanical coupling in tension; and then
radially expanding and
plastically deforming the tubular assembly. In another embodiment, the
mechanical coupling
comprises a conventional threaded connection. In another embodiment, the
conventional
threaded connection comprises a pin and a box member.
[0037] In one embodiment, there is disclosed a method of radially expanding
and plastically
deforming a tubular assembly comprising a first tubular member, a second
tubular member, and
a mechanical coupling for coupling the first tubular member to the second
tubular member, the
method comprising placing the mechanical coupling in tension; and then
radially expanding and
plastically deforming the mechanical coupling. In another embodiment, the
mechanical coupling
comprises a conventional threaded connection. In another embodiment, the
conventional
threaded connection comprises a pin and a box member.
[0038] As illustrated in Figs. 1-3, the first tubular member 14, the second
tubular member 16,
and/or the conventional threaded connection 18 were radially expanded and
plastically deformed
into engagement with the borehole 10. Alternatively, it is contemplated that
there could be a
cement annulus, an existing section of casing, a sleeve member, a pre-existing
structure, or
space left between the first tubular member 14, the second tubular member 16,
and/or the
conventional threaded connection 18 and the borehole 10.
[0039] As illustrated in Fig. 2, the expanded portion of the first tubular
member 14 has been
radially expanded and plastically deformed into engagement with the borehole
10. Alternatively,
it is contemplated that there could be a cement annulus, an existing section
of casing, a sleeve
member, a pre-existing structure, or space left between the first tubular
member 14 and the
borehole 10.
[0040] As illustrated in Fig. 2, the expanded portion of the second tubular
member 16 has been
radially expanded and plastically deformed into engagement with the borehole
10. Alternatively,
it is contemplated that there could be a cement annulus, an existing section
of casing, a sleeve
member, a pre-existing structure, or space left between the second tubular
member 16 and the
borehole 10.
16



CA 02536623 2006-02-22
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[00.1] Suitable expansion devices for the expansion device 22, the first
expansion device 26,
and/or the second expansion device 28 include conventional expandable
expansion devices
commercially available from the Assignee of the present invention; Baker Oil
Tools of Houston,
Texas; or Weatherford Completion Systems of Houston, Texas.
[0042] Suitable expansion devices for the expansion device 22, the first
expansion device 26,
and/or the second expansion device 28 include expandable expansion devices as
disclosed in
United States patent number 6,578,630 and/or United States patent number
6,012,523, the
disclosures of which are herein incorporated by reference in their entirety.
[0043] Suitable expansion devices for the expansion device 22, the first
expansion device 26,
and/or the second expansion device 28 include expandable expansion devices as
disclosed in
one or more of the Related Applications which were referenced and incorporated
by reference
above.
[0044] Suitable expansion devices for the second expansion device 28 include
conventional
expansion devices commercially available from the Assignee of the present
invention; Baker Oil
Tools of Houston, Texas; or Weatherford Completion Systems of Houston, Texas.
[0045] Suitable expansion devices for the second expansion device 28 include
expansion
devices as disclosed in one or more of Related Applications which were
referenced and
incorporated by reference above.
[0046] The connection 18 includes a conventional pin member on the first
tubular member 14,
and a conventional box member on the second tubular member 16, where the pin
member and
the box member are threadably engaged.
[0047] Suitable connections for the connection 18 include conventional
threaded connections,
conventional threaded connections with a pin and a box member, conventional
welded
connections, conventional butt welds, conventional flanges, conventional
bolted flanges, or
conventional threaded fittings.
[0048] Suitable tubular members for the string of casing 12, the first tubular
member 14, and/or
the second tubular member 16 include conventional tubular members commercially
available
from the Assignee of the present invention; Baker Oil Tools of Houston, Texas;
or Weatherford
Completion Systems of Houston, Texas.
[0049] Suitable tubular members for the string of casing 12, the first tubular
member 14, and/or
the second tubular member 16 include tubular members as disclosed in one or
more of the
Related Applications which were referenced and incorporated by reference
above.
[0050] Although Figs. 4-6 show a bottom-up expansion of the second tubular
member 16, then
the first tubular member 14, it is understood that the expansion device 22,
the first expansion
device 26, and/or the second expansion device 28 may be used in a top-down
configuration to
expand the first tubular member 14, then the second tubular member 16.
17



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[005] In several alternative embodiments, the method of radially expanding and
plastically
deforming a tubular member as illustrated in Figs. 1-6, may be implemented in
accordance with
the teachings of one or more of the Related Applications which were referenced
and
incorporated by reference above.
[0052] Although illustrative embodiments of the invention have been shown and
described, a
wide range of modification, changes and substitution is contemplated in the
foregoing disclosure.
In some instances, some features of the present invention may be employed
without a
corresponding use of the other features. Accordingly, it is appropriate that
the appended claims
be construed broadly and in a manner consistent with the scope of the
invention.
18

Representative Drawing