Note: Descriptions are shown in the official language in which they were submitted.
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
EXPANDABLE TUBULAR
Cross Reference To Related Applications
[009] This application claims the benefit of the filing date of US provisional
patent
application serial number 60/600679, attorney docket number 25791.194, filed
on 8111/2004,
the disclosure which is incorporated herein by reference. This application
claims the benefit
of the filing date of US provisional patent application serial number
601585370, attorney
docket number 25791.299, filed on 7/2/2004, the disclosure which is
incorporated herein by
reference. This application claims the benefit of the filing date of US
provisional patent
application serial number 60/500435, attorney docket number 25791.304, filed
on 9/5/2003,
the.disclasure which is incorporated.herein by reference. This application
claims the benefit
of the filing date of US provisional patent application serial number
60/598020, attorney
dAocket number 25797.329, filed on 8/2/2004, the disclosure which is
incorporated herein by
reference. This application claims the benefit of the filing date of US
provisional patent
application serial number 601601502; 'attorney docket number 25791.338, filed
on 8/1312004,
the disclosure which is incorporated herein by reference.
[002] This application is related to the following co-pending applications:
(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 1217198, (2) U.S, patent application serial
no. 091510,913,
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 60/108,558,
filed on 11/16/98,
(5) U.S. patent application serial no. 10/169,434, attorney dogket no.
25791.10.04, filed on
7/1102, which claims priority from provisional application 601183,546, filed
on 2118100, (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 2126/99, (8) U.S. patent number 6,575,240,
which was filed
as patent application serial no. 091511,941, attorney docket no. 25791.16.02,
filed on
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
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 4/26199,
(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.
25791.27.08, filed on 4/30!02, which claims priority from provisional patent
application serial
no. 60/162,671, attorney docket no. 25791.27, filed on 11/1/1999, (15) U.S.
provisional
patent application serial no. 60/154,047, attorney docket no. 25791.29, filed
on 9/16/1999,
(16) U.S. provisional patent application serial no. 60/438,828, attorney
docket no. 25791.31,
filed on 1/9/03, (17) U.S. patent number 6,564,875, which was filed as
application serial no.
09/679,907, attorney docket no. 25791.34.02, on 10/5/00, which claims priority
from
provisional patent application serial no. 60/159,082, attorney docket no.
25791.34, filed on
10/12/1999, (18) U.S. patent application serial no. 10/089,419, filed on
3/27/02, attorney
docket no. 25791.36.03, which claims priority from provisional patent
application serial no.
601159,039, attorney docket no. 25791.36, filed on 10/12/1999, (19) U.S.
patent application
serial no. 09/679,906, filed on 1015/00, 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 12/18/02,
2
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
attorney docket no. 25791.46.07, which claims priority from provisional patent
application
serial no. 60/221,645, attorney docket no. 25791.46, filed on 7/28/2000, (26)
U.S. patent
application serial no. 10/322,947, filed on 1/22/03, attorney docket no.
25791.47.03, which
claims priority from provisional patent application serial no. 60/233,638,
attorney docket no.
25791.47, filed on 9/18/2000, (27) U.S. patent application serial no.
10/406,648, filed on
3/31/03, attorney docket no. 25791.48.06, which claims priority from
provisional patent
application serial no. 60/237,334, attorney docket no. 25791.48, filed on
10/2/2000, (28) PCT
application US02/04353, filed on 2/14/02, attorney docket no. 25791.50.02,
which claims
priority from U.S. provisional patent application serial no. 60/270,007,
attorney docket no.
25791.50, filed on 2/20/2001, (29) U.S. patent application serial no.
10/465,835, filed on
6/13/03, attorney docket no. 25791.51.06, which claims priority from
provisional patent
application serial no. 60/262,434, attorney docket no. 25791.51, filed on
1/17/2001, (30) U.S.
patent application serial no. 10/465,831, filed on 6/13/03, attorney docket
no. 25791.52.06,
which claims priority from U.S. provisional patent application serial no.
60/259,486, attorney
docket no. 25791.52, filed on 1/3/2001, (31) U.S. provisional patent
application serial no.
60/452,303, filed on 3/5/03, attorney docket no. 25791.53, (32) U.S. patent
number
6,470,966, which was filed as patent application serial number 09/850,093,
filed on 5/7/01,
attorney docket no. 25791.55, as a divisional application of U.S. Patent
Number 6,497,289,
which was filed as U.S. Patent Application serial no. 09/454,139, attorney
docket no.
25791.03.02, filed on 12/3/1999, which claims priority from provisional
application
60/111,293, filed on 12/7198, (33) U.S. patent number 6,561,227, which was
filed as patent
application serial number 091852,026 , filed on 5/9/01, attorney docket no.
25791.56, as a
divisional application of U.S. Patent Number 6,497,289, which was filed as
U.S. Patent
Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on
12/3/1999, which
claims priority from provisional application 60/111,293, filed on 12/7/98,
(34) U.S. patent
application serial number 09/852,027, filed on 5/9/01, attorney docket no.
25791.57, as a
divisional application of U.S. Patent Number 6,497,289, which was filed as
U.S. Patent
Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on
12/3/1999, which
claims priority from provisional application 601111,293, filed on 1217/98,
(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
3
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
priority from U.S. provisional patent application serial no. 601303,740,
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 60/124,042,
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. 091523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which
claims priority
from provisional application 60/124,042, filed on 3/11/99, (43) U.S. patent
application serial
no. 09/962,468, filed on 9/25/01, attorney docket no. 25791.66, which is a
divisional of U.S.
patent application serial no. 09/523,468, attorney docket no. 25791.11.02,
filed on
3/10/2000, which claims priority from provisional application 60/124,042,
filed on 3/11/99,
(44) PCT application US 02/25727, filed on 8/14/02, attorney docket no.
25791.67.03, which
claims priority from U.S. provisional patent application serial no.
60/317,985, attorney docket
no. 25791.67, filed on 91612001, and U.S. provisional patent application
serial no.
601318,386, attorney docket no. 25791.67.02, filed on 9/10/2001, (45) PCT
application US
02/39425, filed on 12/10/02, attorney docket no. 25791.68.02, which claims
priority from
U.S. provisional patent application serial no. 60/343,674 , attorney docket
no. 25791.68,
filed on 12/27/2001, (46) U.S. utility patent application serial no.
09/969,922, attorney docket
no. 25791.69, filed on 10/3/2001, which is a continuation-in-part application
of U.S. patent
no. 6,328,113, which was filed as U.S. Patent Application serial number
09/440,338,
attorney docket number 25791.9.02, filed on 11/15/99, which claims priority
from provisional
application 60/108,558, filed on 11/16/98, (47) U.S. utility patent
application serial no.
10/516,467, attorney docket no. 25791.70, filed on 12/10/01, which is a
continuation
application of U.S. utility patent application serial no. 09/969,922, attorney
docket no.
25791.69, filed on 10/3/2001, which is a continuation-in-part application of
U.S. patent no.
6,328,113, which was filed as U.S. Patent Application serial number
09/440,338, attorney
docket number 25791.9.02, filed on 11/15/99, which claims priority from
provisional
application 60/108,558, filed on 11/16/98, (48) PCT application US 03/00609,
filed on 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.
4
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
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. 091512,895,
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 2115/02, 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
601121,841, filed on 2/26/99, (54) U.S. patent application serial no.
10/078,928, attorney
docket no. 25791.79, 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 2126/99, (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
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
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. 091588,946, 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 601121,841, filed on 2/26/99, (61) U.S. patent
application serial no.
10/261,926, attorney docket no. 25791.86, filed on 10/1/02, which is a
divisional of U.S.
patent number 6,557,640, which was filed as patent application serial no.
09/588,946,
attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from
provisional
application 60/137,998, filed on 6/7/99, (62) PCT application US 02/36157,
filed on 11/12/02,
attorney docket no. 25791.87.02, which claims priority from U.S. provisional
patent
application serial no. 60/338,996, attorney docket no. 25791.87, filed on
11/12/01, (63) PCT
application US 02/36267, filed on 11/12/02, attorney docket no. 25791.88.02,
which claims
priority from U.S. provisional patent application serial no. 60/339,013,
attorney docket no.
25791.88, filed on 11/12/01, (64) PCT application US 03/11765, filed on
4/16/03, attorney
docket no. 25791.89.02, which claims priority from U.S. provisional patent
application serial
no. 60/383,917, attorney docket no. 25791.89, filed on 5/29/02, (65) PCT
application US
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, atfiorney 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 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.
6
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
25791.17.02, filed on 6/7/2000, which claims priority from provisional
application 60/137,998,
filed on 6/7199, (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 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
5/5103, attorney
docket no. 25791.107.02, which claims priority from U.S. provisional patent
application
serial no. 60/387,486 , attorney docket no. 25791.107, filed on 6110/02, (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, afitorney
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 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.
7
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
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 121311999, 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
9120102, (87) U.S.
provisional patent application serial no. 60/405,610, attorney docket no.
25791.119, filed on
8123/02, (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
03124779, 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 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 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 7122/03, which is a
divisional of
U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02,
filed on
2/10/2000, which claims priority from provisional application 60/119,611,
filed on 2/11/99,
(97) U.S. provisional patent application serial no. 60/431,184, attorney
docket no.
25791.157, filed on 12/5/02, (98) U.S, provisional patent application serial
no. 60/448,526,
attorney docket no. 25791.185, filed on 2/18/03, (99) U.S. provisional patent
application
serial no. 60/461,539, attorney docket no. 25791.186, filed on 4/9/03, (100)
U.S. provisional
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
8
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
patent application serial no. 60/455,124, attorney docket no. 25791.241, filed
on 3/17/03,
(109) U.S. provisional patent application serial no. 60/453,678, attorney
docket no.
25791.253, filed on 3/11/03, (110) U.S. patent application serial no.
10/421,682, attorney
docket no. 25791.256, filed on 4/23/03, which is a continuation of U.S. patent
application
serial no. 091523,468, attorney docket no. 25791.11.02, filed on 3/10/2000,
which claims
priority from provisional application 60/124,042, filed on 3/11/99, (111) U.S.
provisional
patent application serial no. 60/457,965, attorney docket no. 25791.260, filed
on 3/27/03,
(112) U.S. provisional patent application serial no. 60/455,718, attorney
docket no.
25791.262, filed on 3/78/03, (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. 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/US04/06246, attorney docket no. 25791.238.02, filed
on
2/26/2004, (123) PCT patent application serial number PCT/US04/08170, attorney
docket
number 25791.40.02, filed on 3/15/04, (124) PCT patent application serial
number
PCT/US04/08171, attorney docket number 25791.236.02, filed on 3/15/04, (125)
PCT patent
application serial number PCT/US04/08073, attorney docket number 25791.262.02,
filed on
3/18/04, (126) PCT patent application serial number PCT/1JS04/07711, attorney
docket
number 25791.253.02, filed on 3/11/2004, (127) PCT patent application serial
number
PCT/US04/ , attorney docket number 25791.260.02, filed on 3/26/2004, (128)
9
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
PCT patent application serial number PCT/US04/ , attorney docket number
25791.270.02, filed on 4/2/2004, (129) PCT patent application serial number
PCT/US041 , attorney docket number 25791.272.02, filed on , (130)
PCT patent application serial number PCT/US04/ , attorney docket number
25791.273.02, filed on , (131 ) PCT patent application serial number
PCT/ / , attorney docket number 25791.277.02, filed on , (132)
U.S. provisional patent application serial number , attorney docket number
25791.301, filed on 8/1412003, and (133) U.S. provisional patent application
serial number
attorney docket number 25791.194, filed on , 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.
Summary Of The Invention
[004] According to one aspect of the present invention, a method of forming a
tubular liner
within a preexisting structure is provided that includes positioning a tubular
assembly within
the preexisting structure; and radially expanding and plastically deforming
the tubular
assembly within the preexisting structure, wherein, prior to the radial
expansion and plastic
deformation of the tubular assembly, a predetermined portion of the tubular
assembly has a
lower yield point than another portion of the tubular assembly.
[005] According to another aspect of the present invention, an expandable
tubular member
is provided that includes a steel alloy including: 0.065 % C, 1.44 % Mn, 0.01
% P, 0.002
S, 0.24 % Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr.
[006] According to another aspect of the present invention, an expandable
tubular member
is provided that includes a steel alloy including: 0.18 % C, 1.28 % Mn, 0.017
% P, 0.004
S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr.
[007] According to another aspect of the present invention, an expandable
tubular member
is provided that includes a steel alloy including: 0.08 % C, 0.82 % Mn, 0.006
% P, 0.003
S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr.
[008] According to another aspect of the present invention, an expandable
tubular member
is provided that includes a steel alloy including: 0.02 % C, 1.31 % Mn, 0.02 %
P, 0.001 % S,
0.45 % Si, 9.1 % Ni, and 18.7 % Cr.
[009] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the yield point of the expandable tubular member is at
most about 46.9
ksi prior to a radial expansion and plastic deformation; and wherein the yield
point of the
expandable tubular member is at least about 65.9 ksi after the radial
expansion and plastic
deformation.
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[0010] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein a yield point of the expandable tubular member after a
radial expansion
and plastic deformation is at least about 40 % greater than the yield point of
the expandable
tubular member prior to the radial expansion and plastic deformation.
[0011] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the anisotropy of the expandable tubular member, prior to
the radial
expansion and plastic deformation, is at least about 1.48.
[0012] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the yield point of the expandable tubular member is at
most about 57.8
ksi prior to the radial expansion and plastic deformation; and wherein the
yield point of the
expandable tubular member is at least about 74.4 ks( after the radial
expansion and plastic
deformation.
[0013] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the yield point of the expandable tubular member after a
radial
expansion and plastic deformation is at least about 28 % greater than the
yield point of the
expandable tubular member prior to the radial expansion and plastic
deformation.
[0014] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the anisotropy of the expandable tubular member, prior to
the radial
expansion and plastic deformation, is at least about 1.04.
[0015] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the anisotropy of the expandable tubular member, prior to
the radial
expansion and plastic deformation, is at least about 1.92.
[0016] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the anisotropy of the expandable tubular member, prior to
the radial
expansion and plastic deformation, is at least about 1.34.
[0017] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the anisotropy of the expandable tubular member, prior to
the radial
expansion and plastic deformation, ranges from about 7.04 to about 1.92.
[0018] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the yield point of the expandable tubular member, prior
to the radial
expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7
ksi.
[0019] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the expandability coefficient of the expandable tubular
member, prior to
the radial expansion and plastic deformation, is greater than 0.12.
[0020] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the expandability coefficient of the expandable tubular
member is
11
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
greater than the expandability coefficient of another portion of the
expandable tubular
member.
[0021] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the tubular member has a higher ductility and a lower
yield point prior to
a radial expansion and plastic deformation than after the radial expansion and
plastic
deformation.
[0022] According to another aspect of the present invention, a method of
radially expanding
and plastically deforming a tubular assembly including a first tubular member
coupled to a
second tubular member is provided that includes radially expanding and
plastically
deforming the tubular assembly within a preexisting structure; and using less
power to
radially expand each unit length of the first tubular member than to radially
expand each unit
length of the second tubular member.
[0023] According to another aspect of the present invention, a system for
radially expanding
and plastically deforming a tubular assembly including a first tubular member
coupled to a
second tubular member is provided that includes means for radially expanding
the tubular
assembly within a preexisting structure; and means for using less power to
radialiy expand
each unit length of the first tubular member than required to radially expand
each unit length
of the second tubular member.
[0024] According to another aspect of the present invention, a method of
manufacturing a
tubular member is provided that includes processing a tubular member until the
tubular
member is characterized by one or more intermediate characteristics;
positioning the tubular
member within a preexisting structure; and processing the tubular member
within the
preexisting structure until the tubular member is characterized one or more
final
characteristics.
[0025] According to another aspect of the present invention, an apparatus is
provided that
includes an expandable tubular assembly; and an expansion device coupled to
the
expandable tubular assembly; wherein a predetermined portion of the expandable
tubular
assembly has a lower yield point than another portion of the expandable
tubular assembly.
[0026] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein a yield point of the expandable tubular member after a
radial expansion
and plastic deformation is at (east about 5.8 % greater than the yield point
of the expandable
tubular member prior to the radial expansion and plastic deformation.
[0027] According to another aspect of the present invention, a method of
determining the
expandability of a selected tubular member is provided that includes
determining an
anisotropy value for the selected tubular member, determining a strain
hardening value for
the selected tubular member; and multiplying the anisotropy value times the
strain hardening
value to generate an expandability value for the selected tubular member.
12
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[0028] According to another aspect of the present invention, a method of
radially expanding
and plastically deforming tubular members is provided that includes selecting
a tubular
member; determining an anisotropy value for the selected tubular member;
determining a
strain hardening value for the selected tubular member; multiplying the
anisotropy value
times the strain hardening value to generate an expandability value for the
selected tubular
member; and if the anisotropy value is greater than 0.12, then radially
expanding and
plastically deforming the selected tubular member.
[0029] According to another aspect of the present invention, a radially
expandable tubular
member apparatus is provided that includes a first tubular member; a second
tubular
member engaged with the first tubular member forming a joint; and a sleeve
overlapping and
coupling the first and second tubular members at the joint; wherein, prior to
a radial
expansion and plastic deformation of the apparatus, a predetermined portion of
the
apparatus has a lower yield point than another portion of the apparatus.
[0030] According to another aspect of the present invention, a radially
expandable tubular
member apparatus is provided that includes: a first tubular member; a second
tubular
member engaged with the first tubular member forming a joint; a sleeve
overlapping and
coupling the first and second tubular members at the joint; the sleeve having
opposite
tapered ends and a flange engaged in a recess formed in an adjacent tubular
member; and
one of the tapered ends being a surface formed on the flange; wherein, prior
to a radial
expansion and plastic deformation of the apparatus, a predetermined portion of
the
apparatus has a lower yield point than another portion of the apparatus.
[0031] According to another aspect of the present invention, a method of
joining radially
expandable tubular members is provided that includes: providing a first
tubular member;
engaging a second tubular member with the first tubular member to form a
joint; providing a
sleeve; mounting the sleeve for overlapping and coupling the first and second
tubular
members at the joint; wherein the first tubular member, the second tubular
member, and the
sleeve define a tubular assembly; and radially expanding and plastically
deforming the
tubular assembly; wherein, prior to the radial expansion and plastic
deformation, a
predetermined portion of the tubular assembly has a lower yield point than
another portion of
the tubular assembly.
j0032] According to another aspect of the present invention, a method of
joining radially
expandable tubular members is provided that includes providing a first tubular
member;
engaging a second tubular member with the first tubular member to form a
joint; providing a
sleeve having opposite tapered ends and a flange, one of the tapered ends
being a surface
formed on the flange; mounting the sleeve for overlapping and coupling the
first and second
tubular members at the joint, wherein the flange is engaged in a recess formed
in an
adjacent one of the tubular members; wherein the first tubular member, the
second tubular
13
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
member, and the sleeve define a tubular assembly; and radially expanding and
plastically
deforming the tubular assembly; wherein, prior to the radial expansion and
plastic
deformation, a predetermined portion of the tubular assembly has a lower yield
point than
another portion of the tubular assembly.
[0033] According to another aspect of the present invention, an expandable
tubular
assembly is provided that includes a first tubular member; a second tubular
member coupled
to the first tubular member; a first threaded connection for coupling a
portion of the first and
second tubular members; a second threaded connection spaced apart from the
first
threaded connection for coupling another portion of the first and second
tubular members; a
tubular sleeve coupled to and receiving end portions of the first and second
tubular
members; and a sealing element positioned between the first and second spaced
apart
threaded connections for sealing an interface between the first and second
tubular member;
wherein the sealing element is positioned within an annulus defined between
the first and
second tubular members; and wherein, prior to a radial expansion and plastic
deformation of
the assembly, a predetermined portion of the assembly has a lower yield point
than another
portion of the apparatus.
[0034] According to another aspect of the present invention, a method of
joining radially
expandable tubular members is provided that includes: providing a first
tubular member;
providing a second tubular member; providing a sleeve; mounting the sleeve for
overlapping
and coupling the first and second tubular members; threadably coupling the
first and second
tubular members at a first location; threadably coupling the first and second
tubular
members at a second location spaced apart from the first location; sealing an
interface
between the first and second tubular members between the first and second
locations using
a compressible sealing element, wherein the first tubular member, second
tubular member,
sleeve, and the sealing element define a tubular assembly; and radially
expanding and
plastically deforming the tubular assembly; wherein, prior to the radial
expansion and plastic
deformation, a predetermined portion of the tubular assembly has a lower yield
point than
another portion of the tubular assembly.
[0035] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the carbon content of the tubular member is less than or
equal to 0.12
percent; and wherein the carbon equivalent value for the tubular member is
less than 0.21.
[0036] According to another aspect of the present invention, an expandable
tubular member
is provided, wherein the carbon content of the tubular member is greater than
0.12 percent;
and wherein the carbon equivalent value for the tubular member is less than
0.36.
[0037] According to another aspect of the present invention, a method of
selecting tubular
members for radial expansion and plastic deformation is provided that includes
selecting a
tubular member from a collection of tubular member; determining a carbon
content of the
14
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
selected tubular member; determining a carbon equivalent value for the
selected tubular
member; and if the carbon content of the selected tubular member is less than
or equal to
0.12 percent and the carbon equivalent value for the selected tubular member
is less than
0.21, then determining that the selected tubular member is suitable for radial
expansion and
plastic deformation.
[0038] According to another aspect of the present invention, a method of
selecting, tubular
members for radial expansion and plastic deformation is provided that includes
selecting a
tubular member from a collection of tubular member; determining a carbon
content of the
selected tubular member; determining a carbon equivalent value for the
selected tubular
member; and if the carbon content of the selected tubular member is greater
than 0.12
percent and the carbon equivalent value for the selected tubular member is
less than 0.36,
then determining that the selected tubular member is suitable for radial
expansion and
plastic deformation.
[0039] According to another aspect of the present invention, an expandable
tubular member
is provided that includes a tubular body; wherein a yield point of an inner
tubular portion of
the tubular body is less than a yield point of an outer tubular portion of the
tubular body.
[0040] According to another aspect of the present invention, a method of
manufacturing an
expandable tubular member has been provided that includes: providing a tubular
member;
heat treating the tubular member; and quenching the tubular member; wherein
following the
quenching, the tubular member comprises a microstructure comprising a hard
phase
structure and a soft phase structure.
[0041] According to another aspect of the present invention, an expandable
tubular member
has been provided that includes a steel alloy comprising: 0.07% Carbon, 1.64%
Manganese,
0.011 % Phosphor, 0.001 % Sulfur, 0.23% Silicon, 0.5%Nickel, 0.51 % Chrome,
0.31
Molybdenum, 0.15% Copper, 0.021 % Aluminum, 0.04% Vanadium, 0.03% Niobium, and
0.007% Titanium.
[0042] According to another aspect of the present invention, an expandable
tubular member
has been provided that includes a collapse strength of approximately 70 ksi
comprising:
0.07% Carbon, 1.64% Manganese, 0.011 % Phosphor, 0.001 % Sulfur, 0.23%
Silicon,
0.5%Nickel, 0.51 % Chrome, 0.31 % Molybdenum, 0.15% Copper, 0.021 % Aluminum,
0.04%
Vanadium, 0.03% Niobium, and 0.007% Titanium, wherein, upon radial expansion
and
plastic deformation, the collapse strength increases to approximately 110 ksi.
[0043] According to another aspect of the present invention, an expandable
tubular member
has been provided that includes an outer surface and means for increasing the
collapse
strength of a tubular assembly when the expandable tubular member is radially
expanded
and plastically deformed against a preexisting structure, the means coupled to
the outer
surface.
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[0044] According to another aspect of the present invention, a preexisting
structure for
accepting an expandable tubular member has been provided that includes a
passage
defined by the structure, an inner surface on the passage and means for
increasing the
collapse strength of a tubular assembly when an expandable tubular member is
radially
expanded and plastically deformed against the preexisting structure, the means
coupled to
the inner surface.
[0045] According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes a structure defining a passage
therein, an
expandable tubular member positioned in the passage and means for increasing
the
collapse strength of the assembly when the expandable tubular member is
radially expanded
and plastically deformed against the structure, the means positioned between
the
expandable tubular member and the structure.
[0046] According to another aspect of the present invention, a tubular
assembly has been
provided that includes a structure defining a passage therein, an expandable
tubular
member positioned in the passage and an interstitial layer positioned between
the structure
and expandable tubular member, wherein the collapse strength of the assembly
with the
interstitial layer is at least 20% greater than the collapse strength without
the interstitial layer.
[0047] According to another aspect of the present invention, a tubular
assembly has been
provided that includesa structure defining a passage therein, an expandable
tubular member
positioned in the passage and an interstitial layer positioned between the
structure and
expandable tubular member, wherein the collapse strength of the assembly with
the
interstitial layer is at least 30% greater than the collapse strength without
the interstitial layer.
[0048] According to another aspect of the present invention, a tubular
assembly has been
provided that includes a structure defining a passage therein, an expandable
tubular
member positioned in the passage and an interstitial layer positioned between
the structure
and expandable tubular member, wherein the collapse strength of the assembly
with the
interstitial layer is at least 40% greater than the collapse strength without
the interstitial layer.
[0049] According to another aspect of the present invention, a tubular
assembly has been
provided that includesa structure defining a passage therein, an expandable
tubular member
positioned in the passage and an interstitial layer positioned between the
structure and
expandable tubular member, wherein the collapse strength of the assembly with
the
interstitial layer is at feast 50% greater than the collapse strength without
the interstitial layer.
[0050] According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes an outer tubular member comprising a
steel alloy
and defining a passage, an inner tubular member comprising a steel alloy and
positioned in
the passage and an interstitial layer between the inner tubular member and the
outer tubular
member, the interstitial layer comprising an aluminum material lining an inner
surface of the
16
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
outer tubular member, whereby the collapse strength of the assembly with the
interstitial
layer is greater than the collapse strength of the assembly without the
interstitial layer.
[0051] According to another aspect of the present invention, a method for
increasing the
collapse strength of a tubular assembly has been provided that includes
providing a
preexisting structure defining a passage therein, providing an expandable
tubular member,
coating the expandable tubular member with an interstitial material,
positioning the
expandable tubular member in the passage defined by the preexisting structure
and
expanding the expandable tubular member such that the interstitial material
engages the
preexisting structure, whereby the collapse strength of the preexisting
structure and
expandable tubular member with the interstitial material is greater than the
collapse strength
of the preexisting structure and expandable tubular member without the
interstitial material.
[0052] According to another aspect of the present invention, a method for
increasing the
collapse strength of a tubular assembly has been provided that includes
providing a
preexisting structure defining a passage therein, providing an expandable
tubular member,
coating the preexisting structure with an interstitial material, positioning
the expandable
tubular member in the passage defined by the preexisting structure and
expanding the
expandable tubular member such that the interstitial material engages the
expandable
tubular member, whereby the collapse strength of the preexisting structure and
expandable
tubular member with the interstitial material is greater than the collapse
strength of the
preexisting structure and expandable tubular member without the interstitial
material.
[0053] According to another aspect of the present invention, an expandable
tubular member
has been provided that includes an outer surface and an interstitial layer on
the outer
surface, wherein the interstitial layer comprises an aluminum material
resulting in a required
expansion operating pressure of approximately 3900 psi for the tubular member.
[0054] According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes an outer surface and an interstitial
layer on the
outer surface, wherein the interstitial layer comprises an aluminum/zinc
material resulting in
a required expansion operating pressure of approximately 3700 psi for the
tubular member.
[0055] According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes an outer surface and an interstitial
layer on the
outer surface, wherein the interstitial layer comprises an plastic material
resulting in a
required expansion operating pressure of approximately 3600 psi for the
tubular member.
[0056] According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes a structure defining a passage
therein, an
expandable tubular member positioned in the passage and an interstitial layer
positioned
between the expandable tubular member and the structure, wherein the
interstitial layer has
a thickness of approximately 0.05 inches to 0.15 inches.
17
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[0057) According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes a structure defining a passage
therein, an
expandable tubular member positioned in the passage and an interstitial layer
positioned
between the expandable tubular member and the structure, wherein the
interstitial layer has
a thickness of approximately 0.07 inches to 0.13 inches.
[0058] According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes a structure defining a passage
therein, an
expandable tubular member positioned in the passage and an interstitial layer
positioned
between the expandable tubular member and the structure, wherein the
interstitial layer has
a thickness of approximately 0.06 inches to 0.14 inches.
[0059] According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes a structure defining a passage
therein, an
expandable tubular member positioned in the passage and an interstitial layer
positioned
between the expandable tubular member and the structure, wherein the
interstitial layer has
a thickness of approximately 1.6 mm to 2.5 mm between the structure and the
expandable
tubular member.
[0060] According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes a structure defining a passage
therein, an
expandable tubular member positioned in the passage and an interstitial layer
positioned
between the expandable tubular member and the structure, wherein the
interstitial layer has
a thickness of approximately 2.6 mm to 3.1 mm between the structure and the
expandable
tubular member.
[0061) According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes a structure defining a passage
therein, an
expandable tubular member positioned in the passage and an interstitial layer
positioned
between the expandable tubular member and the structure, wherein the
interstitial layer has
a thickness of approximately 1.9 mm to 2.5 mm between the structure and the
expandable
tubular member.
[0062] According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes a structure defining a passage
therein, an
expandable tubular member positioned in the passage, an interstitial layer
positioned
between the expandable tubular member and the structure and a collapse
strength greater
than approximately 20000 psi.
[0063] According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes a structure defining a passage
therein, an
expandable tubular member positioned in the passage, an interstitial layer
positioned
18
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
between the expandable tubular member and the structure and a collapse
strength greater
than approximately 14000 psi.
[0064] According to another aspect of the present invention, a method for
determining the
collapse resistance of a tubular assembly has been provided that includes
measuring the
collapse resistance of a first tubular member, measuring the collapse
resistance of a second
tubular member, determining the value of a reinforcement factor for a
reinforcement of the
first and second tubular members and multiplying the reinforcement factor by
the sum of the
collapse resistance of the first tubular member and the collapse resistance of
the second
tubular member.
[0065] According to another aspect of the present invention, an expandable
tubular
assembly has been provided that includes a structure defining a passage
therein, an
expandable tubular member positioned in the passage and means for modifying
the residual
stresses in at least one of the structure and the expandable tubular member
when the
expandable tubular member is radially expanded and plastically deformed
against the
structure, the means positioned between the expandable tubular member and the
structure.
Brief Description of the Drawings
[0066] Fig. 1 is a fragmentary cross sectional view of an exemplary embodiment
of an
expandable tubular member positioned within a preexisting structure.
[0067] Fig. 2 is a fragmentary cross sectional view of the expandable tubular
member of Fig.
1 after positioning an expansion device within the expandable tubular member.
[0068] Fig. 3 is a fragmentary cross sectional view of the expandable tubular
member of Fig.
2 after operating the expansion device within the expandable tubular member to
radially
expand and plastically deform a portion of the expandable tubular member.
[0069] Fig. 4 is a fragmentary cross sectional view of the expandable tubular
member of Fig.
3 after operating the expansion device within the expandable tubular member to
radially
expand and plastically deform another portion of the expandable tubular
member.
[0070] Fig. 5 is a graphical illustration of exemplary embodiments of the
stresslstrain curves
for several portions of the expandable tubular member of Figs. 1-4.
[0071] Fig. 6 is a graphical illustration of the an exemplary embodiment of
the yield strength
vs. ductility curve for at least a portion of the expandable tubular member of
Figs. 1-4.
[0072] Fig. 7 is a fragmentary cross sectional illustration of an embodiment
of a series of
overlapping expandable tubular members.
[0073] Fig. 8 is a fragmentary cross sectional view of an exemplary embodiment
of an
expandable tubular member positioned within a preexisting structure.
[0074] Fig. 9 is a fragmentary cross sectional view of the expandable tubular
member of Fig.
8 after positioning an expansion device within the expandable tubular member.
[0075] Fig. 10 is a fragmentary cross sectional view of the expandable tubular
member of
19
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
Fig. 9 after operating the expansion device within the expandable tubular
member to radially
expand and plastically deform a portion of the expandable tubular member.
[0076] Fig. 11 is a fragmentary cross sectional view of the expandable tubular
member of
Fig. 10 after operating the expansion device within the expandable tubular
member to
radially expand and plastically deform another portion of the expandable
tubular member.
[0077] Fig. 12 is a graphical illustration of exemplary embodiments of the
stress/strain
curves for several portions of the expandable tubular member of Figs. 8-11.
[0078] Fig. 13 is a graphical illustration of an exemplary embodiment of the
yield strength vs.
ductility curve for at least a portion of the expandable tubular member of
Figs. 8-11.
[0079] Fig. 14 is a fragmentary cross sectional view of an exemplary
embodiment of an
expandable tubular member positioned within a preexisting structure.
[0080] Fig. 15 is a fragmentary cross sectional view of the expandable tubular
member of
Fig. 14 after positioning an expansion device within the expandable tubular
member.
[0081] Fig. 16 is a fragmentary cross sectional view of the expandable tubular
member of
Fig. 15 after operating the expansion device within the expandable tubular
member to
radially expand and plastically deform a portion of the expandable tubular
member.
[0082] Fig. 17 is a fragmentary cross sectional view of the expandable tubular
member of
Fig. 16 after operating the expansion device within the expandable tubular
member to
radially expand and plastically deform another portion of the expandable
tubular member.
[0083] Fig. 18 is a flow charfi illustration of an exemplary embodiment of a
method of
processing an expandable tubular member.
[0084] Fig. 19 is a graphical illustration of the an exemplary embodiment of
the yield
strength vs. ductility curve for at least a portion of the expandable tubular
member during the
operation of the method of Fig. 18.
[0085] Fig. 20 is a graphical illustration of stress/strain curves for an
exemplary embodiment
of an expandable tubular member.
[0086] Fig. 21 is a graphical illustration of stress/strain curves for an
exemplary embodiment
of an expandable tubular member.
[0087] Fig. 22 is a fragmentary cross-sectional view illustrating an
embodiment of the
radial expansion and plastic deformation of a portion of a first tubular
member having an
internally threaded connection at an end portion, an embodiment of a tubular
sleeve
supported by the end portion of the first tubular member, and a second tubular
member
having an externally threaded portion coupled to the internally threaded
portion of the first
tubular member and engaged by a flange of the sleeve. The sleeve includes the
flange at
one end for increasing axial compression loading.
[0088] Fig. 23 is a fragmentary cross-sectional view illustrating an
embodiment of the radial
expansion and plastic deformation of a portion of a first tubular member
having an internally
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
threaded connection at an end portion, a second tubular member having an
externally
threaded portion coupled to the internally threaded portion of the first
tubular member, and
an embodiment of a tubular sleeve supported by the end portion of both tubular
members.
The sleeve includes flanges at opposite ends for increasing axial tension
loading.
[0089] Fig. 24 is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of a first tubular member having an internally
threaded connection at
an end portion, a second tubular member having an externally threaded portion
coupled to
the internally threaded portion of the first tubular member, and an embodiment
of a tubular
sleeve supported by the end portion of both tubular members. The sleeve
includes flanges
at opposite ends for increasing axial compression/tension loading.
[0090] Fig. 25 is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of a first tubular member having an internally
threaded connection at i
an end portion, a second tubular member having an externally threaded portion
coupled to
the internally threaded portion of the first tubular member, and an embodiment
of a tubular
sleeve supported by the end portion of both tubular members. The sleeve
includes flanges
at opposite ends having sacrificial material thereon.
[0091] Fig. 26 is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of a first tubular member having an internally
threaded connection at
an end portion, a second tubular member having an externally threaded portion
coupled to
the internally threaded portion of the first tubular member, and an embodiment
of a tubular
sleeve supported by the end portion of both tubular members. The sleeve
includes a thin
walled cylinder of sacrificial material.
[0092] Fig. 27 is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of a first tubular member having an internally
threaded connection at
an end portion, a second tubular member having an externally threaded portion
coupled to
the internally threaded portion of the first tubular member, and an embodiment
of a tubular
sleeve supported by the end portion of both tubular members. The sleeve
includes a
variable thickness along the length thereof.
[0093] Fig. 28 is a fragmentary cross-sectional illustration of the radial
expansion and plastic
deformation of a portion of a first tubular member having an internally
threaded connection at
an end portion, a second tubular member having an externally threaded portion
coupled to
the internally threaded portion of the first tubular member, and an embodiment
of a tubular
sleeve supported by the end portion of both tubular members. The sleeve
includes a
member coiled onto grooves formed in the sleeve for varying the sleeve
thickness.
[0094] Fig. 29 is a fragmentary cross-sectional illustration of an exemplary
embodiment of
an expandable connection.
21
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[0095] Figs. 30a-30c are fragmentary cross-sectional illustrations of
exemplary
embodiments of expandable connections.
(0096] Fig. 31 is a fragmentary cross-sectional illustration of an exemplary
embodiment of
an expandable connection.
[0097] Figs. 32a and 32b are fragmentary cross-sectional illustrations of the
formation of an
exemplary embodiment of an expandable connection.
(0098] Fig. 33 is a fragmentary cross-sectional illustration of an exemplary
embodiment of
an expandable connection.
[0099] Figs. 34a, 34b and 34c are fragmentary cross-sectional illustrations of
an exemplary
embodiment of an expandable connection.
[00100] Fig. 35a is a fragmentary cross-sectional illustration of an exemplary
embodiment of an expandable tubular member.
[00101] Fig. 35b is a graphical illustration of an exemplary embodiment of the
variation in the yield point for the expandable tubular member of Fig. 35a.
[00102] Fig. 36a is a flow chart illustration of an exemplary embodiment of a
method
for processing a tubular member.
[00103] Fig. 36b is an illustration of the microstructure of an exemplary
embodiment of
a tubular member prior to thermal processing.
[00104] Fig. 36c is an illustration of the microstructure of an exemplary
embodiment of
a tubular member after thermal processing.
(00105] Fig. 37a is a flow chart illustration of an exemplary embodiment of a
method
for processing a tubular member.
[00106] Fig. 37b is an illustration of the microstructure of an exemplary
embodiment of
a tubular member prior to thermal processing.
[00107] Fig. 37c is an illustration of the microstructure of an exemplary
embodiment of
a tubular member after thermal processing.
(00108] Fig. 38a is a flow chart illustration of an exemplary embodiment of a
method
for processing a tubular member.
[00109] Fig. 38b is an illustration of the microstructure of an exemplary
embodiment of
a tubular member prior to thermal processing.
[00110] Fig. 38c is an illustration of the microstructure of an exemplary
embodiment of
a tubular member after thermal processing.
[00111] Fig 39 is a schematic view illustrating an exemplary embodiment of a
method
for increasing the collapse strength of a tubular assembly.
[00112] Fig 40 is a perspective view illustrating an exemplary embodiment of
an
expandable tubular member used in the method of Fig. 39.
22
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00113] Fig 41 a is a perspective view illustrating an exemplary embodiment of
the
expandable tubular member of Fig. 40 coated with a layer of material according
to the
method of Fig. 39.
[00114] Fig 41 b is a cross sectional view taken along line 41 b in Fig. 41 a
illustrating
an exemplary embodiment of the expandable tubular member of Fig. 40 coated
with a layer
of material according to the method of Fig. 39.
[00115] Fig 41 c is a perspective view illustrating an exemplary embodiment of
the
expandable tubular member and layer of Fig. 41 a where the coating layer is
plastic
according to the method of Fig. 39.
[00116] Fig 41 d is a perspective view illustrating an exemplary embodiment of
the
expandable tubular member and layer of Fig. 41 a where the coating layer is
aluminum
according to the method of Fig. 39.
[00117] Fig 42 is a perspective view illustrating an exemplary embodiment of
the
expandable tubular member and layer of Fig. 41a positioned within a
preexisting structure
according to the method of Fig. 39.
[00118] Fig 43 is a perspective view illustrating an exemplary embodiment of
the
expandable tubular member and layer within the preexisting structure of Fig.
42 with the
expandable tubular member being expanded according to the method of Fig. 39.
[00119] Fig 44 is a perspective view illustrating an exemplary embodiment of
the
expandable tubular member and layer within the preexisting structure of Fig.
42 with the
expandable tubular member expanded according to the method of Fig. 39.
[00120] Fig 45 is a schematic view illustrating an exemplary embodiment of a
method
for increasing the collapse strength of a tubular assembly.
[00121] Fig 46 is a perspective view illustrating an exemplary embodiment of a
preexisting structure used in the method of Fig. 45.
[00122] Fig 47a is a perspective view illustrating an exemplary embodiment of
the
preexisting structure of Fig. 46 being coated with a layer of material
according to the method
of Fig. 45.
[00123] Fig 47b is a cross sectional view taken along line 47b in Fig. 47a
illustrating
an exemplary embodiment of the preexisting structure of Fig. 46 coated with a
layer of
material according to the method of Fig. 45.
[00124] Fig 48 is a perspective view illustrating an exemplary embodiment of
an
expandable tubular member positioned within the preexisting structure and
layer of material
of Fig. 47a according to the method of Fig. 45.
[00125] Fig 49 is a perspective view illustrating an exemplary embodiment of
the
expandable tubular member within the preexisting structure and layer of Fig.
48 with the
expandable tubular member being expanded according to the method of Fig. 45.
23
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00126] Fig 50 is a perspective view illustrating an exemplary embodiment of
the
expandable tubular member within the preexisting structure and layer of Fig.
48 with the
expandable tubular member expanded according to the method of Fig. 45.
[00127] Fig 51a is a perspective view illustrating an exemplary embodiment of
the
expandable tubular member of Fig 40 coated with multiple layers of material
according to the
method of Fig. 39.
[00128] Fig 51 b is a perspective view illustrating an exemplary embodiment of
the
preexisting structure of Fig. 46 coated with multiple layers of material
according to the
method of Fig. 39.
[00129j Fig 52a is a perspective view illustrating an exemplary embodiment of
the
expandable tubular member of Fig 40 coated by winding a wire around its
circumference
according to the method of Fig. 39.
[00130] Fig 52b is a perspective view illustrating an exemplary embodiment of
the
expandable tubular member of Fig 40 coated by winding wire around its
circumference
according to the method of Fig. 39.
[00131] Fig 52c is a cross sectional view taken along line 52c of Fig. 52b
illustrating
an exemplary embodiment of the expandable tubular member of Fig 40 coated by
winding
wire around its circumference according to the method of Fig. 39.
[00132] Fig 53 is a chart view illustrating an exemplary experimental
embodiment of
the energy required to expand a plurality of tubular assemblies produced by
the methods of
Fig. 39 and Fig. 45.
[00133] Fig 54a is a cross sectional view illustrating an exemplary
experimental
embodiment of a tubular assembly produced by the method of Fig. 39.
[00134] Fig 54b is a cross sectional view illustrating an exemplary
experimental
embodiment of a tubular assembly produced by the method of Fig. 39.
[00135] Fig 54c is a chart view illustrating an exemplary experimental
embodiment of
the thickness of the interstitial layer for a plurality of tubular assemblies
produced by the
method of Fig. 39.
[00136] Fig 55a is a chart view illustrating an exemplary experimental
embodiment of
the thickness of the interstitial layer for a plurality of tubular assemblies
produced by the
method of Fig. 39.
[00137] Fig 55b is a chart view illustrating an exemplary experimental
embodiment of
the thickness of the interstitial layer for a plurality of tubular assemblies
produced by the
method of Fig. 39.
[00138] Fig 56 is a cross sectional view illustrating an exemplary
experimental
embodiment of a tubular assembly produced by the method of Fig. 39 but
omitting the
coating with a layer of material.
24
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00139] Fig 56a is a close up cross sectional view illustrating an exemplary
experimental embodiment of a tubular assembly produced by the method of Fig.
39 but
omitting the coating with a layer of material.
j00140] Fig 57a is a graphical view illustrating an exemplary experimental
embodiment of the collapse strength for a tubular assembly produced by the
method of Fig.
39 but omitting the coating with a layer of material.
[00141] Fig 57b is a graphical view illustrating an exemplary experimental
embodiment of the thickness of the air gap for a tubular assembly produced by
the method
of Fig. 39 but omitting the coating with a layer of material.
[00142] Fig 58 is a graphical view illustrafiing an exemplary experimental
embodiment
of the thickness of the air gap and the collapse strength for a tubular
assembly produced by
the method of Fig. 39 but omitting the coating with a layer of material.
[00143] Fig 59 is a graphical view illustrating an exemplary experimental
embodiment
of the thickness of the interstitial layer and the collapse strength for a
tubular assembly
produced by the method of Fig. 39.
[00144] Fig 60a is a graphical view illustrating an exemplary experimental
embodiment of the thickness of the air gap for a tubular assembly produced by
the method
of Fig. 39 but omitting the coating with a layer of material.
[00145] Fig 60b is a graphical view illustrating an exemplary experimental
embodiment of the thickness of the interstitial layer for a tubular assembly
produced by the
method of Fig. 39.
[00146] Fig 60c is a graphical view illustrating an exemplary experimental
embodiment of the thickness of the interstitial layer for a tubular assembly
produced by the
method of Fig. 39.
[00147] Fig 61 a is a graphical view illustrating an exemplary experimental
embodiment of the wall thickness of an expandable tubular member for a tubular
assembly
produced by the method of Fig. 39 but omitting the coating with a layer of
material,
[00148] Fig 61 b is a graphical view illustrating an exemplary experimental
embodiment of the wall thickness of an expandable tubular member for a tubular
assembly
produced by the method of Fig. 39.
[00149] Fig 61 c is a graphical view illustrating an exemplary experimental
embodiment of the wall thickness of an expandable tubular member for a tubular
assembly
produced by the method of Fig. 39.
[00150] Fig 62a is a graphical view illustrating an exemplary experimental
embodiment of the wall thickness of a preexisting structure for a tubular
assembly produced
by the method of Fig. 39 but omitting the coating with a layer of material.
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00151] Fig 62b is a graphical view illustrating an exemplary experimental
embodiment of the wall thickness of a preexisting structure for a tubular
assembly produced
by the method of Fig. 39.
[00152] Fig 62c is a graphical view illustrating an exemplary experimental
embodiment of the wall thickness of a preexisting structure for a tubular
assembly produced
by the method of Fig. 39.
[00153] Fig 63 is a graphical view illustrating an exemplary experimental
embodiment
of the collapse strength for a tubular assembly produced by the method of Fig.
39.
Detailed Description of the Illustrative Embodiments
[00154] Referring initially to Fig. 1, an exemplary embodiment of an
expandable tubular
assembly 10 includes a first expandable tubular member 12 coupled to a second
expandable tubular member 14. In several exemplary embodiments, the ends of
the first
and second expandable tubular members, 12 and 14, are coupled using, for
example, a
conventional mechanical coupling, a welded connection, a brazed connection, a
threaded
connection, and/or an interFerence fit connection. In an exemplary embodiment,
the first
expandable tubular member 12 has a plastic yield point YP,, and the second
expandable
tubular member 14 has a plastic yield point YP~. In an exemplary embodiment,
the
expandable tubular assembly 10 is positioned within a preexisting structure
such as, for
example, a wellbore 16 that traverses a subterranean formation 18.
[00155] As illustrated in Fig. 2, an expansion device 20 may then be
positioned within the
second expandable tubular member 14. In several exemplary embodiments, the
expansion
device 20 may include, for example, one or more of the following conventional
expansion
devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming
expansion
device; d) an impulsive force expansion device; d) any one of the expansion
devices
commercially available from, or disclosed in any of the published patent
applications or
issued patents, of Weatherford International, Baker Hughes, Halliburton Energy
Services,
Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C. In
several
exemplary embodiments, the expansion device 20 is positioned within the second
expandable tubular member 14 before, during, or after the placement of the
expandable
tubular assembly 10 within the preexisting structure 16.
[00156] As illustrated in Fig. 3, the expansion device 20 may then be operated
to radially
expand and plastically deform at least a portion of the second expandable
tubular member
14 to form a bell-shaped section.
[00157] As illustrated in Fig. 4, the expansion device 20 may then be operated
to radially
expand and plastically deform the remaining portion of the second expandable
tubular
member 14 and at least a portion of the first expandable tubular member 12.
[00158] In an exemplary embodiment, at least a portion of at least a portion
of at least
26
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
one of the first and second expandable tubular members, 12 and 14, are
radially expanded
info intimate contact with the interior surface of the preexisting structure
16.
[00159] In an exemplary embodiment, as illustrated in Fig. 5, the plastic
yield point YP, is
greater than the plastic yield point YP2. In this manner, in an exemplary
embodiment, the
amount of power and/or energy required to radially expand the second
expandable tubular
member 14 is less than the amount of power and/or energy required to radially
expand the
first expandable tubular member 12.
[00160] In an exemplary embodiment, as illustrated in Fig. 6, the first
expandable tubular
member 12 and/or the second expandable tubular member 14 have a ductility DPE
and a
yield strength YSPE prior to radial expansion and plastic deformation, and a
ductility DAE and
a yield strength YSAE after radial expansion and plastic deformation. In an
exemplary
embodiment, DPE is greater than DAE, and YSAE is greater than YSPE. In this
manner, the first
expandable tubular member 12 and/or the second expandable tubular member 14
are
transformed during the radial expansion and plastic deformation process.
Furthermore, in
this manner, in an exemplary embodiment, the amount of power and/or energy
required to
radially expand each unit length of the first and/or second expandable tubular
members, 12
and 14, is reduced. Furthermore, because the YSAE is greater than YSPE, the
collapse
strength of the first expandable tubular member 12 and/or the second
expandable tubular
member 14 is increased after the radial expansion and plastic deformation
process.
[00161] In an exemplary embodiment, as illustrated in Fig. 7, following the
completion of
the radial expansion and plastic deformation of the expandable tubular
assembly 10
described above with reference to Figs. 1-4, at least a portion of the second
expandable
tubular member 14 has an inside diameter that is greater than at least the
inside diameter of
the first expandable tubular member 12. In this manner a bell-shaped section
is formed
using at least a portion of the second expandable tubular member 14. Another
expandable
tubular assembly 22 that includes a first expandable tubular member 24 and a
second
expandable tubular member 26 may then be positioned in overlapping relation to
the first
expandable tubular assembly 10 and radially expanded and plastically deformed
using the
methods described above with reference to Figs. 1-4. Furthermore, following
the completion
of the radial expansion and plastic deformation of the expandable tubular
assembly 20, in an
exemplary embodiment, at least a portion of the second expandable tubular
member 26 has
an inside diameter that is greater than at least the inside diameter of the
first expandable
tubular member 24. In this manner a bell-shaped section is formed using at
least a portion
of the second expandable tubular member 26. Furthermore, in this manner, a
mono-
diameter tubular assembly is formed that defines an internal passage 28 having
a
substantially constant cross-sectional area andlor inside diameter.
[00162] Referring to Fig. 8, an exemplary embodiment of an expandable tubular
assembly
27
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
100 includes a first expandable tubular member 102 coupled to a tubular
coupling 104. The
tubular coupling 104 is coupled to a tubular coupling 106. The tubular
coupling 106 is
coupled to a second expandable tubular member 108. In several exemplary
embodiments,
the tubular couplings, 104 and 106, provide a tubular coupling assembly for
coupling the first
and second expandable tubular members, 102 and 108, together that may include,
for
example, a conventional mechanical coupling, a welded connection, a brazed
connection, a
threaded connection, and/or an interference fit connection. In an exemplary
embodiment,
the first and second expandable tubular members 12 have a plastic yield point
YP,, and the
tubular couplings, 104 and 106, have a plastic yield point YP2. In an
exemplary
embodiment, the expandable tubular assembly 100 is positioned within a
preexisting
structure such as, for example, a wellbore 110 that traverses a subterranean
formation 112.
[00163] As illustrated in Fig. 9, an expansion device 114 may then be
positioned within
the second expandable tubular member 108. In several exemplary embodiments,
the
expansion device 114 may include, for example, one or more of the following
conventional
expansion devices: a) an expansion cone; b) a rotary expansion device; c) a
hydroforming
expansion device; d) an impulsive force expansion device; d) any one of the
expansion
devices commercially available from, or disclosed in any of the published
patent applications
or issued patents, of Weatherford International, Baker Hughes, Halliburton
Energy Services,
Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C. In
several
exemplary embodiments, the expansion device 114 is positioned within the
second
expandable tubular member 108 before, during, or after the placement of the
expandable
tubular assembly 100 within the preexisting structure 110.
[00164] As illustrated in Fig. 10, the expansion device 114 may then be
operated to
radially expand and plastically deform at least a portion of the second
expandable tubular
member 108 to form a bell-shaped section.
[00165] As illustrated in Fig. 11, the expansion device 114 may then be
operated to
radially expand and plastically deform the remaining portion of the second
expandable
tubular member 108, the tubular couplings, 104 and 106, and at least a portion
of the first
expandable tubular member 102.
[00166] In an exemplary embodiment, at least a portion of at least a portion
of at least
one of the first and second expandable tubular members, 102 and 108, are
radially
expanded into intimate contact with the interior surface of the preexisting
structure 110.
[00167] In an exemplary embodiment, as illustrated in Fig. 12, the plastic
yield point YP,
is less than the plastic yield point YP~. In this manner, in an exemplary
embodiment, the
amount of power and/or energy required to radially expand each unit length of
the first and
second expandable tubular members, 102 and 108, is less than the amount of
power and/or
energy required to radially expand each unit length of the tubular couplings,
104 and 106.
28
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00168] In an exemplary embodiment, as illustrated in Fig. 13, the first
expandable tubular
member 12 and/or the second expandable tubular member 14 have a ductility DPE
and a
yield strength YSPE prior to radial expansion and plastic deformation, and a
ductility DAE and
a yield strength YSAE after radial expansion and plastic deformation. In an
exemplary
embodiment, DPE is greater than DAE, and YSAE is greater than YSPE. In this
manner, the first
expandable tubular member 12 and/or the second expandable tubular member 14
are
transformed during the radial expansion and plastic deformation process.
Furthermore, in
this manner, in an exemplary embodiment, the amount of power and/or energy
required to
radially expand each unit length of the first and/or second expandable tubular
members, 12
and 14, is reduced. Furthermore, because the YSqE is greater than YSPE, the
collapse
strength of the first expandable tubular member 12 and/or the second
expandable tubular
member 14 is increased after the radial expansion and plastic deformation
process.
[00169] Referring to Fig. 14, an exemplary embodiment of an expandable tubular
assembly 200 includes a first expandable tubular member 202 coupled to a
second
expandable tubular member 204 that defines radial openings 204a, 204b, 204c,
and 204d.
In several exemplary embodiments, the ends of the first and second expandable
tubular
members, 202 and 204, are coupled using, for example, a conventional
mechanical
coupling, a welded connection, a brazed connection, a threaded connection,
and/or an
interference tit connection. In an exemplary embodiment, one or more of the
radial
openings, 204a, 204b, 204c, and 204d, have circular, oval, square, and/or
irregular cross
sections and/or include portions that extend to and interrupt either end of
the second
expandable tubular member 204. In an exemplary embodiment, the expandable
tubular
assembly 200 is positioned within a preexisting structure such as, for
example, a wellbore
206 that traverses a subterranean formation 208.
[00170] As illustrated in Fig. 15, an expansion device 210 may then be
positioned within
the second expandable tubular member 204. In several exemplary embodiments,
the
expansion device 210 may include, for example, one or more of the foNowing
conventional
expansion devices: a) an expansion cone; b) a rotary expansion device; c) a
hydroforming
expansion device; d) an impulsive force expansion device; d) any one of the
expansion
devices commercially available from, or disclosed in any of the published
patent applications
or issued patents, of Weatherford International, Baker Hughes, Halliburton
Energy Services,
Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C. In
several
exemplary embodiments, the expansion device 210 is positioned within the
second
expandable tubular member 204 before, during, or after the placement of the
expandable
tubular assembly 200 within the preexisting structure 206.
[00171] As illustrated in Fig. 16, the expansion device 210 may then be
operated to
radially expand and plastically deform at least a portion of the second
expandable tubular
29
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
member 204 to form a bell-shaped section.
[00172] As illustrated in Fig. 16, the expansion device 20 may then be
operated to radially
expand and plastically deform the remaining portion of the second expandable
tubular
member 204 and at least a portion of the first expandable tubular member 202.
[00173] In an exemplary embodiment, the anisotropy ratio AR for the first and
second
expandable tubular members is defined by the following equation:
AR = In (WTf/WTo)/In (Df/Do);
where AR = anisotropy ratio;
where WTf = final wall thickness of the expandable tubular member following
the
radial expansion and plastic deformation of the expandable tubular member;
where WT; = initial wall thickness of the expandable tubular member prior to
the
radial expansion and plastic deformation of the expandable tubular member;
where Df = final inside diameter of the expandable tubular member following
the
radial expansion and plastic deformation of the expandable tubular member; and
where D; = initial inside diameter of the expandable tubular member prior to
the
radial expansion and plastic deformation of the expandable tubular member.
[00174] In an exemplary embodiment, the anisotropy ratio AR for the first
and/or second
expandable tubular members, 204 and 204, is greater than 1.
[00175] In an exemplary experimental embodiment, the second expandable tubular
member 204 had an anisotropy ratio AR greater than 1, and the radial expansion
and plastic
deformation of the second expandable tubular member did not result in any of
the openings,
204x, 204b, 204c, and 2044, splitting or otherwise fracturing the remaining
portions of the
second expandable tubular member. This was an unexpected result.
[00176] Referring to Fig. 18, in an exemplary embodiment, one or more of the
expandable
tubular members, 12, 14, 24, 26, 7 02, 104, 106, 108, 202 and/or 204 are
processed using a
method 300 in which a tubular member in an initial state is thermo-
mechanically processed
in step 302. In an exemplary embodiment, the thermo-mechanical processing 302
includes
one or more heat treating and/or mechanical forming processes. As a result, of
the thermo-
mechanical processing 302, the tubular member is transformed to an
intermediate state.
The tubular member is then further thermo-mechanically processed in step 304.
In an
exemplary embodiment, the thermo-mechanical processing 304 includes one or
more heat
treating and/or mechanical forming processes. As a result, of the thermo-
mechanical
processing 304, the tubular member is transformed to a final state.
[00177] In an exemplary embodiment, as illustrated in Fig. 19, during the
operation of the
method 300, the tubular member has a ductility DPE and a yield strength YSPE
prior to the
final thermo-mechanical processing in step 304, and a ductility DAE and a
yield strength YSAE
after final thermo-mechanical processing. In an exemplary embodiment, DPE is
greater than
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
DqE, and YSAE is greater than YSpE. In this manner, the amount of energy
and/or power
required to transform the tubular member, using mechanical forming processes,
during the
final thermo-mechanical processing in step 304 is reduced. Furthermore, in
this manner,
because the YSAE is greater than YSPE, the collapse strength of the tubular
member is
increased after the final thermo-mechanical processing in step 304.
[00178 In an exemplary embodiment, one or more of the expandable tubular
members,
12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, have the following
characteristics:
Characteristic Value
Tensile Strength 60 to 120 ksi
Yield Strength 50 to 900 ksi
Y/T Ratio Maximum of 50/85
Elongation During Radial ExpansionMinimum of 35
and
Plastic Deformation
Width Reduction During Radial Minimum of 40
Expansion
and Plastic Deformation
Wall Thickness Reduction During Minimum of 30
Radial
Expansion and Plastic Deformation
Anisotropy Minimum of 1.5
Minimum Absorbed Energy at -4 80 ft-ib
F (-20 C) in
the Longitudinal Direction
Minimum Absorbed Energy at -4 60 ft-Ib
F (-20 C) in
the Transverse Direction
Minimum Absorbed Energy at -4 60 ft-Ib
F (-20 C)
Transverse To A Weld Area
Flare Expansion Testing Minimum of 75% Without A Failure
Increase in Yield Strength Due Greater than 5.4
To Radial
Expansion and Plastic Deformation
[00179] In an exemplary embodiment, one or more of the expandable tubular
members,
31
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, are characterized by an
expandability
coefficient f:
i. f=rXn
ii. where f = expandability coefficient;
1. r = anisotropy coefficient; and
2. n = strain hardening exponent.
[00180] In an exemplary embodiment, the anisotropy coefficient for one or more
of the
expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204
is greater
than 1. In an exemplary embodiment, the strain hardening exponent for one or
more of the
expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204
is greater
than 0.12. In an exemplary embodiment, the expandability coefficient for one
or more of the
expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204
is greater
than 0.12.
[00181] In an exemplary embodiment, a tubular member having a higher
expandability
coefficient requires less power and/or energy to radially expand and
plastically deform each
unit length than a tubular member having a lower expandability coefficient. In
an exemplary
embodiment, a tubular member having a higher expandability coefficient
requires less power
and/or energy per unit length to radially expand and plastically deform than a
tubular
member having a lower expandability coefficient.
[00182] In several exemplary experimental embodiments, one or more of the
expandable
tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, are steel
alloys having
one of the following compositions:
Element
and
Percentage
By
Weight
Steel C Mn P S Si Cu Ni Cr
AI loy
A 0.065 1.44 0.01 0.002 0.24 0.01 0.01 0.02
B 0.18 1.28 0.017 0.004 0.29 0.01 0.01 0.03
C 0.08 0.82 0.006 0.003 0.30 0.16 0.05 0.05
D 0.02 1.31 0.02 0.001 0.45 - 9.1 18.7
[00183] In exemplary experimental embodiment, as illustrated in Fig. 20, a
sample of an
expandable tubular member composed of Alloy A exhibited a yield point before
radial
expansion and plastic deformation YPBE, a yield point after radial expansion
and plastic
deformation of about 16 % YPA~,6~ro, and a yield point after radial expansion
and plastic
deformation of about 24 % YPA~~4aa. In an exemplary experimental embodiment,
YPqE~4% >
YPqEl6% > YPB~. Furthermore, in an exemplary experimental embodiment, the
ductility of the
32
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
sample of the expandable tubular member composed of Alloy A also exhibited a
higher
ductility prior to radial expansion and plastic deformation than after radial
expansion and
plastic deformation. These were unexpected results.
[00184] In an exemplary experimental embodiment, a sample of an expandable
tubular
member composed of Alloy A exhibited the following tensile characteristics
before and after
radial expansion and plastic deformation:
Yield Yield ElongationWidth Wall Anisotropy
Point Ratio % ReductionThickness
ksi % Reduction
Before 46.9 0.69 53 -52 55 0.93
Radial
Expansion
and Plastic
Deformation
After 16% 65.9 0.83 17 42 51 0.78
Radial
Expansion
After 24% 68.5 0.83 5 44 54 0.76
Radial
Expansion
Increase 40% for
16%
radial
expansion
46% for
24%
radial
expansion
[00185] In exemplary experimental embodiment, as illustrated in Fig. 21, a
sample of an
expandable tubular member composed of Alloy B exhibited a yield point before
radial
expansion and plastic deformation YPBE, a yield point after radial expansion
and plastic
deformation of about 16 % YPA~,soo, and a yield point after radial expansion
and plastic
deformation of about 24 % YPAE24%~ In an exemplary embodiment, YPp,Eg4% ~
YPAE16%
YPBE. Furthermore, in an exemplary experimental embodiment, the ductility of
the sample of
33
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
the expandable tubular member composed of Alloy B also exhibited a higher
ductility prior to
radial expansion and plastic deformation than after radial expansion and
plastic deformation.
These were unexpected results.
[00186] In an exemplary experimental embodiment, a sample of an expandable
tubular
member composed of Alloy B exhibited the following tensile characteristics
before and after
radial expansion and plastic deformation:
Yield Yield ElongationWidth Wall Anisotropy
Point Ratio % ReductionThickness
ksi % Reduction
Before 57.8 0.71 44 43 46 0.93
Radial
Expansion
and Plastic
Deformation
After 16% 74.4 0.84 16 38 42 0.87
Radial
a
Expansion
After 24% 79.8 0.86 20 36 42 0.81
Radial
Expansion
Increase 28.7%
increase
for 16%
radial
expansion
38%
increase
for 24%
radial
expansion
[00187] In an exemplary experimental embodiment, samples of expandable
tubulars
composed of Alloys A, B, C, and D exhibited the following tensile
characteristics prior to
radial expansion and plastic deformation:
34
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
Steel Yield Yield ElongationAnisotropyAbsorbed Expandability
Atloy ksi Ratio % Energy Coefficient
ft-Ib
A 47.6 0.71 44 1.48 145
B 57.8 0.71 44 1.04 62.2
C 61.7 0.80 39 1.92 268
D 48 0.55 56 1.34
[00188] In an exemplary embodiment, one or more of the expandable tubular
members,
12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 have a strain hardening
exponent greater
than 0.12, and a yield ratio is less than 0.85.
[00189] In an exemplary embodiment, the carbon equivalent Ce, for tubular
members
having a carbon content (by weight percentage) less than or equal to 0.12%, is
given by the
following expression:
Ce =C+Mnl6+~Cr+Mo+V+Ti+Nb~IS+~Ni+Cu~llS
where Ce - carbon equivalent value;
a. C - carbon percentage by weight;
b. Mn - manganese percentage by weight;
c. Cr - chromium percentage by weight;
d. Mo - molybdenum percentage by weight;
e. V - vanadium percentage by weight;
f. Ti - titanium percentage by weight;
g. Nb - niobium percentage by weight;
h. Ni - nickel percentage by weight; and
i. Cu - copper percentage by weight.
[00190] In an exemplary embodiment, the carbon equivalent value Ce, for
tubular
members having a carbon content less than or equal to 0.12% (by weight), for
one or more
of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202
and/or 204 is
less than 0.21.
[00191] In an exemplary embodiment, the carbon equivalent Ce, for tubular
members
having more than 0.12% carbon content (by weight), is given by the following
expression:
C~ =C+Sil30+~Mh+Cu+Ct-)l20+Nil60+MollS+YllO+5*B
where Ce = carbon equivalent value;
a. C - carbon percentage by weight;
b. Si - silicon percentage by weight;
c. Mn - manganese percentage by weight;
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
d. Cu copper percentage by weight;
-
e. Cr chromium percentage by weight;
-
f. Ni nickel percentage by weight;
-
g. Mo molybdenum percentage by weight;
-
h. V - vanadium percentage by weight;
and
i. B - boron percentage by weight.
[00192] In an exemplary embodiment, the carbon equivalent value Ce, for
tubular
members having greater than 0.12% carbon content (by weight), for one or more
of the
expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204
is less
than 0.36.
[00193] Referring to Fig. 22 in an exemplary embodiment, a first tubular
member 2210
includes an internally threaded connection 2212 at an end portion 2214. A
first end of a
tubular sleeve 2216 that includes an internal flange 2218 having a tapered
portion 2220, and
a second end that includes a tapered portion 2222, is then mounted upon and
receives the
end portion 2214 of the first tubular member 2210. In an exemplary embodiment,
the end
portion 2214 of the first tubular member 2210 abuts one side of the internal
flange 2218 of
the tubular sleeve 2216, and the internal diameter of the internal flange 2218
of the tubular
sleeve 2216 is substantially equal to or greater than the maximum internal
diameter of the
internally threaded connection 2212 of the end portion 2214 of the first
tubular member
2210. An externally threaded connection 2224 of an end portion 2226 of a
second tubular
member 2228 having an annular recess 2230 is then positioned within the
tubular sleeve
2216 and threadably coupled to the internally threaded connection 2212 of the
end portion
2214 of the first tubular member 2210. In an exemplary embodiment, the
internal flange
2218 of the tubular sleeve 2216 mates with and is received within the annular
recess 2230 of
the end portion 2226 of the second tubular member 2228. Thus, the tubular
sleeve 2216 is
coupled to and surrounds the external surfaces of the first and second tubular
members,
2210 and 2228.
[00194] The internally threaded connection 2212 of the end portion 2214 of the
first
tubular member 2210 is a box connection, and the externally threaded
connection 2224 of
the end portion 2226 of the second tubular member 2228 is a pin connection. In
an
exemplary embodiment, the internal diameter of the tubular sleeve 2216 is at
least
approximately .020" greater than the outside diameters of the first and second
tubular
members, 2210 and 2228. In this manner, during the threaded coupling of the
first and
second tubular members, 2210 and 2228, fluidic materials within the first and
second tubular
members may be vented from the tubular members.
[00195] As illustrated in Fig. 22, the first and second tubular members, 2210
and
2228, and the tubular sleeve 2216 may be positioned within another structure
2232 such as,
36
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
for example, a cased or uncased wellbore, and radially expanded and
plastically deformed,
for example, by displacing and/or rotating a conventional expansion device
2234 within
and/or through the interiors of the first and second tubular members. The
tapered portions,
2220 and 2222, of the tubular sleeve 2216 facilitate the insertion and
movement of the first
and second tubular members within and through the structure 2232, and the
movement of
the expansion device 2234 through the interiors of the first and second
tubular members,
2210 and 2228, may be, for example, from top to bottom or from bottom to top.
[00196] During the radial expansion and plastic deformation of the first and
second
tubular members, 2210 and 2228, the tubular sleeve 2216 is also radially
expanded and
plastically deformed. As a result, the tubular sleeve 2216 may be maintained
in
circumferential tension and the end portions, 2214 and 2226, of the first and
second tubular
members, 2210 and 2228, may be maintained in circumferential compression.
[00197] Sleeve 2216 increases the axial compression loading of the connection
between tubular members 2210 and 2228 before and after expansion by the
expansion
device 2234. Sleeve 2216 may, for example, be secured to tubular members 2210
and
2228 by a heat shrink fit.
[00198] In several alternative embodiments, the first and second tubular
members,
2210 and 2228, are radially expanded and plastically deformed using other
conventional
methods for radially expanding and plastically deforming tubular members such
as, for
example, internal pressurization, hydroforming, and/or roller expansion
devices and/or any
one or combination of the conventional commercially available expansion
products and
services available from Baker Hughes, Weathertord International, and/or
Enventure Global
Technology L.L.C.
[00199] The use of the tubular sleeve 2216 during (a) the coupling of the
first tubular
member 2210 to the second tubular member 2228, (b) the placement of the first
and second
tubular members in the structure 2232, and (c) the radial expansion and
plastic deformation
of the first and second tubular members provides a number of significant
benefits. For
example, the tubular sleeve 2216 protects the exterior surfaces of the end
portions, 2214
and 2226, of the first and second tubular members, 2210 and 2228, during
handling and
insertion of the tubular members within the structure 2232. In this manner,
damage to the
exterior surfaces of the end portions, 2214 and 2226, of the first and second
tubular
members, 2210 and 2228, is avoided that could otherwise result in stress
concentrations
that could cause a catastrophic failure during subsequent radial expansion
operations.
Furthermore, the tubular sleeve 2216 provides an alignment guide that
facilitates the
insertion and threaded coupling of the second tubular member 2228 to the first
tubular
member 2210. In this manner, misalignment that could result in damage to the
threaded
connections, 2212 and 2224, of the first and second tubular members, 2210 and
2228, may
37
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
be avoided. In addition, during the relative rotation of the second tubular
member with
respect to the first tubular member, required during the threaded coupling of
the first and
second tubular members, the tubular sleeve 2216 provides an indication of to
what degree
the first and second tubular members are threadably coupled. For example, if
the tubular
sleeve 2216 can be easily rotated, that would indicate that the first and
second tubular
members, 2210 and 2228, are not fully threadably coupled and in intimate
contact with the
internal flange 2218 of the tubular sleeve. Furthermore, the tubular sleeve
2216 may
prevent crack propagation during the radial expansion and plastic deformation
of the first
and second tubular members, 2210 and 2228. In this manner, failure modes such
as, for
example, longitudinal cracks in the end portions, 2214 and 2226, of the first
and second
tubular members may be limited in severity or eliminated all together. In
addition, after
completing the radial expansion and plastic deformation of the first and
second tubular
members, 2210 and 2228, the tubular sleeve 2216 may provide a fluid tight
metal-to-metal
seal between interior surFace of the tubular sleeve 2216 and the exterior
surfaces of the end
portions, 2214 and 2226, of the first and second tubular members. In this
manner, fluidic
materials are prevented from passing through the threaded connections, 2212
and 2224, of
the first and second tubular members, 2210 and 2228, into the annulus between
the first and
second tubular members and the structure 2232. Furthermore, because, following
the radial
expansion and plastic deformation of the first and second tubular members,
2210 and 2228,
the tubular sleeve 2216 may be maintained in circumferential tension and the
end portions,
2214 and 2226, of the first and second tubular members, 2210 and 2228, may be
maintained in circumferential compression, axial loads and/or torque loads may
be
transmitted through the tubular sleeve.
[00200] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 2210 and 2228, and the tubular sleeve 2216 have one or
more of
the material properties of one or more of the tubular members 12, 14, 24, 26,
102, 104, 106,
108, 202 and/or 204.
[00201] Referring to Fig. 23, in an exemplary embodiment, a first tubular
member 210
includes an internally threaded connection 2312 at an end portion 2314. A
first end of a
tubular sleeve 2316 includes an internal flange 2318 and a tapered portion
2320. A second
end of the sleeve 2316 includes an internal flange 2321 and a tapered portion
2322. An
externally threaded connection 2324 of an end portion 2326 of a second tubular
member
2328 having an annular recess 2330, is then positioned within the tubular
sleeve 2316 and
threadably coupled to the internally threaded connection 2312 of the end
portion 2314 of the
first tubular member 2310. The internal flange 2318 of the sleeve 2316 mates
with and is
received within the annular recess 2330.
38
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00202] The first tubular member 2310 includes a recess 2331. The internal
flange
2321 mates with and is received within the annular recess 2331. Thus, the
sleeve 2316 is
coupled to and surrounds the external surfaces of the first and second tubular
members
2310 and 2328.
[00203] The internally threaded connection 2312 of the end portion 2314 of the
first
tubular member 2310 is a box connection, and the externally threaded
connection 2324 of
the end portion 2326 of the second tubular member 2328 is a pin connection. In
an
exemplary embodiment, the internal diameter of the tubular sleeve 2316 is at
least
approximately .020" greater than the outside diameters of the first and second
tubular
members 2310 and 2328. In this manner, during the threaded coupling of the
first and
second tubular members 2310 and 2328, fluidic materials within the first and
second tubular
members may be vented from the tubular members.
[00204] As illustrated in Fig. 23, the first and second tubular members 2310
and 2328,
and the tubular sleeve 2316 may then be positioned within another structure
2332 such as,
for example, a wellbore, and radially expanded and plastically deformed, for
example, by
displacing and/or rotating an expansion device 2334 through and/or within the
interiors of the
first and second tubular members. The tapered portions 2320 and 2322, of the
tubular
sleeve 2316 facilitates the insertion and movement of the first and second
tubular members
within and through the structure 2332, and the displacement of the expansion
device 2334
through the interiors of the first and second tubular members 2310 and 2328,
may be from
fop to bottom or from bottom to top.
[00205] During the radial expansion and plastic deformation of the first and
second
tubular members 2310 and 2328, the tubular sleeve 2316 is also radially
expanded and
plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 2316 may
be maintained in circumferential tension and the end portions 2314 and 2326,
of the first and
second tubular members 2310 and 2328, may be maintained in circumferential
compression.
[00206] Sleeve 2316 increases the axial tension loading of the connection
between
tubular members 2310 and 2328 before and after expansion by the expansion
device 2334.
Sleeve 2316 may be secured to tubular members 2310 and 2328 by a heat shrink
fit.
[00207] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 2310 and 2328, and the tubular sleeve 2316 have one or
more of
the material properties of one or more of the tubular members 12, 14, 24, 26,
102, 104, 106,
108, 202 and/or 204.
[00208] Referring to Fig. 24, in an exemplary embodiment, a first tubular
member
2410 includes an internally threaded connection 2412 at an end portion 2414. A
first end of
a tubular sleeve 2416 includes an internal flange 2418 and a tapered portion
2420. A
second end of the sleeve 2416 includes an internal flange 2421 and a tapered
portion 2422.
39
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
An externally threaded connection 2424 of an end portion 2426 of a second
tubular member
2428 having an annular recess 2430, is then positioned within the tubular
sleeve 2416 and
threadably coupled to the internally threaded connection 2412 of the end
portion 2414 of the
first tubular member 2410. The internal flange 2418 of the sleeve 2416 mates
with and is
received within the annular recess 2430. The first tubular member 2410
includes a recess
2431. The internal flange 2421 mates with and is received within the annular
recess 2431.
Thus, the sleeve 2416 is coupled to and surrounds the external surfaces of the
first and
second tubular members 2410 and 2428.
[00209] The internally threaded connection 2412 of the end portion 2414 of the
first
tubular member 2410 is a box connection, and the externally threaded
connection 2424 of
the end portion 2426 of the second tubular member 2428 is a pin connection. In
an
exemplary embodiment, the internal diameter of the tubular sleeve 2416 is at
least
approximately .020" greater than the outside diameters of the first and second
tubular
members 2410 and 2428. In this manner, during the threaded coupling of the
first and
second tubular members 2410 and 2428, fluidic materials within the first and
second tubular
members may be vented from the tubular members.
[00210] As illustrated in Fig. 24, the first and second tubular members 2410
and 2428,
and the tubular sleeve 2416 may then be positioned within another structure
2432 such as,
for example, a wellbore, and radially expanded and plastically deformed, for
example, by
displacing andlor rotating an expansion device 2434 through and/or within the
interiors of the
first and second tubular members. The tapered portions 2420 and 2422, of the
tubular
sleeve 2416 facilitate the insertion and movement of the first and second
tubular members
within and through the structure 2432, and the displacement of the expansion
device 2434
through the interiors of the first and second tubular members, 2410 and 2428,
may be from
top to bottom or from bottom to top.
[00211] During the radial expansion and plastic deformation of the first and
second
tubular members, 2410 and 2428, the tubular sleeve 2416 is also radially
expanded and
plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 2416 may
be maintained in circumferential tension and the end portions, 2414 and 2426,
of the first
and second tubular members, 2410 and 2428, may be maintained in
circumferential
compression.
[00212] The sleeve 2416 increases the axial compression and tension loading of
the
connection between tubular members 2410 and 2428 before and after expansion by
expansion device 2424. Sleeve 2416 may be secured to tubular members 2410 and
2428
by a heat shrink fit.
[00213] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 2410 and 2428, and the tubular sleeve 2416 have one or
more of
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
the material properties of one or more of the tubular members 12, 14, 24, 26,
102, 104, 106,
108, 202 and/or 204.
[00214] Referring to Fig. 25, in an exemplary embodiment, a first tubular
member
2510 includes an internally threaded connection 2512 at an end portion 2514. A
first end of
a tubular sleeve 2516 includes an internal flange 2518 and a relief 2520. A
second end of
the sleeve 2516 includes an internal flange 2521 and a relief 2522. An
externally threaded
connection 2524 of an end portion 2526 of a second tubular member 2528 having
an
annular recess 2530, is then positioned within the tubular sleeve 2516 and
threadably
coupled to the internally threaded connection 2512 of the end portion 2514 of
the first tubular
member 2510. The internal flange 2518 of the sleeve 2516 mates with and is
received
within the annular recess 2530. The first tubular member 2510 includes a
recess 2531. The
internal flange 2521 mates with and is received within the annular recess
2531. Thus, the
sleeve 2516 is coupled fio and surrounds the external surfaces of the first
and second tubular
members 2510 and 2528.
[00215] The internally threaded connection 2512 of the end portion 2514 of the
first
tubular member 2510 is a box connection, and the externally threaded
connection 2524 of
the end portion 2526 of the second tubular member 2528 is a pin connection. In
an
exemplary embodiment, the internal diameter of the tubular sleeve 2516 is at
least
approximately .020" greater than the outside diameters of the first and second
tubular
members 2510 and 2528. In this manner, during the threaded coupling of the
first and
second tubular members 2510 and 2528, fiuidic materials within the first and
second tubular
members may be vented from the tubular members.
[00216] As illustrated in Fig. 25, the first and second tubular members 2510
and 2528,
and the tubular sleeve 2516 may then be positioned within another structure
2532 such as,
for example, a wellbore, and radially expanded and plastically deformed, for
example, by
displacing and/or rotating an expansion device 2534 through and/or within the
interiors of the
first and second tubular members. The reliefs 2520 and 2522 are each filled
with a
sacrificial material 2540 including a tapered surface 2542 and 2544,
respectively. The
material 2540 may be a metal or a synthetic, and is provided to facilitate the
insertion and
movement of the first and second tubular members 2510 and 2528, through the
structure
2532. The displacement of the expansion device 2534 through the interiors of
the first and
second tubular members 2510 and 2528, may, for example, be from top to bottom
or from
bottom to top.
[00217] During the radial expansion and plastic deformation of the first and
second
tubular members 2510 and 2528, the tubular sleeve 2516 is also radially
expanded and
plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 2516 may
be maintained in circumferential tension and the end portions 2514 and 2526,
of the first and
41
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
second tubular members, 2510 and 2528, may be maintained in circumferential
compression.
[00218] The addition of the sacrificial material 2540, provided on sleeve
2516, avoids
stress risers on the sleeve 2516 and the tubular member 2510. The tapered
surfaces 2542
and 2544 are intended to wear or even become damaged, thus incurring such wear
or
damage which would otherwise be borne by sleeve 2516. Sleeve 2516 may be
secured to
tubular members 2510 and 2528 by a heat shrink fit.
[00219] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 2510 and 2528, and the tubular sleeve 2516 have one or
more of
the material properties of one or more of the tubular members 12, 14, 24, 26,
102, 104, 106,
108, 202 and/or 204.
[00220] Referring to Fig. 26, in an exemplary embodiment, a first tubular
member
2610 includes an internally threaded connection 2612 at an end portion 2614. A
first end of
a tubular sleeve 2616 includes an internal flange 2618 and a tapered portion
2620. A
second end of the sleeve 2616 includes an internal flange 2621 and a tapered
portion 2622.
An externally threaded connection 2624 of an end portion 2626 of a second
tubular member
2628 having an annular recess 2630, is then positioned within the tubular
sleeve 2616 and
threadably coupled to the internally threaded connection 2612 of the end
portion 2614 of the
first tubular member 2610. The internal flange 2618 of the sleeve 2616 mates
with and is
received within the annular recess 2630.
[00221] The first tubular member 2610 includes a recess 2631. The internal
flange
2621 mates with and is received within the annular recess 2631. Thus, the
sleeve 2616 is
coupled to and surrounds the external surfaces of the first and second tubular
members
2610 and 2628.
[00222] The internally threaded connection 2612 of the end portion 2614 of the
first
tubular member 2610 is a box connection, and the externally threaded
connection 2624 of
the end portion 2626 of the second tubular member 2628 is a pin connection. In
an
exemplary embodiment, the internal diameter of the tubular sleeve 2616 is at
least
approximately .020" greater than the outside diameters of the first and second
tubular
members 2610 and 2628. In this manner, during the threaded coupling of the
first and
second tubular members 2610 and 2628, fluidic materials within the first and
second tubular
members may be vented from the tubular members.
[00223] As illustrated in Fig. 26, the first and second tubular members 2610
and 2628,
and the tubular sleeve 2616 may then be positioned within another structure
2632 such as,
for example, a wellbore, and radially expanded and plastically deformed, for
example, by
displacing and/or rotating an expansion device 2634 through and/or within the
interiors of the
first and second tubular members. The tapered portions 2620 and 2622, of the
tubular
42
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
sleeve 2616 facilitates the insertion and movement of the first and second
tubular members
within and through the structure 2632, and the displacement of the expansion
device 2634
through the interiors of the first and second tubular members 2610 and 2628,
may, for
example, be from top to bottom or from bottom to top.
[00224] During the radial expansion and plastic deformation of the first and
second
tubular members 2610 and 2628, the tubular sleeve 2616 is also radially
expanded and
plasfiically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 2616 may
be maintained in circumferential tension and the end portions 2614 and 2626,
of the first and
second tubular members 2610 and 2628, may be maintained in circumferential
compression.
[00225] Sleeve 2616 is covered by a thin walled cylinder of sacrificial
material 2640.
Spaces 2623 and 2624, adjacent tapered portions 2620 and 2622, respectively,
are also
filled with an excess of the sacrificial material 2640. The material may be a
metal or a
synthetic, and is provided to facilitate the insertion and movement of the
first and second
tubular members 2610 and 2628, through the structure 2632.
[00226] The addition of the sacrificial material 2640, provided on sleeve
2616, avoids
stress risers on the sleeve 2616 and the tubular member 2610. The excess of
the sacrificial
material 2640 adjacent tapered portions 2620 and 2622 are intended to wear or
even
become damaged, thus incurring such wear or damage which would otherwise be
borne by
sleeve 2616. Sleeve 2616 may be secured to tubular members 2610 and 2628 by a
heat
shrink fit.
[00227] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 2610 and 2628, and the tubular sleeve 2616 have one or
more of
the material properties of one or more of the tubular members 12, 14, 24, 26,
102, 104, 106,
108, 202 and/or 204.
[00228] Referring to Fig. 27, in an exemplary embodiment, a first tubular
member
2710 includes an internally threaded connection 2712 at an end portion 2714. A
first end of
a tubular sleeve 2716 includes an internal flange 2718 and a tapered portion
2720. A
second end of the sleeve 2716 includes an internal flange 2721 and a tapered
portion 2722.
An externally threaded connection 2724 of an end portion 2726 of a second
tubular member
2728 having an annular recess 2730, is then positioned within the tubular
sleeve 2716 and
threadably coupled to the internally threaded connection 2712 of the end
portion 2714 of the
first tubular member 2710. The internal flange 2718 of the sleeve 2716 mates
with and is
received within the annular recess 2730.
[00229] The first tubular member 2710 includes a recess 2731. The internal
flange
2721 mates with and is received within the annular recess 2731. Thus, the
sleeve 2716 is
coupled to and surrounds the external surfaces of the first and second tubular
members
2710 and 2728.
43
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00230] The internally threaded connection 2712 of the end portion 2714 of the
first
tubular member 2710 is a box connection, and the externally threaded
connection 2724 of
the end portion 2726 of the second tubular member 2728 is a pin connection. In
an
exemplary embodiment, the internal diameter of the tubular sleeve 2716 is at
least
approximately .020" greater than the outside diameters of the first and second
tubular
members 2710 and 2728. In this manner, during the threaded coupling of the
first and
second tubular members 2710 and 2728, fluidic materials within the first and
second tubular
members may be vented from the tubular members.
[00231] As illustrated in Fig. 27, the first and second tubular members 2710
and 2728,
and the tubular sleeve 2716 may then be positioned within another structure
2732 such as,
for example, a wellbore, and radially expanded and plastically deformed, for
example, by
displacing and/or rotating an expansion device 2734 through and/or within the
interiors of the
first and second tubular members. The tapered portions 2720 and 2722, of the
tubular
sleeve 2716 facilitates the insertion and movement of the first and second
tubular members
within and through the structure 2732, and the displacement of the expansion
device 2734
through the interiors of the first and second tubular members 2710 and 2728,
may be from
top to bottom or from bottom to top.
[00232] During the radial expansion and plastic deformation of the first and
second
tubular members 2710 and 2728, the tubular sleeve 2716 is also radially
expanded and
plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 2776 may
be maintained in circumferential tension and the end portions 2714 and 2726,
of the first and
second tubular members 2710 and 2728, may be maintained in circumferential
compression.
[00233] Sleeve 2716 has a variable thickness due to one or more reduced
thickness
portions 2790 and/or increased thickness portions 2792.
[00234] Varying the thickness of sleeve 2716 provides the ability to control
or induce
stresses at selected positions along the length of sleeve 2716 and the end
portions 2724
and 2726. Sleeve 2716 may be secured to tubular members 2710 and 2728 by a
heat
shrink fit.
[00235] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 2710 and 2728, and the tubular sleeve 2716 have one or
more of
the material properties of one or more of the tubular members 12, 14, 24, 26,
102, 104, 106,
108, 202 and/or 204.
[00236] Referring to Fig. 28, in an alternative embodiment, instead of varying
the
thickness of sleeve 2716, the same result described above with reference to
Fig. 27, may be
achieved by adding a member 2740 which may be coiled onto the grooves 2739
formed in
sleeve 2716, thus varying the thickness along the length of sleeve 2716.
44
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00237] Referring to Fig. 29, in an exemplary embodiment, a first tubular
member
2910 includes an internally threaded connection 2912 and an interns( annular
recess 2914 at
an end portion 2916. A first end of a tubular sleeve 2918 includes an internal
flange 2920,
and a second end of the sleeve 2916 mates with and receives the end portion
2916 of the
first tubular member 2910. An externally threaded connection 2922 of an end
portion 2924
of a second tubular member 2926 having an annular recess 2928, is then
positioned within
the tubular sleeve 2918 and threadably coupled to the internally threaded
connection 2912
of the end portion 2916 of the first tubular member 2910. The internal flange
2920 of the
sleeve 2918 mates with and is received within the annular recess 2928. A
sealing element
2930 is received within the internal annular recess 2914 of the end portion
2916 of the first
tubular member 2910.
[00238] The internally threaded connection 2912 of the end portion 2916 of the
first
tubular member 2910 is a box connection, and the externally threaded
connection 2922 of
the end portion 2924 of the second tubular member 2926 is a pin connection. In
an
exemplary embodiment, the internal diameter of the tubular sleeve 2918 is at
least
approximately .020" greater than the outside diameters of the first tubular
member 2910. In
this manner, during the threaded coupling of the first and second tubular
members 2910 and
2926, fluidic materials within the first and second tubular members may be
vented from the
tubular members.
[00239] The first and second tubular members 2910 and 2926, and the tubular
sleeve
2918 may be positioned within another structure such as, for example, a
wellbore, and
radially expanded and plastically deformed, for example, by displacing and/or
rotating an
expansion device through and/or within the interiors of the first and second
tubular members.
[00240] During the radial expansion and plastic deformation of the first and
second
tubular members 2910 and 2926, the tubular sleeve 2918 is also radially
expanded and
plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 2918 may
be maintained in circumferential tension and the end portions 2916 and 2924,
of the first and
second tubular members 2910 and 2926, respectively, may be maintained in
circumferential
compression.
[00241] In an exemplary embodiment, before, during, and after the radial
expansion
and plastic deformation of the first and second tubular members 2910 and 2926,
and the
tubular sleeve 2918, the sealing element 2930 seals the interface between the
first and
second tubular members. In an exemplary embodiment, during and after the
radial
expansion and plastic deformation of the first and second tubular members 2910
and 2926,
and the tubular sleeve 2918, a metal to metal seal is formed between at least
one of: the first
and second tubular members 2910 and 2926, the first tubular member and the
tubular
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
sleeve 2918, and/or the second tubular member and the tubular sleeve. In an
exemplary
embodiment, the metal to metal seal is both fluid tight and gas tight.
[00242] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 2910 and 2926, the tubular sleeve 2918, and the
sealing element
2930 have one or more of the material properties of one or more of the tubular
members 12,
14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
[00243] Referring to Fig. 30a, in an exemplary embodiment, a first tubular
member
3010 includes internally threaded connections 3012a and 3012b, spaced apart by
a
cylindrical internal surface 3014, at an end portion 3016. Externally threaded
connections
3018a and 3018b, spaced apart by a cylindrical external surface 3020, of an
end portion
3022 of a second tubular member 3024 are threadably coupled to the internally
threaded
connections, 3012a and 3012b, respectively, of the end portion 3016 of the
first tubular
member 3010. A sealing element 3026 is received within an annulus defined
between the
internal cylindrical surface 3014 of the first tubular member 3010 and the
external cylindrical
surface 3020 of the second tubular member 3024.
[00244] The internaNy threaded connections, 3012a and 3012b, of the end
portion
3016 of the first tubular member 3010 are box connections, and the externally
threaded
connections, 3018a and 3018b, of the end portion 3022 of the second tubular
member 3024
are pin connections. In an exemplary embodiment, the sealing element 3026 is
an
elastomeric and/or metallic sealing element.
[00245] The first and second tubular members 3010 and 3024 may be positioned
within another structure such as, for example, a wellbore, and radially
expanded and
plastically deformed, for example, by displacing and/or rotating an expansion
device through
and/or within the infieriors of the first and second tubular members.
[00246] In an exemplary embodiment, before, during, and after the radial
expansion
and plastic deformation of the first and second tubular members 3010 and 3024,
the sealing
element 3026 seals the interface between the first and second tubular members.
In an
exemplary embodiment, before, during and/or after the radial expansion and
plastic
deformation of the first and second tubular members 3010 and 3024, a metal to
metal seal is
formed between at least one of: the first and second tubular members 3010 and
3024, the
first tubular member and the sealing element 3026, and/or the second tubular
member and
the sealing element. In an exemplary embodiment, the metal to metal seal is
both fluid fight
and gas tight.
[00247] In an alternative embodiment, the sealing element 3026 is omitted, and
during
and/or after the radial expansion and plastic deformation of the first and
second tubular
members 3010 and 3024, a metal to metal seal is formed between the first and
second
tubular members.
46
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00248] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 3010 and 3024, the sealing element 3026 have one or
more of the
material properties of one or more of the tubular members 12, 14, 24, 26, 102,
104, 106,
108, 202 and/or 204.
[00249] Referring to Fig. 30b, in an exemplary embodiment, a first tubular
member
3030 includes internally threaded connections 3032a and 3032b, spaced apart by
an
undulating approximately cylindrical internal surface 3034, at an end portion
3036.
Externally threaded connections 3038a and 3038b, spaced apart by a cylindrical
external
surface 3040, of an end portion 3042 of a second tubular member 3044 are
threadably
coupled to the internally threaded connections, 3032a and 3032b, respectively,
of the end
portion 3036 of the first tubular member 3030. A sealing element 3046 is
received within an
annulus defined between the undulating approximately cylindrical internal
surface 3034 of
the first tubular member 3030 and the external cylindrical surface 3040 of the
second tubular
member 3044.
[00250] The internally threaded connections, 3032a and 3032b, of the end
portion
3036 of the first tubular member 3030 are box connections, and the externally
threaded
connections, 3038a and 3038b, of the end portion 3042 of the second tubular
member 3044
are pin connections. In an exemplary embodiment, the sealing element 3046 is
an
elastomeric and/or metallic sealing element.
(00251] The first and second tubular members 3030 and 3044 may be positioned
within another structure such as, for example, a wellbore, and radially
expanded and
plastically deformed, for example, by displacing and/or rotating an expansion
device through
and/or within the interiors of the first and second tubular members.
[00252] In an exemplary embodiment, before, during, and after the radial
expansion
and plastic deformation of the first and second tubular members 3030 and 3044,
the sealing
element 3046 seals the interface between the first and second tubular members.
In an
exemplary embodiment, before, during and/or after the radial expansion and
plastic
deformation of the first and second tubular members 3030 and 3044, a metal to
metal seal is
formed between at feast one of: the first and second tubular members 3030 and
3044, the
first tubular member and the sealing element 3046, and/or the second tubular
member and
the sealing element. In an exemplary embodiment, the metal to metal seal is
both fluid tight
and gas tight.
[00253] In an alternative embodiment, the sealing element 3046 is omitted, and
during
and/or after the radial expansion and plastic deformation of the first and
second tubular
members 3030 and 3044, a metal to metal seal is formed between the first and
second
tubular members.
47
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00254] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 3030 and 3044, the sealing element 3046 have one or
more of the
material properties of one or more of the tubular members 12, 14, 24, 26, 102,
104, 106,
108, 202 and/or 204.
[00255] Referring to Fig. 30c, in an exemplary embodiment, a first tubular
member
3050 includes internally threaded connections 3052a and 3052b, spaced apart by
a
cylindrical internal surface 3054 including one or more square grooves 3056,
at an end
portion 3058. Externally threaded connections 3060a and 3060b, spaced apart by
a
cylindrical external surface 3062 including one or more square grooves 3064,
of an end
portion 3066 of a second tubular member 3068 are threadably coupled to the
internally
threaded connections, 3052a and 3052b, respectively, of the end portion 3058
of the first
tubular member 3050. A sealing element 3070 is received within an annulus
defined
between the cylindrical internal surface 3054 of the first tubular member 3050
and the
external cylindrical surface 3062 of the second tubular member 3068.
[00256] The internally threaded connections, 3052a and 3052b, of the end
portion
3058 of the first tubular member 3050 are box connections, and the externally
threaded
connections, 3060a and 3060b, of the end portion 3066 of the second tubular
member 3068
are pin connections. In an exemplary embodiment, the sealing element 3070 is
an
elastomeric and/or metallic sealing element.
[00257] The first and second tubular members 3050 and 3068 may be positioned
within another structure such as, for example, a wellbore, and radially
expanded and
plastically deformed, for example, by displacing and/or rotating an expansion
device through
and/or within the interiors of the first and second tubular members.
[00258] In an exemplary embodiment, before, during, and after the radial
expansion
and plastic deformation of the first and second tubular members 3050 and 3068,
the sealing
element 3070 seals the interFace between the first and second tubular members.
In an
exemplary embodiment, before, during and/or after the radial expansion and
plastic
deformation of the first and second tubular members, 3050 and 3068, a metal to
metal seal
is formed between at least one of: the first and second tubular members, the
first tubular
member and the sealing element 3070, and/or the second tubular member and the
sealing
element. In an exemplary embodiment, the metal to metal seal is both fluid
tight and gas
tight.
[00259] In an alternative embodiment, the sealing element 3070 is omitted, and
during
and/or after the radial expansion and plastic deformation of the first and
second tubular
members 950 and 968, a metal to metal seal is formed between the first and
second tubular
members.
48
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00260] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 3050 and 3068, the sealing element 3070 have one or
more of the
material properties of one or more of the tubular members 12, 14, 24, 26, 102,
104, 106,
108, 202 and/or 204.
[00261] Referring to Fig. 31, in an exemplary embodiment, a first tubular
member
3110 includes internally threaded connections, 3112a and 3112b, spaced apart
by a non-
threaded internal surface 3114, at an end portion 3116. Externally threaded
connections,
3118a and 3118b, spaced apart by a non-threaded external surface 3120, of an
end portion
3122 of a second tubular member 3124 are threadably coupled to the internally
threaded
connections, 3112a and 3112b, respectively, of the end portion 3122 of the
first tubular
member 3124.
[00262] First, second, and/or third tubular sleeves, 3126, 3128, and 3130, are
coupled
the external surface of the first tubular member 3110 in opposing relation to
the threaded
connection formed by the internal and external threads, 3112a and 3118x, the
interface
between the non-threaded surfaces, 3114 and 3120, and the threaded connection
formed by
the internal and external threads, 3112b and 3118b, respectively.
[00263] The internally threaded connections, 3112a and 3112b, of the end
portion
3116 of the first tubular member 3110 are box connections, and the externally
threaded
connections, 3118a and 3118b, of the end portion 3122 of the second tubular
member 3924
are pin connections.
[00264] The first and second tubular members 3110 and 3124, and the tubular
sleeves 3126, 3128, and/or 3130, may then be positioned within another
structure 3132 such
as, for example, a wellbore, and radially expanded and plastically deformed,
for example, by
displacing and/or rotating an expansion device 3134 through and/or within the
interiors of the
first and second tubular members.
[00265] During the radial expansion and plastic deformation of the first and
second
tubular members 3110 and 3124, the tubular sleeves 3126, 3128 and/or 3130 are
also
radially expanded and plastically deformed. In an exemplary embodiment, as a
result, the
tubular sleeves 3126, 3128, and/or 3130 are maintained in circumferential
tension and the
end portions 3116 and 3122, of the first and second tubular members 3110 and
3124, may
be maintained in circumferential compression.
[00266] The sleeves 3126, 3128, and/or 3130 may, for example, be secured to
the
first tubular member 3110 by a heat shrink fit.
[00267] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 3110 and 3124, and the sleeves, 3126, 3128, and 3130,
have one
or more of the material properties of one or more of the tubular members 12,
14, 24, 26, 102,
104, 106, 108, 202 and/or 204.
49
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00268] Referring to Fig. 32a, in an exemplary embodiment, a first tubular
member
3210 includes an internally threaded connection 3212 at an end portion 3214.
An externally
threaded connection 3216 of an end portion 3218 of a second tubular member
3220 are
threadably coupled to the internally threaded connection 3212 of the end
portion 3214 of the
first tubular member 3210.
[00269] The internally threaded connection 3212 of the end portion 3214 of the
first
tubular member 3210 is a box connection, and the externally threaded
connection 3216 of
the end portion 3218 of the second tubular member 3220 is a pin connection.
[00270] A tubular sleeve 3222 including internal flanges 3224 and 3226 is
positioned
proximate and surrounding the end portion 3214 of the first tubular member
3210. As
illustrated in Fig. 32b, the tubular sleeve 3222 is then forced into
engagement with the
external surface of the end portion 3214 of the first tubular member 3210 in a
conventional
manner. As a result, the end portions, 3214 and 3218, of the first and second
tubular
members, 3210 and 3220, are upset in an undulating fashion.
[00271] The first and second tubular members 3210 and 3220, and the tubular
sleeve
3222, may then be positioned within another structure such as, for example, a
wellbore, and
radially expanded and plastically deformed, for example, by displacing and/or
rotating an
expansion device through and/or within the interiors of the first and second
tubular members.
[00272] During the radial expansion and plastic deformation of the first and
second
tubular members 3210 and 3220, the tubular sleeve 3222 is also radially
expanded and
plastically deformed. In an exemplary embodiment, as a result, the tubular
sleeve 3222 is
maintained in circumferential tension and the end portions 3214 and 3218, of
the first and
second tubular members 3210 and 3220, may be maintained in circumferential
compression.
[00273] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 3210 and 3220, and the sleeve 3222 have one or more of
the
material properties of one or more of the tubular members 12, 14, 24, 26, 102,
104, 106,
108, 202 and/or 204.
[00274] Referring to Fig. 33, in an exemplary embodiment, a first tubular
member
3310 includes an internally threaded connection 3312 and an annular projection
3314 at an
end portion 3316.
[00275] A first end of a tubular sleeve 3318 that includes an internal flange
3320
having a tapered portion 3322 and an annular recess 3324 for receiving the
annular
projection 3314 of the first tubular member 3310, and a second end that
includes a tapered
portion 3326, is then mounted upon and receives the end portion 3316 of the
first tubular
member 3310.
[00276] In an exemplary embodiment, the end portion 3316 of the first tubular
member 3310 abuts one side of the internal flange 3320 of the tubular sleeve
3318 and the
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
annular projection 3314 of the end portion of the first tubular member mates
with and is
received within the annular recess 3324 of the internal flange of the tubular
sleeve, and the
internal diameter of the internal flange 3320 of the tubular sleeve 3318 is
substantially equal
to or greater than the maximum internal diameter of the internally threaded
connection 3312
of the end portion 3316 of the first tubular member 3310. An externally
threaded connection
3326 of an end portion 3328 of a second tubular member 3330 having an annular
recess
3332 is then positioned within the tubular sleeve 3318 and threadably coupled
to the
internally threaded connection 3312 of the end portion 3316 of the first
tubular member
3310. In an exemplary embodiment, the internal flange 3332 of the tubular
sleeve 3318
mates with and is received within the annular recess 3332 of the end portion
3328 of the
second tubular member 3330. Thus, the tubular sleeve 3318 is coupled to and
surrounds
the external surfaces of the first and second tubular members, 3310 and 3328.
[00277] The internally threaded connection 3312 of the end portion 3316 of the
first
tubular member 3310 is a box connection, and the externally threaded
connection 3326 of
the end portion 3328 of the second tubular member 3330 is a pin connection. In
an
exemplary embodiment, the internal diameter of the tubular sleeve 3318 is at
least
approximately .020" greater than the outside diameters of the first and second
tubular
members, 3310 and 3330. In this manner, during the threaded coupling of the
first and
second tubular members, 3310 and 3330, fluidic materials within the first and
second tubular
members may be vented from the tubular members.
[00278] As illustrated in Fig. 33, the first and second tubular members, 3310
and
3330, and the tubular sleeve 3318 may be positioned within another structure
3334 such as,
for example, a cased or uncased wellbore, and radially expanded and
plastically deformed,
for example, by displacing and/or rotating a conventional expansion device
3336 within
and/or through the interiors of the first and second tubular members. The
tapered portions,
3322 and 3326, of the tubular sleeve 3318 facilitate the insertion and
movement of the first
and second tubular members within and through the structure 3334, and the
movement of
the expansion device 3336 through the interiors of the first and second
tubular members,
3310 and 3330, may, for example, be from top to bottom or from bottom to top.
[00279] During the radial expansion and plastic deformation of the first and
second
tubular members, 3310 and 3330, the tubular sleeve 3318 is also radially
expanded and
plastically deformed. As a result, the tubular sleeve 3318 may be maintained
in
circumferential tension and the end portions, 3316 and 3328, of the first and
second tubular
members, 3310 and 3330, may be maintained in circumferential compression.
[00280] Sleeve 3316 increases the axial compression loading of the connection
between tubular members 3310 and 3330 before and after expansion by the
expansion
device 3336. Sleeve 3316 may be secured to tubular members 3310 and 3330, for
51
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
example, by a heat shrink fit.
[00281] In several alternative embodiments, the first and second tubular
members,
3310 and 3330, are radially expanded and plastically deformed using other
conventional
methods for radially expanding and plastically deforming tubular members such
as, for
example, internal pressurization, hydroforming, and/or roller expansion
devices and/or any
one or combination of the conventional commercially available expansion
products and
services available from Baker Hughes, Weatherford International, and/or
Enventure Global
Technology L.L.C.
[00282] The use of fihe tubular sleeve 3318 during (a) the coupling of the
first tubular
member 3310 to the second tubular member 3330, (b) the placement of the first
and second
tubular members in the structure 3334, and (c) the radial expansion and
plastic deformation
of the first and second tubular members provides a number of significant
benefits. For
example, the tubular sleeve 3318 protects the exterior surfaces of the end
portions, 3316
and 3328, of the first and second tubular members, 3310 and 3330, during
handling and
insertion of the tubular members within the structure 3334. In this manner,
damage to the
exterior surfaces of the end portions, 3316 and 3328, of the first and second
tubular
members, 3310 and 3330, is avoided that could otherwise result in stress
concentrations
that could cause a catastrophic failure during subsequent radial expansion
operations.
Furthermore, the tubular sleeve 3318 provides an alignment guide that
facilitates the
insertion and threaded coupling of the second tubular member 3330 to the first
tubular
member 3310. In this manner, misalignment that could result in damage to the
threaded
connections, 3312 and 3326, of the first and second tubular members, 3310 and
3330, may
be avoided. In addition, during the relative rotation of the second tubular
member with
respect to the first tubular member, required during the threaded coupling of
the first and
second tubular members, the tubular sleeve 3318 provides an indication of to
what degree
the first and second tubular members are threadably coupled. For example, if
the tubular
sleeve 3318 can be easily rotated, that would indicate that the first and
second tubular
members, 3310 and 3330, are not fully threadably coupled and in intimate
contact with the
internal flange 3320 of the tubular sleeve. Furthermore, the tubular sleeve
3318 may
prevent crack propagation during the radial expansion and plastic deformation
of the first
and second tubular members, 3310 and 3330. In this manner, failure modes such
as, for
example, longitudinal cracks in the end portions, 3316 and 3328, of the first
and second
tubular members may be limited in severity or eliminated all together. In
addition, after
completing the radial expansion and plastic deformation of the first and
second tubular
members, 3310 and 3330, the tubular sleeve 3318 may provide a fluid tight
metal-to-metal
seal between interior surface of the tubular sleeve 3318 and the exterior
surfaces of the end
portions, 3316 and 3328, of the first and second tubular members. In this
manner, fluidic
52
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
materials are prevented from passing through the threaded connections, 3312
and 3326, of
the first and second tubular members, 3310 and 3330, into the annulus between
the first and
second tubular members and the structure 3334. Furthermore, because, following
the radial
expansion and plastic deformation of the first and second tubular members,
3310 and 3330,
the tubular sleeve 3318 may be maintained in circumferential tension and the
end portions,
3316 and 3328, of the first and second tubular members, 3310 and 3330, may be
maintained in circumferential compression, axial loads and/or torque loads may
be
transmitted fihrough the tubular sleeve.
[00283] In several exemplary embodiments, one or more portions of the first
and
second tubular members, 3310 and 3330, and the sleeve 3318 have one or more of
the
material properties of one or more of the tubular members 12, 14, 24, 26, 102,
104, 106,
108, 202 and/or 204.
[00284] Referring to Figs. 34a, 34b, and 34c, in an exemplary embodiment, a
first
tubular member 3410 includes an internally threaded connection 1312 and one or
more
external grooves 3414 at an end portion 3416.
[00285] A first end of a tubular sleeve 3418 that includes an internal flange
3420 and
a tapered portion 3422, a second end that includes a tapered portion 3424, and
an
intermediate portion that includes one or more longitudinally aligned openings
3426, is then
mounted upon and receives the end portion 3416 of the first tubular member
3410.
[00286] In an exemplary embodiment, the end portion 3416 of the first tubular
member 3410 abuts one side of the internal flange 3420 of the tubular sleeve
3418, and the
internal diameter of the internal flange 3420 of the tubular sleeve 3416 is
substantially equal
to or greater than the maximum internal diameter of the internally threaded
connection 3412
of the end portion 3416 of the first tubular member 3410. An externally
threaded connection
3428 of an end portion 3430 of a second tubular member 3432 that includes one
or more
internal grooves 3434 is then positioned within the tubular sleeve 3418 and
threadably
coupled to the internally threaded connection 3412 of the end portion 3416 of
the first tubular
member 3410. In an exemplary embodiment, the internal flange 3420 of the
tubular sleeve
3418 mates with and is received within an annular recess 3436 defined in the
end portion
3430 of the second tubular member 3432. Thus, the tubular sleeve 3418 is
coupled to and
surrounds the external surfaces of the first and second tubular members, 3410
and 3432.
[00287] The first and second tubular members, 3410~and 3432, and the tubular
sleeve
3418 may be positioned within another structure such as, for example, a cased
or uncased
wellbore, and radially expanded and plastically deformed, for example, by
displacing and/or
rotating a conventional expansion device within and/or through the inferiors
of the first and
second tubular members. The tapered portions, 3422 and 3424, of the tubular
sleeve 3418
facilitate the insertion and movement of the first and second tubular members
within and
53
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
through the structure, and the movement of the expansion device through the
interiors of the
first and second tubular members, 3410 and 3432, may be from top to bottom or
from
bottom to top.
[00288] During the radial expansion and plastic deformation of the first and
second
tubular members, 3410 and 3432, the tubular sleeve 3418 is also radially
expanded and
plastically deformed. As a result, the tubular sleeve 3418 may be maintained
in
circumferential tension and the end portions, 3416 and 3430, of the first and
second tubular
members, 3410 and 3432, may be maintained in circumferential compression.
[00289] Sleeve 3416 increases the axial compression loading of the connection
between tubular members 3410 and 3432 before and after expansion by the
expansion
device. The sleeve 3418 may be secured to tubular members 3410 and 3432, for
example,
by a heat shrink fit.
[00290] During the radial expansion and plastic deformation of the first and
second
tubular members, 3410 and 3432, the grooves 3414 and/or 3434 and/or the
openings 3426
provide stress concentrations that in turn apply added stress forces to the
mating threads of
the threaded connections, 3412 and 3428. As a result, during and after the
radial expansion
and plastic deformation of the first and second tubular members, 3410 and
3432, the mating
threads of the threaded connections, 3412 and 3428, are maintained in metal to
metal
contact thereby providing a fluid and gas tight connection. In an exemplary
embodiment, the
orientations of the grooves 3414 and/or 3434 and the openings 3426 are
orthogonal to one
another. In an exemplary embodiment, the grooves 3414 andlor 3434 are helical
grooves.
[00291] In several alternative embodiments, the first and second tubular
members,
3410 and 3432, are radially expanded and plastically deformed using other
conventional
methods for radially expanding and plastically deforming tubular members such
as, for
example, internal pressurization, hydroforming, and/or roller expansion
devices and/or any
one or combination of the conventional commercially available expansion
products and
services available from Baker Hughes, Weatherford International, and/or
Enventure Global
Technology L.L.C.
[00292] The use of the tubular sleeve 3418 during (a) the coupling of the
first tubular
member 3410 to the second tubular member 3432, (b) the placement of the first
and second
tubular members in the structure, and (c) the radial expansion and plastic
deformation of the
first and second tubular members provides a number of significant benefits.
For example,
the tubular sleeve 3418 protects the exterior surfaces of the end portions,
3416 and 3430, of
the first and second tubular members, 3410 and 3432, during handling and
insertion of the
tubular members within the structure. In this manner, damage to the exterior
surfaces of the
end portions, 3416 and 3430, of the first and second tubular members, 3410 and
3432, is
avoided that could otherwise result in stress concentrations that could cause
a catastrophic
54
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
failure during subsequent radial expansion operations. Furthermore, the
tubular sleeve 3418
provides an alignment guide that facilitates the insertion and threaded
coupling of the
second tubular member 3432 to the first tubular member 3410. In this manner,
misalignment that could result in damage to the threaded connections, 3412 and
3428, of
the first and second tubular members, 3410 and 3432, may be avoided. In
addition, during
the relative rotation of the second tubular member with respect to the first
tubular member,
required during the threaded coupling of the first and second tubular members,
the tubular
sleeve 3416 provides an indication of to what degree the first and second
tubular members
are threadably coupled. For example, if the tubular sleeve 3418 can be easily
rotated, that
would indicate that the first and second tubular members, 3410 and 3432, are
not fully
threadably coupled and in intimate contact with the internal flange 3420 of
the tubular
sleeve. Furthermore, the tubular sleeve 3418 may prevent crack propagation
during the
radial expansion and plastic deformation of the first and second tubular
members, 3410 and
3432. In this .manner, failure modes such as, for example, longitudinal cracks
in the end
portions, 3416 and 3430, of the first and second tubular members may be
limited in severity
or eliminated all together. In addition, after completing the radial expansion
and plastic
deformation of the fiirst and second tubular members, 3410 and 3432, the
tubular sleeve
3418 may provide a fluid and gas tight metal-to-metal seal between interior
surface of the
tubular sleeve 3418 and the exterior surfaces of the end portions, 3416 and
3430, of the first
and second tubular members. In this manner, fluidic materials are prevented
from passing
through the threaded connections, 3412 and 3430, of the first and second
tubular members,
3410 and 3432, into the annulus between the first and second tubular members
and the
structure. Furthermore, because, following the radial expansion and plastic
deformation of
the first and second tubular members, 3410 and 3432, the tubular sleeve 3418
may be
maintained in circumferential tension and the end portions, 3416 and 3430, of
the first and
second tubular members, 3410 and 3432, may be maintained in circumferential
compression, axial loads and/or torque loads may be transmitted through the
tubular sleeve.
[00293] In several exemplary embodiments, the first and second tubular members
described above with reference to Figs. 1 to 34c are radially expanded and
plastically
deformed using the expansion device in a conventional manner and/or using one
or more of
the methods and apparatus disclosed in one or more of the following: The
present
application is related to the following: (1) U.S. patent application serial
no. 09!454,139,
attorney docket no. 25791.03.02, filed on 12/3/1999, (2) U.S. patent
application serial no.
09/510,913, attorney docket no. 25791.7.02, filed on 2/23/2000, (3) U.S.
patent application
serial no. 09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, (4)
U.S. patent
application serial no. 09/440,338, attorney docket no. 25791.9.02, filed on
11/15/1999, (5)
U.S. patent application serial no. 09/523,460, attorney docket no.
25791.11.02, filed on
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
3110/2000, (6) U.S. patent application serial no. 09/512,895, attorney docket
no.
25791.12.02, filed on 2/24/2000, (7) U.S. patent application serial no.
09/511,941, attorney
docket no. 25791.16.02, filed on 2/24/2000, (8) U.S. patent application serial
no. 09/588,946,
attorney docket no. 25791.17.02, filed on 6/7/2000, (9) U.S. patent
application serial no.
09/559,122, attorney docket no. 25791.23.02, filed on 4/26/2000, (10) PCT
patent
application serial no. PCT/US00/18635, attorney docket no. 25791.25.02, filed
on 7/9/2000,
(11 ) U.S. provisional patent application serial no. 60/162,671, attorney
docket no. 25791.27,
filed on 11/1/1999, (12) U.S. provisional patent application serial no.
60/154,047, attorney
docket no. 25791.29, filed on 9/16/1999, (13) U.S. provisional patent
application serial no.
60/159,082, attorney docket no. 25791.34, filed on 10/12/1999, (14) U.S.
provisional patent
application serial no. 60/159,039, attorney docket no. 25791.36, filed on
10/12/1999, (15)
U.S. provisional patent application serial no. 60/159,033, attorney docket no.
25791.37, filed
on 10/12/1999, (16) U.S. provisional patent application serial no. 60/212,359,
attorney
docket no. 25791.38, filed on 6/19/2000, (17) U.S. provisional patent
application serial no.
60!165,228, attorney docket no. 25791.39, filed on 11/12/1999, (18) U.S.
provisional patent
application serial no. 60/221,443, attorney docket no. 25791.45, filed on
7/28/2000, (19) U.S.
provisional patent application serial no. 60/221,645, attorney docket no.
25791.46, filed on
7/28/2000, (20) U.S. provisional patent application serial no. 60/233,638,
attorney docket no.
25791.47, filed on 9/1812000, (21 ) U.S. provisional patent application serial
no. 60/237,334,
attorney docket no. 25791.48, filed on 10/2/2000, (22) U.S. provisional patent
application
serial no. 60/270,007, attorney docket no. 25791.50, filed on 2120/2001, (23)
U.S. provisional
patent application serial no. 60/262,434, attorney docket no. 25791.51, filed
on 1/17/2001,
(24) U.S, provisional patent application serial no. 60/259,486, attorney
docket no. 25791.52,
filed on 1/3/2001, (25) U.S. provisional patent application serial no.
60/303,740, attorney
docket no. 25791.61, filed on 7/6/2001, (26) U.S. provisional patent
application serial no.
60/313,453, attorney docket no. 25791.59, filed on 8/20/2001, (27) U.S.
provisional patent
application serial no. 60/317,985, attorney docket no. 25791.67, filed on
9/6/2001, (28) U.S.
provisional patent application serial no. 60/3318,386, attorney docket no.
25791.67.02, filed
on 9/10/2001, (29) U.S. utility patent application serial no. 09/969,922,
attorney docket no.
25791.69, filed on 10/3/2001, (30) U.S. utility patent application serial no.
10/016,467,
attorney docket no. 25791.70, filed on December 10, 2001, (31) U.S.
provisional patent
application serial no. 60/343,674, attorney docket no. 25791.68, filed on
12/27/2001; and
(32) U.S. provisional patent application serial no. 60/346,309, attorney
docket no. 25791.92,
filed on 01/07/02, the disclosures of which are incorporated herein by
reference.
[00294.] Referring to Fig. 35a an exemplary embodiment of an expandable
tubular
member 3500 includes a first tubular region 3502 and a second tubular portion
3504. In an
exemplary embodiment, the material properties of the first and second tubular
regions, 3502
56
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
and 3504, are different. In an exemplary embodiment, the yield points of the
first and
second tubular regions, 3502 and 3504, are different. In an exemplary
embodiment, the
yield point of the first tubular region 3502 is less than the yield point of
the second tubular
region 3504. In several exemplary embodiments, one or more of the expandable
tubular
members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 incorporate the
tubular
member 3500.
[00295] Referring to Fig. 35b, in an exemplary embodiment, the yield point
within the
first and second tubular regions, 3502a and 3502b, of the expandable tubular
member 3502
vary as a function of the radial position within the expandable tubular
member. In an
exemplary embodiment, the yield point increases as a function of the radial
position within
the expandable tubular member 3502. In an exemplary embodiment, the
relationship
between the yield point and the radial position within the expandable tubular
member 3502 is
a linear relationship. In an exemplary embodiment, the relationship between
the yield point
and the radial position within the expandable tubular member 3502 is a non-
linear
relationship. In an exemplary embodiment, the yield point increases at
different rates within
the first and second tubular regions, 3502a and 3502b, as a function of fihe
radial position
within the expandable tubular member 3502. In an exemplary embodiment, the
functional
relationship, and value, of the yield points within the first and second
tubular regions, 3502a
and 3502b, of the expandable tubular member 3502 are modified by the radial
expansion
and plastic deformation of the expandable tubular member.
[00296] In several exemplary embodiments, one or more of the expandable
tubular
members, 12, 14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502, prior to a
radial
expansion and plastic deformation, include a microstructure that is a
combination of a hard
phase, such as martensite, a soft phase, such as ferrite, and a transitionary
phase, such as
retained austentite. In this manner, the hard phase provides high strength,
the soft phase
provides ductility, and the transitionary phase transitions to a hard phase,
such as
martensite, during a radial expansion and plastic deformation. Furthermore, in
this manner,
the yield point of the tubular member increases as a result of the radial
expansion and
plastic deformation. Further, in this manner, the tubular member is ductile,
prior to the radial
expansion and plastic deformation, thereby facilitating the radial expansion
and plastic
deformation. In an exemplary embodiment, the composition of a dual-phase
expandable
tubular member includes (weight percentages): about 0.1 % C, 1.2% Mn, and 0.3%
Si.
[00297] In an exemplary experimental embodiment, as illustrated in Figs. 36a-
36c,
one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106,
108, 202,
204 and/or 3502 are processed in accordance with a method 3600, in which, in
step 3602,
an expandable tubular member 3602a is provided that is a steel alloy having
following
material composition (by weight percentage): 0.065% C, 1.44% Mn, 0.01 % P,
0.002% S,
57
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
0.24% Si, 0.01 % Cu, 0.01 % Ni, 0.02% Cr, 0.05% V, 0.01 %Mo, 0.07 % Nb, and
0.01 % Ti. In
an exemplary experimental embodiment, the expandable tubular member 3602a
provided in
step 3602 has a yield strength of 45 ksi, and a tensile strength of 69 ksi.
[00298] In an exemplary experimental embodiment, as illustrated in Fig. 36b,
in step
3602, the expandable tubular member 3602a includes a microstructure that
includes
martensite, pearlite, and V, Ni, and/or Ti carbides.
[00299] In an exemplary embodiment, the expandable tubular member 3602a is
then
heated at a temperature of 790 °C for about 10 minutes in step 3604.
[00300] In an exemplary embodiment, the expandable tubular member 3602a is
then
quenched in water in step 3606.
[00301] In an exemplary experimental embodiment, as illustrated in Fig. 36c,
following
the completion of step 3606, the expandable tubular member 3602a includes a
microstructure that includes new ferrite, grain pearlite, martensite, and
ferrite. In an
exemplary experimental embodiment, following the completion of step 3606, the
expandable
tubular member 3602a has a yield strength of 67 ksi, and a tensile strength of
95 ksi.
[00302] In an exemplary embodiment, the expandable tubular member 3602a is
then
radially expanded and plastically deformed using one or more of the methods
and apparatus
described above. In an exemplary embodiment, following the radial expansion
and plastic
deformation of the expandable tubular member 3602a, the yield strength of the
expandable
tubular member is about 95 ksi.
[00303] In an exemplary experimental embodiment, as illustrated in Figs. 37a-
37c,
one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106,
108, 202,
204 and/or 3502 are processed in accordance with a method 3700, in which, in
step 3702,
an expandable tubular member 3702a is provided that is a steel alloy having
following
material composition (by weight percentage): 0.18% C, 1.28% Mn, 0.017% P,
0.004% S,
0.29% Si, 0.01 % CU, 0.01 % Ni, 0.03% Cr, 0.04% V, 0.01 %Mo, 0.03% Nb, and
0.01 % Ti. In
an exemplary experimental embodiment, the expandable tubular member 3702a
provided in
step 3702 has a yield strength of 60 ksi, and a tensile strength of 80 ksi.
[00304] In an exemplary experimental embodiment, as illustrated in Fig. 37b,
in step
3702, the expandable tubular member 3702a includes a microstructure that
includes pearlite
and pearlite striation.
[00305] In an exemplary embodiment, the expandable tubular member 3702a is
then
heated at a temperature of 790 °C for about 10 minutes in step 3704.
[00306] In an exemplary embodiment, the expandable tubular member 3702a is
then
quenched in water in step 3706.
58
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00307] In an exemplary experimental embodiment, as illustrated in Fig. 37c,
following
the completion of step 3706, the expandable tubular member 3702a includes a
microstructure that includes ferrite, martensite, and bainite. In an exemplary
experimental
embodiment, following the completion of step 3706, the expandable tubular
member 3702a
has a yield strength of 82 ksi, and a tensile strength of 130 ksi.
[00308] In an exemplary embodiment, the expandable tubular member 3702a is
then
radially expanded and plastically deformed using one or more of the methods
and apparatus
described above. In an exemplary embodiment, following the radial expansion
and plastic
deformation of the expandable tubular member 3702a, the yield strength of the
expandable
tubular member is about 130 ksi.
[00309] In an exemplary experimental embodiment, as illustrated in Figs. 38a-
38c,
one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106,
108, 202,
204 and/or 3502 are processed in accordance with a method 3800, in which, in
step 3802,
an expandable tubular member 3802a is provided that is a steel alloy having
following
material composition (by weight percentage): 0.08% C, 0.82% Mn, 0.006% P,
0.003% S,
0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03%Mo, 0.01 % Nb, and 0.01
% Ti. In
an exemplary experimental embodiment, the expandable tubular member 3802a
provided in
step 3802 has a yield strength of 56 ksi, and a tensile strength of 75 ksi.
[00310] fn an exemplary experimental embodiment, as illustrated in Fig. 38b,
in step
3802, the expandable tubular member 3802a includes a microstructure that
includes grain
pearlite, widmanstatten martensite and carbides of V, Ni, and/or Ti.
[00311] In an exemplary embodiment, the expandable tubular member 3802a is
then
heated at a temperature of 790 °C for about 10 minutes in step 3804.
[00312] In an exemplary embodiment, the expandable tubular member 3802a is
then
quenched in water in step 3806.
[00313] In an exemplary experimental embodiment, as illustrated in Fig. 38c,
following
the completion of step 3806, the expandable tubular member 3802a includes a
microstructure that includes bainite, pearlite, and new ferrite. In an
exemplary experimental
embodiment, following the completion of step 3806, the expandable tubular
member 3802a
has a yield strength of 60 ksi, and a tensile strength of 97 ksi.
[00314] In an exemplary embodiment, the expandable tubular member 3802a is
then
radially expanded and plastically deformed using one or more of the methods
and apparatus
described above. In an exemplary embodiment, following the radial expansion
and plastic
deformation of the expandable tubular member 3802a, the yield strength of the
expandable
tubular member is about 97 ksi.
[00315] In an exemplary embodiment, as illustrated in Fig. 39 and 40, a method
3900
for increasing the collapse strength of a tubular assembly begins with step
3902 in which an
59
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
expandable tubular member 3902a is provided. The expandable tubular member
3902a
includes an inner surface 3902b having an inner diameter D~, an outer surface
3902c having
an outer diameter D~, and a wall thickness 3902d. In an exemplary embodiment,
expandable tubular member 3902a may be, for example, the tubular member 12,
14, 24, 26,
102, 108, 202, 204, 2210, 2228, 2310, 2328, 2410, 2428, 2510, 2528, 2610,
2628, 2710,
2728, 2910, 2926, 3010, 3024, 3030, 3044, 3050, 3068, 3110, 3124, 3210, 3220,
3310,
3330, 3410, 3432, or 3500. In an exemplary embodiment, the expandable tubular
member
3902a may be, for example, the tubular assembly 10, 22, 100, or 200.
[00316] Referring now to Figs. 39, 41 a, 41 b, 41 c and 41 d, the method 3900
continues
at step 3904 in which the expandable tubular member 3902a is coated with a
layer 3904a of
material. In an exemplary embodiment, the layer 3904a of material includes a
plastic such
as, for example, a PVC plastic 3904aa as illustrated in Fig. 41 c, and/or a
soft metal such as,
for example, aluminum 3904ab as illustrated in Fig. 41 d, an aluminum/zinc
combination, or
equivalent metals known in the art, and/or a composite material such as, for
example, a
carbon fiber material, and substantially covers the outer surface 3902c of
expandable tubular
member 3902a. In an exemplary embodiment, the layer 3904a of material is
applied using
conventional methods such as, for example, spray coating, vapor deposition,
adhering layers
of material to the surface, or a variety of other methods known in the art.
[00317] Referring now to Figs. 39, 40 and 42, the method 3900 continues at
step
3906 in which the expandable tubular member 3902a is positioned within a
passage 3906a
defined by a preexisting structure 3906b which includes an inner surface
3906c, an outer
surface 3906d, and a wall thickness 3906e. In an exemplary embodiment, the
preexisting
structure 3906b may be, for example, the wellbores 16, 110, or 206. In an
exemplary
embodiment, the preexisting structure 3906b may be, for example, the tubular
member 12,
14, 24, 26, 102, 108, 202, 204, 2210, 2228, 2310, 2328, 2410, 2428, 2510,
2528, 2610,
2628, 2710, 2728, 2910, 2926, 3010, 3024, 3030, 3044, 3050, 3068, 3110, 3124,
3210,
3220, 3310, 3330, 3410, 3432, or 3500. In an exemplary embodiment, preexisting
structure
3906b may be, for example, the tubular assembly 10, 22, 100, or 200. In an
exemplary
embodiment, the cross sections of expandable tubular member 3902a and
preexisting
structure 3906b are substantially concentric when the expandable tubular
member 3902a is
positioned in the passage 3906a defined by preexisting structure 3906b.
[00318] Referring now to Figs. 39, 43, and 44, the method continues at step
3908 in
which the expandable tubular member 3902a is radially expanded and plastically
deformed.
In an exemplary embodiment, a force F is applied radially towards the inner
surface 3902b of
expandable tubular member 3902a, the force F being sufficient to radially
expand and
plastically deform the expandable tubular member 3902a and the accompanying
layer 3904a
on its outer surface 3902c. The force F increases the inner diameter D~ and
the outer
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
diameter Dz of expandable tubular member 3902a until the layer 3904a engages
the inner
surface 3906c of preexisting structure 3906b and forms an interstitial layer
between the
expandable tubular member 3902a and the preexisting structure 3906b. In
several
exemplary embodiments, the expandable tubular member 3902a is radially
expanded and
plastically deformed using one or more conventional commercially available
devices and/or
using one or more of the methods disclosed in the present application.
[00319] In an exemplary embodiment, following step 3908 of method 3900, the
layer
3904a forms an interstitial layer filling some or all of the annulus between
the expandable
tubular member 3902a and the preexisting structure 3906b. In an exemplary
embodiment,
the interstitial layer formed from the layer 3904a between the expandable
tubular member
3902a and the preexisting structure 3906b results in the combination of
expandable tubular
member 3902a, the layer 3904a, and the preexisting structure 3906b exhibiting
a higher
collapse strength than would be exhibited without the interstitial layer. In
an exemplary
embodiment, the radial expansion and plastic deformation of expandable tubular
member
3902a wifih layer 3904a into engagement with preexisting structure 3906b
results in a
modification of the residual stresses in one or both of the expandable tubular
member 3902a
and the preexisting structure 3906b. In an exemplary embodiment, the radial
expansion and
plastic deformation of expandable tubular member 3902a with layer 3904a into
engagement
with preexisting structure 3906b places at least a portion of the wall
thickness of preexisting
structure 3906b in circumferential tension.
[00320] In an alternative embodiment, as illustrated in Fig. 45 and 46, a
method 4000
for increasing the collapse strength of a tubular assembly begins with step
4002 in which a
preexisting structure 4002a is provided. The preexisting structure 4002a
defines a
substantially cylindrical passage 4002b and includes an inner surface 4002c.
In an
exemplary embodiment, the preexisting structure 4002a may be, for example, the
wellbores
16, 110, or 206. In an exemplary embodiment, the preexisting structure 4002a
may be, for
example, the tubular member 12, 14, 24, 26, 102, 108, 202, 204, 2210, 2228,
2310, 2328,
2410, 2428, 2510, 2528, 2610, 2628, 2710, 2728, 2910, 2926, 3010, 3024, 3030,
3044,
3050, 3068, 3110, 3124, 3210, 3220, 3310, 3330, 3410, 3432, or 3500. In an
exemplary
embodiment, the preexisting structure 4002a may be, for example, the tubular
assembly 10,
22, 100, or 200.
[00321] Referring now to Figs. 45, 47a and 47b, the method 4000 continues at
step
4004 in which the inner surface 4002c in passage 4002b of preexisting
structure 4002a is
coated with a layer 4004a of material. In an exemplary embodiment, the layer
3904a of
material includes a plastic, and/or a soft metal such as, for example,
aluminum, aluminum
and zinc, or equivalent metals known in the art, and/or a composite material
such as, for
example, carbon fiber, and substantially covers the inner surface 4002c of
preexisting
61
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
structure 4002a. In an exemplary embodiment, the layer 3904a of material is
applied using
conventional methods such as, for example, spray coating, vapor deposition,
adhering layers
of material to the surface, or a variety of other methods known in the art.
[00322] Referring now to Figs. 40, 45 and 48, the method 4000 continues at
step
4006 in which expandable tubular member 3902a including inner surface 3902b,
outer
surface 3902c, and wall thickness 3902d, is positioned within passage 4002b
defined by
preexisting structure 4002a. In an exemplary embodiment, the cross sections of
expandable
tubular member 3902a and preexisting structure 4002a are substantially
concentric when the
expandable tubular member 3902a is positioned in the passage 4002b defined by
preexisting structure 4002a.
[00323] Referring now to Figs. 45, 49, and 50, the method 4000 continues at
step
4008 in which the expandable tubular member 3902a is radially expanded and
plastically
deformed. In an exemplary embodiment, a force F is applied radially towards
the inner
surface 3902b of expandable tubular member 3902a, the force F being sufficient
to radially
expand and plastically deform the expandable tubular member 3902a. The force F
increases the inner diameter D~ and the outer diameter D~ of expandable
tubular member
3902a until the outer surface 3902c of expandable tubular member 3902a engages
layer
4004a on preexisting structure 4002a and forms an interstitial layer between
the expandable
tubular member 3902a and the preexisting structure 4002a. in several exemplary
embodiments, the expandable tubular member 3902a is radially expanded and
plastically
deformed using one or more conventional commercially available devices and/or
using one
or more of the methods disclosed in the present application.
[00324] In an exemplary embodiment, following step 4008 of method 4000, the
layer
4004a forms an interstitial layer filling some or all of the annulus between
the expandable
tubular member 3902a and the preexisting structure 4002a. In an exemplary
embodiment,
the interstitial layer formed from the layer 4004a between the expandable
tubular member
3902a and the preexisting structure 4002a results in the combination of the
expandable
tubular member 3902a, the layer 3904a, and the preexisting structure 4002a
exhibiting a
higher collapse strength than would be exhibited without the interstitial
layer. In an
exemplary embodiment, the radial expansion and plastic deformation of
expandable tubular
member 3902a into engagement with preexisting structure 4002a with layer 4004a
results in
a modification of the residual stresses in one or both of the expandable
tubular member
3902a and the preexisting structure 4002a. In an exemplary embodiment, the
radial
expansion and plastic deformation of expandable tubular member 3902a with
layer 4004a
into engagement with preexisting structure 4002a places at least a portion of
the wall
thickness of the preexisting structure 4002a in circumferential tension.
62
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00325] In an alternative embodiment, as illustrated in Fig. 51 a, step 3904
of method
3900 may include coating multiple layers of material such as, for example,
layers 3904a and
4100, on tubular member 3902x, illustrated in Fig. 40. In an exemplary
embodiment, the
layers 3904a and/or 4100 may be applied using conventional methods such as,
for example,
spray coating, vapor deposition, adhering layers of material to the surface,
or a variety of
other methods known in the art.
[00326] In an alternative embodiment, as illustrated in Fig. 51 b, step 4004
of method
4000 may include coating multiple layers of material such as, for example,
layers 4002c and
4200, on tubular member 4002x. In an exemplary embodiment, the layers 4002c
and 4200
may be applied using conventional methods such as, for example, spray coating,
vapor
deposition, adhering layers of material to the surface, or a variety of other
methods known in
the art.
[00327] In an exemplary embodiment, steps 3904 of method 3900 and step 4004 of
method 4000 may include coating the expandable tubular member 3902a with a
layer 3904a
of varying thickness. In an exemplary embodiment, step 3904 of method 3900 may
include
coating the expandable tubular member 3902a with a non uniform layer 3904a
which, for
example, may include exposing portions of the outer surface 3902c of
expandable tubular
member 3902x. In an exemplary embodiment, step 4004 of method 4000 may include
coating the preexisting structure 4002a with a non uniform layer 4004a which,
for example,
may include exposing portions of the inner surface 4002c of preexisting
structure 4002x.
[00328] In an alternative embodiment, as illustrated in Fig. 52x, 52b, and
52c, step
3904 of method 3900 may be accomplished by laying a material 4300 around an
expandable
tubular member 4302, which may be the expandable tubular member 3902a in Fig.
40. In
an alternative embodiment, step 4004 of method 4000 may be accomplished by
using the
material 4300 to line the inner surtace of the preexisting structure such as,
for example, the
inner surface 4002c of preexisting structure 4002x. In an exemplary
embodiment, the
material 4300 may be a plastic, and/or a metal such as, for example, aluminum,
aluminum/zinc, or other equivalent metals known in the art, and/or a composite
material
such as, for example, carbon fiber. In an exemplary embodiment, the material
4300 may
include a wire that is wound around the expandable tubular member 4302 or
fined on the
inner surface 4002c of preexisting structure 4002x. In an exemplary
embodiment, the
material 4300 may include a plurality of rings place around the expandable
tubular member
4302 or lined on the inner surface 4002c of preexisting structure 4002x. In an
exemplary
embodiment, the material 4300 may be a plurality of discrete components placed
on the
expandable tubular member 4302 or lined on the inner surface 4002c or
preexisting
structure 4002x.
63
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00329] In an exemplary experimental embodiment EXP, of method 3900, as
illustrated in Fig. 53, a plurality of tubular members 3902a were provided, as
per step 3902
of method 3900, which had a 7 5/8 inch diameter. Each tubular member 3902a was
coated,
as per step 3904 of method 3900, with a layer 3904a. The tubular member 3902a
was then
radially expanded and plastically deformed and the energy necessary to
radially expand and
plastically deform it such as, for example, the operating pressure required to
radially expand
and plastically deform the tubular member 3902a, was recorded. In EXP~A, fihe
layer 3904a
was aluminum, requiring a maximum operating pressure of approximately 3900 psi
to
radially expand and plastically deform the tubular member 3902a. In EXP~B, the
layer
3904a was aluminum/zinc, requiring a maximum operating pressure of
approximately 3700
psi to radially expand and plastically deform the tubular member 3902a. In
EXP~~, the layer
3904a was PVC plastic, requiring a maximum operating pressure of approximately
3600 psi
to radially expand and plastically deform the tubular member 3902a. fn EXP,p,
the layer
3904a was omitted resulting in an air gap, and requiring a maximum operating
pressure of
approximately 3400 psi to radially expand and plastically deform the tubular
member 3902a.
[00330] In an exemplary experimental embodiment EXP~ of method 3900, as
illustrated in Fig. 54a, 54b, and 54c, a plurality of expandable tubular
members 3902a were
provided, as per step 3902 of method 3900. Each tubular member 3902a was
coated, as
per step 3904 of method 3900, with a layer 3904a. Each tubular member 3902a
was then
positioned within a preexisting structure 3906b as per step 3906 of method
3900. Each
tubular member 3902a was then radially expanded and plastically deformed 13.3%
and the
thickness of layer 3904a between the tubular member 3902a and the preexisting
structure
3906b was measured. In EXP~, the layer 3904a was aluminum and had a thickness
between approximately 0.05 inches and 0.15 inches. In EXP~B, the layer 3904a
was
aluminum/zinc and had a thickness between approximately 0.07 inches and 0.13
inches. In
EXP2~, the layer 3904a was PVC plastic and had a thickness between
approximately 0.06
inches and 0.14 inches. In EXP2p, the layer 3904a was omitted which resulted
in an air gap
between the tubular member 3902a and the preexisting structure 3906b between
approximately 0.02 and 0.04 inches.
[0033'!] In an exemplary experimental embodiment EXP3 of method 3900,
illustrated
in Fig. 55a and 55b, a plurality of expandable tubular members 3902a were
provided, as per
step 3902 of method 3900. Each tubular member 3902a was coated, as per step
3904 of
method 3900, with a layer 3904a. Each tubular member 3902a was then positioned
within a
preexisting structure 3906b as per step 3906 of method 3900. Each tubular
member 3902a
was then radially expanded and plastically deformed in a preexisting structure
3906b and the
thickness of layer 3904a between the tubular member 3902a and the preexisting
structure
3906b was measured. In EXP3A, the layer 3904a was plastic with a thickness
between
64
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
approximately 1.6 mm and 2.5 mm. In EXP3B, the layer 3904a was aluminum with a
thickness between approximately 2.6 mm and 3.1 mm. In EXP3~, the layer 3904a
was
aluminum/zinc with a thickness between approximately 1.9 mm and 2.5 mm. In
EXP3p, the
layer 3904a was omitted, resulting in an air gap between the tubular member
3902a and the
preexisting structure 3906b between approximately 1.1 mm and 1.7 mm. Fig. 55b
illustrates
the distribution of the gap thickness between the tubular member and the
preexisting
structure for EXP3A, EXP3B, EXP3~, and EXP3~, illustrating that combinations
with an layer
between the tubular member 3902a and the preexisting structure 3906b exhibit a
more
uniform gap distribution.
[00332] In an exemplary experimental embodiment EXP4 of method 3900, a
plurality
of expandable tubular members 3902a were provided, as per step 3902 of method
3900.
Each tubular member 3902a was coated, as per step 3904 of method 3900, with a
layer
3904x. Each tubular member 3902a was then positioned within a preexisting
structure
3906b as per step 3906 of method 3900. Each tubular member 3902a was then
radially
expanded and plastically deformed in a preexisting structure 3906b, and
conventional
collapse testing was performed on the tubular assembly comprised of the
tubular member
3902x, layer 3904a and preexisting structure 3906b combination. For the
testing, the
preexisting structure 3906b was composed of a P-110 Grade pipe with an inner
diameter of
approximately 9 5/8 inches. The expandable tubular member 3902a was composed
of an
LSX-80 Grade pipe with an inner diameter of approximately 7 5/8 inches. The
tubular
member assemblies exhibited the following collapse strengths:
Collapse
Layer Remarks
EXP4 Strength
3904a ,
~psl)
EXP4A plastic 14230 This was an unexpected
result.
EXP4B aluminum/zinc 20500 This was an unexpected
result.
EXP4~ air 14190 This was an unexpected
result.
EXP4D aluminum 20730 This was an unexpected
result.
EXP4A, EXP4g, EXP4C, and EXP4p illustrate that using a soft metal such as, for
example
aluminum and or aluminum/zinc, as layer 3904a in method 3900 increases the
collapse
strength of the tubular assembly comprising the expandable tubular member
3902x, layer
3904x, and preexisting structure 3906b by approximately 50% when compared to
using a
layer 3904a of plastic or omitting the layer 3904x. This was an unexpected
result.
[00333] In an exemplary experimental embodiment EXPS of method 3900, as
illustrated in Fig. 56 and 56x, an expandable tubular member 3902a was
provided, as per
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
step 3902 of method 3900. The coating of step 3904 with a layer 3904a was
omitted. The
tubular member 3902a was then positioned within a preexisting structure 3906b
as per step
3906 of method 3900. The tubular member 3902a was then radially expanded and
plastically deformed in a preexisting structure 3906b, resulting,in an air gap
between the
tubular member 3902a and the preexisting structure.
(00334] In an exemplary embodiment, the collapse resistance of a tubular
assembly
that includes a pair of overlapping tubular members coupled to each other may
be
determined using the following equation:
Pcc = K~P~o + P~~)
P~o is the collapse resistance of an outer casing such as, for example, the
preexisting
structure 3906b or 4002a, or the wellbores 16, 110, or 206. P~; is the
collapse resistance of
an inner casing such as, for example, the tubular member 12, 14, 24, 26, 102,
108, 202,
204, 2210, 2228, 2310, 2328, 2410, 2428, 2510, 2528, 2610, 2628, 2710, 2728,
2910, 2926,
3010, 3024, 3030, 3044, 3050, 3068, 3110, 3124, 3210, 3220, 3310, 3330, 3410,
3432,
3500, or 3902a, or the tubular assembly 10, 22, 100, or 200. K is a
reinforcement factor
provided by a coating such as, for example, the coating 3904a or 4004a. In an
exemplary
embodiment, the reinforcement factor K increases as the strength of the
material used for
the coating increases.
[00335] In an exemplary experimental embodiment EXP6 of method 3900, as
illustrated in Figs. 58a, 58b , a computer simulation was run for an
expandable tubular
member 3902a provided, as per step 3902 of method 3900, positioned within a
preexisting
structure 3906b, as per step 3906 of method 3900, and radially expanded and
plastically
deformed in the preexisting structure 3906b. The coating of step 3904 with a
layer 3904a
was omitted. The radial expansion and plastic deformation of expandable
tubular member
3902a resulted in an air gap distribution between the expanded tubular member
3902a and
the preexisting structure 3906b, illustrated in Fig. 58b. The tubular member
3902a was a
LSX-80 Grade pipe with a 7 5/8 inch inner diameter and the preexisting
structure 3906b was
a P110 Grade pipe with a 9 5/8 inch inner diameter. The tubular member 3902a
was
radially expanded and plastically deformed 13.3% from its original diameter.
After
expansion, the maximum air gap was approximately 2 mm. The expandable tubular
member 3902a and preexisting structure 3906b combination exhibited a collapse
strength of
approximately 13200 psi. This was an unexpected result.
[00336] In an exemplary experimental embodiment EXP, of method 3900, as
illustrated in Figs. 58, a computer simulation was run for an expandable
tubular members
3902a provided, as per step 3902 of method 3900, positioned within a
preexisting structure
3906b, as per step 3906 of method 3900, and radially expanded and plastically
deformed in
the preexisting structure 3906b. The coating of step 3904 with a layer 3904a
was omitted.
66
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
The radial expansion and plastic deformation of expandable tubular member
3902a resulted
in an air gap distribution between the expanded tubular member 3902a and the
preexisting
structure 3906b, illustrated. The tubular member 3902a was a LSX-80 Grade pipe
with a 7
5/8 inch inner diameter and the preexisting structure 3906b was a P110 Grade
pipe with a 9
5/8 inch inner diameter. The tubular member 3902a was radially expanded and
plastically
deformed 14.9% from its original diameter. After expansion, the maximum air
gap was
approximately 1.55 mm. The expandable tubular member 3902a and preexisting
structure
3906b combination exhibited a collapse strength of approximately 13050 psi.
This was an
unexpected result.
[00337] In an exemplary experimental embodiment EXP$ of method 3900, as
illustrated in Figs. 59, a computer simulation was run for an expandable
tubular member
3902a provided, as per step 3902 of method 3900, coated with a layer 3904a of
soft metal,
as per step 3904 of method 3900, positioned within a preexisting structure
3906b as per step
3906 of method 3900, and radially expanded and plastically deformed in a
preexisting
structure 3906b. The tubular member 3902a was a LSX-80 Grade pipe with a 7 5/8
inch
inner diameter and the preexisting structure 3906b was a P110 Grade pipe with
a 9 5/8 inch
inner diameter. In an exemplary embodiment, the soft metal distribution
between the tubular
member 3902a and the preexisting structure 3906b included aluminum. In an
exemplary
embodiment, the soft metal distribution between the tubular member 3902a and
the
preexisting structure 3906b included aluminum and zinc. The tubular member
3906 was
radially expanded and plastically deformed 13.3% from ifs original diameter.
After
expansion, the soft metal layer 3904a included a maximum thickness of
approximately 2
mm. The expandable tubular member 3902a, preexisting structure 3906b, and soft
metal
layer 3904a combination exhibited a collapse strength of greater than 20000
psi. This was
an unexpected result.
[00338] In an exemplary experimental embodiment EXP9A of method 3900, as
illustrated in Fig. 60a, an expandable tubular member 3902a was provided, as
per step 3902
of method 3900. The expandable tubular member 3902a was then positioned within
a
preexisting structure 3906b, as per step 3906 of method 3900. The coating of
step 3904
with a layer 3904a was omitted. The expandable tubular member 3902a was then
radially
expanded and plastically deformed in the preexisting structure 3906b,
resulting in an air gap
distribution between the expandable tubular member 3902a and the preexisting
structure
3906b, which was then measured. A minimum air gap of approximately 1.2 mm and
a
maximum air gap of approximately 3.7 mm were exhibited.
[00339] In an exemplary experimental embodiment EXP9B of method 3900, as
illustrated in Fig. 60b, an expandable tubular member 3902a was provided,
as.per step 3902
of method 3900. The expandable tubular member 3902a was then coated with a
layer
67
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
3904a of soft metal, as per step 3904 of method 3900. The expandable tubular
member
3902a was then positioned within a preexisting structure 3906b, as per step
3906 of method
3900. The expandable tubular member 3902a was then radially expanded and
plastically
deformed in the preexisting structure 3906b and the soft metal layer 3904a
between the
expandable tubular member 3902a and the preexisting structure 3906b was
measured. A
minimum soft metal layer 3904a thickness of approximately 3.2 mm and a maximum
soft
metal layer 3904a thickness 5202b of approximately 3.7 mm were exhibited.
[00340] In an exemplary experimental embodiment EXP9~ of method 3900, as
illustrated in Fig. 60c, an expandable tubular member 3902a was provided, as
per step 3902
of method 3900. The expandable tubular member 3902a was then coated with a
layer
3904a of plastic, as per step 3904 of method 3900. The expandable tubular
member 3902a
was then positioned within a preexisting structure 3906b, as per step 3906 of
method 3900.
The expandable tubular member 3902a was then radiaUy expanded and plastically
deformed
in the preexisting structure 3906b and the plastic layer 3904a between the
expandable
tubular member 3902a and the preexisting structure 3906b was measured. A
minimum
plastic layer 3904a thickness 5204a of approximately 1.7 mm and a maximum
plastic layer
3904a thickness 5204b of approximately 2.5 mm were exhibited.
[00341] In an exemplary experimental embodiment EXP~oA of method 3900, as
illustrated in Fig. 61 a, an expandable tubular member 3902a was provided, as
per step 3902
of method 3900., The expandable tubular member 3902a was then positioned
within a
preexisting structure 3906b, as per step 3906 of method 3900. The coating of
step 3904
with a layer 3904a was omitted. The expandable tubular member 3902a was then
radially
expanded and plastically deformed in the preexisting structure, resulting in
an air gap
between the expandable tubular member 3902a and the preexisting structure
3906b. The
wall thickness of the expandable tubular member 3902a was then measured. A
minimum
wall thickness for the expandable tubular member 3902a of approximately 8.6 mm
and a
maximum wall for the expandable tubular member 3902a of approximately 9.5 mm
were
exhibited.
[00342] In an exemplary experimental embodiment EXP~oB of method 3900, as
illustrated in Fig. 61 b, an expandable tubular member 3902a was provided, as
per step 3902
of method 3900. The expandable tubular member 3902a was then coated with a
layer
3904a of plastic, as per step 3904 of method 3900. The expandable tubular
member 3902a
was then positioned within a preexisting structure 3906b, as per step 3906 of
method 3900.
The expandable tubular member 3902a was then radially expanded and plastically
deformed
in the preexisting structure 3906b. The wall thickness of the expandable
tubular member
3902a was then measured. A minimum wall thickness for the expandable tubular
member
68
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
3902a of approximately 9.1 mm and a maximum wall thickness for the expandable
tubular
member 3902a of approximately 9.6 mm were exhibited.
[00343] In an exemplary experimental embodiment EXP,oc of method 3900, as
illustrated in Fig. 61 c, an expandable tubular member 3902a was provided, as
per step 3902
of method 3900. The expandable tubular member 3902a was then coated with a
layer
3904a of soft metal, as per step 3904 of method 3900. The expandable tubular
member
3902a was then positioned within a preexisting structure 3906b, as per step
3906 of method
3900. The expandable tubular member 3902a was then radially expanded and
plastically
deformed in the preexisting structure 3906b. The wall thickness of the
expandable tubular
member 3902a was then measured. A minimum wall thickness for the expandable
tubular
member 3902a of approximately 9.3 mm and a maximum wall thickness for the
expandable
tubular member 3902a of approximately 9.6 mm were exhibited.
[00344] In an exemplary experimental embodiment EXP,~A of method 3900, as
illustrated in Fig. 62a, an expandable tubular member 3902a was provided, as
per step 3902
of method 3900. The expandable tubular member 3902a was then positioned within
a
preexisting structure 3906b, as per step 3906 of method 3900. The coating of
step 3904
with a layer 3904a was omitted. The expandable tubular member 3902a was then
radially
expanded and plastically deformed in the preexisting structure, resulting in
an air gap
between the expandable tubular member 3902a and the preexisting structure
3906b. The
wall thickness of the preexisting structure 3906b was then measured. A minimum
wall
thickness for the preexisting structure 3906b of approximately 13.5 mm and a
maximum wall
thickness for the preexisting structure 3906b of approximately 14.6 mm were
exhibited.
[00345] In an exemplary experimental embodiment EXP,~g of method 3900, as
illustrated in Fig. 62b, an expandable tubular member 3902a was provided, as
per step 3902
of method 3900. The expandable tubular member 3902a was then coated with a
layer
3904a of soft metal, as per step 3904 of method 3900. The expandable tubular
member
3902a was then positioned within a preexisting structure 3906b, as per step
3906 of method
3900. The expandable tubular member 3902a was then radially expanded and
plastically
deformed in the preexisting structure 3906b. The wall thickness of the
preexisting structure
3906b was then measured. A minimum wall thickness for the preexisting
structure 3906b of
approximately 13.5 mm and a maximum wall thickness for the preexisting
structure 3906b of
approximately 14.3 mm were exhibited.
[00346] In an exemplary experimental embodiment EXP~~c of method 3900, as
illustrated in Fig. 62c, an expandable tubular member 3902a was provided, as
per step 3902
of method 3900. The expandable tubular member 3902a was then coated with a
layer
3904a of plastic, as per step 3904 of method 3900. The expandable tubular
member 3902a
was then positioned within a preexisting structure 3906b, as per step 3906 of
method 3900.
69
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
The expandable tubular member 3902a was then radially expanded and plastically
deformed
in the preexisting structure 3906b. The wall thickness of the preexisting
structure 3906b was
then measured. A minimum wall thickness for the preexisting structure 3906b of
approximately 13.5 mm and a maximum wall thickness for the preexisting
structure 3906b
of approximately 14.6 mm were exhibited.
[00347] In an exemplary experimental embodiment EXP,~ of method 3900, as
illustrated in Fig. 63, an expandable tubular member 3902a was provided, as
per step 3902
of method 3900. The expandable tubular member 3902a was then coated with a
layer
3904a, as per step 3904 of method 3900. The expandable tubular member 3902a
was then
positioned within a preexisting structure 3906b, as per step 3906 of method
3900. The
expandable tubular member 3902a was then radially expanded and plastically
deformed in
the preexisting structure 3906b. The expandable tubular member 3902a was
radially
expanded and plastically deformed 13.3% from its original inner diameter
against the
preexisting structure 3906b. The expandable tubular member 3902a was an LSX-80
Grade
pipe with a 7 5/8 inch inner diameter and the preexisting structure 3906b was
a P110 Grade
pipe with a 9 5/8 inch inner diameter. The collapse strength of the expandable
tubular
member 3902a with layer 3904a and preexisting structure 3906b was measured at
approximately 6300 psi. This was an unexpected result.
[00348] In an exemplary experimental embodiment of method 3900, an expandable
tubular member 3902a was provided, as per step 3902 of method 3900. The
expandable
tubular member 3902a was then coated with a layer 3904a, as per step 3904 of
method
3900. The expandable tubular member 3902a was then positioned within a
preexisting
structure 3906b, as per step 3906 of method 3900. The expandable tubular
member 3902a
was then radially expanded and plastically deformed in the preexisting
structure 3906b. an
expandable tubular member 3902a was provided, as per step 3902 of method 3900.
The
expandable tubular member 3902a was then coated with a layer 3904a, as per
step 3904 of
method 3900. The expandable tubular member 3902a was then positioned within a
preexisting structure 3906b, as per step 3906 of method 3900. The expandable
tubular
member 3902a was then radially expanded and plastically deformed in the
preexisting
structure 3906b, expanding the preexisting structure 3096b by approximately 1
mm. The
measurements and grades for the expandable tubular member 3902a and
preexisting
structure 3906b where:
Outside diameter Wall thickness Grade
(mm) (mm)
Preexisting structure219.1 13.58 X65
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
Expandable tubular
member 173.9 2.5 316L
The collapse strength of the expandable tubular member 3902a and the
preexisting structure
3906b combination was measure before and after expansion and found to increase
by 21 %.
[00349] !n an exemplary experimental embodiment, an expandable tubular member
was provided which had a collapse strength of approximately 70 ksi and
included, by weight
percent, 0.07% Carbon, 1.64% Manganese, 0.011 % Phosphor, 0.001 % Sulfur,
0.23%
Silicon, 0.5%Nickel, 0.51 % Ghrome, 0.31 % Molybdenum, 0.15% Copper, 0.021 %
Aluminum,
0.04% Vanadium, 0.03% Niobium, and 0.007% Titanium. Upon radial expansion and
plastic deformation of the expandable tubular member, the collapse strength of
the
expandable tubular member increased to approximately 110 ksi.
[00350] In several exemplary embodiments, the teachings of the present
disclosure
are combined with one or more of the teachings disclosed in FR 2 841 626,
filed on
6/28/2002, and published on 1/2/2004, the disclosure of which is incorporated
herein by
reference.
[00351] A method of forming a tubular liner within a preexisting structure has
been
described that includes positioning a tubular assembly within the preexisting
structure; and
radially expanding and plastically deforming the tubular assembly within the
preexisting
structure, wherein, prior to the radial expansion and plastic deformation of
the tubular
assembly, a predetermined portion of the tubular assembly has a lower yield
point than
another portion of the tubular assembly. In an exemplary embodiment, the
predetermined
portion of the tubular assembly has a higher ductility and a lower yield point
prior to the
radial expansion and plastic deformation than after the radial expansion and
plastic
deformation. In an exemplary embodiment, the predetermined portion of the
tubular
assembly has a higher ductility prior to the radial expansion and plastic
deformation than
after the radial expansion and plastic deformation. In an exemplary
embodiment, the
predetermined portion of the tubular assembly has a lower yield point prior to
the radial
expansion and plastic deformation than after the radial expansion and plastic
deformation.
In an exemplary embodiment, the predetermined portion of the tubular assembly
has a
larger inside diameter after the radial expansion and plastic deformation than
other portions
of the tubular assembly. In an exemplary embodiment, the method further
includes
positioning another tubular assembly within the preexisting structure in
overlapping relation
to the tubular assembly; and radially expanding and plastically deforming the
other tubular
assembly within the preexisting structure, wherein, prior to the radial
expansion and plastic
deformation of the tubular assembly, a predetermined portion of the other
tubular assembly
has a lower yield point than another portion of the other tubular assembly. In
an exemplary
71
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
embodiment, the inside diameter of the radially expanded and plastically
deformed other
portion of the tubular assembly is equal to the inside diameter of the
radially expanded and
plastically deformed other portion of the other tubular assembly. In an
exemplary
embodiment, the predetermined portion of the tubular assembly includes an end
portion of
the tubular assembly. In an exemplary embodiment, the predetermined portion of
the
tubular assembly includes a plurality of predetermined portions of the tubular
assembly. In
an exemplary embodiment, the predetermined portion of the tubular assembly
includes a
plurality of spaced apart predetermined portions of the tubular assembly. In
an exemplary
embodiment, the other portion of the tubular assembly includes an end portion
of the tubular
assembly. In an exemplary embodiment, the other portion of the tubular
assembly includes
a plurality of other portions of the tubular assembly. In an exemplary
embodiment, the other
portion of the tubular assembly includes a plurality of spaced apart other
portions of the
tubular assembly. In an exemplary embodiment, the tubular assembly includes a
plurality of
tubular members coupled to one another by corresponding tubular couplings. In
an
exemplary embodiment, the tubular couplings include the predetermined portions
of the
tubular assembly; and wherein the tubular members comprise the other portion
of the tubular
assembly. In an exemplary embodiment, one or more of the tubular couplings
include the
predetermined portions of the tubular assembly. In an exemplary embodiment,
one or more
of the tubular members include the predetermined portions of the tubular
assembly. In an
exemplary embodiment, the predetermined portion of the tubular assembly
defines one or
more openings. In an exemplary embodiment, one or more of the openings include
slots. In
an exemplary embodiment, the anisotropy for the predetermined portion of the
tubular
assembly is greater than 1. In an exemplary embodiment, the anisotropy for the
predetermined portion of the tubular assembly is greater than 1. In an
exemplary
embodiment, the strain hardening exponent for the predetermined portion of the
tubular
assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for
the
predetermined portion of the tubular assembly is greater than 1; and the
strain hardening
exponent for the predetermined portion of the tubular assembly is greater than
0.12. In an
exemplary embodiment, the predetermined portion of the tubular assembly is a
first steel
alloy including: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si, 0.01 %
Cu, 0.01
Ni, and 0.02 % Cr. In an exemplary embodiment, the yield point of the
predetermined
portion of the tubular assembly is at most about 46.9 ksi prior to the radial
expansion and
plastic deformation; and the yield point of the predetermined portion of the
tubular assembly
is at least about 65.9 ksi after the radial expansion and plastic deformation.
In an exemplary
embodiment, the yield point of the predetermined portion of the tubular
assembly after the
radial expansion and plastic deformation is at least about 40 % greater than
the yield point of
the predetermined portion of the tubular assembly prior to the radial
expansion and plastic
72
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
deformation. In an exemplary embodiment, the anisotropy of the predetermined
portion of
the tubular assembly, prior to the radial expansion and plastic deformation,
is about 1.48. In
an exemplary embodiment, the predetermined portion of the tubular assembly
includes a
second steel alloy including: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29
% Si, 0.01
Cu, 0.01 % Ni, and 0.03 % Cr. In an exemplary embodiment, the yield point of
the
predetermined portion of the tubular assembly is at most about 57.8 ksi prior
to the radial
expansion and plastic deformation; and the yield point of the predetermined
portion of the
tubular assembly is at least about 74.4 ksi after the radial expansion and
plastic deformation.
In an exemplary embodiment, the yield point of the predetermined portion of
the tubular
assembly after the radial expansion and plastic deformation is at least about
28 % greater
than the yield point of the predetermined portion of the tubular assembly
prior to the radial
expansion and plastic deformation. In an exemplary embodiment, the anisotropy
of the
predetermined portion of the tubular assembly, prior to the radial expansion
and plastic
deformation, is about 1.04. In an exemplary embodiment, the predetermined
portion of the
tubular assembly includes a third steel alloy including: 0.08 % C, 0.82 % Mn,
0.006 % P,
0.003 % S, 0.30 % St, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr. In an exemplary
embodiment,
the anisotropy of the predetermined portion of the tubular assembly, prior to
the radial
expansion and plastic deformation, is about 1.92. In an exemplary embodiment,
the
predetermined portion of the tubular assembly includes a fourth steel alloy
including: 0.02
C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the tubular
assembly, prior to
the radial expansion and plastic deformation, is about 1.34. In an exemplary
embodiment,
the yield point of the predetermined portion of the tubular assembly is at
most about 46.9 ksi
prior to the radial expansion and plastic deformation; and wherein the yield
point of the
predetermined portion of the tubular assembly is at least about 65.9 ksi after
the radial
expansion and plastic deformation. In an exemplary embodiment, the yield point
of the
predetermined portion of the tubular assembly after the radial expansion and
plastic
deformation is at least about 40 % greater than the yield point of the
predetermined portion
of the tubular assembly prior to the radial expansion and plastic deformation.
In an
exemplary embodiment, the anisotropy of the predetermined portion of the
tubular assembly,
prior to the radial expansion and plastic deformation, is at least about 1.48.
In an exemplary
embodiment, the yield point of the predetermined portion of the tubular
assembly is at most
about 57.8 ksi prior to the radial expansion and plastic deformation; and the
yield point of the
predetermined portion of the tubular assembly is at least about 74.4 ksi after
the radial
expansion and plastic deformation. In an exemplary embodiment, the yield point
of the
predetermined portion of the tubular assembly after the radial expansion and
plastic
deformation is at least about 28 % greater than the yield point of the
predetermined portion
73
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
of the tubular assembly prior to the radial expansion and plastic deformation.
In an
exemplary embodiment, the anisotropy of the predetermined portion of the
tubular assembly,
prior to the radial expansion and plastic deformation, is at least about 1.04.
In an exemplary
embodiment, the anisotropy of the predetermined portion of the tubular
assembly, prior to
the radial expansion and plastic deformation, is at least about 1.92. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the tubular
assembly, prior to
the radial expansion and plastic deformation, is at least about 1.34. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the tubular
assembly, prior to
the radial expansion and plastic deformation, ranges from about 1.04 to about
1.92. In an
exemplary embodiment, the yield point of the predetermined portion of the
tubular assembly,
prior to the radial expansion and plastic deformation, ranges from about 47.6
ksi to about
61.7 ksi. In an exemplary embodiment, the expandability coefficient of the
predetermined
portion of the tubular assembly, prior to the radial expansion and plastic
deformation, is
greater than 0.72. In an exemplary embodiment, the expandability coefficient
of the
predetermined portion of the tubular assembly is greater than the
expandability coefficient of
the other portion of the tubular assembly. in an exemplary embodiment, the
tubular
assembly includes a wellbore casing, a pipeline, or a structural support. In
an exemplary
embodiment, the carbon content of the predetermined portion of the tubular
assembly is less
than or equal to 0.12 percent; and wherein the carbon equivalent value for the
predetermined portion of the tubular assembly is less than 0.21. In an
exemplary
embodiment, the carbon content of the predetermined portion of the tubular
assembly is
greafier than 0.12 percent; and wherein the carbon equivalent value for the
predetermined
portion of the tubular assembly is less than 0.36. In an exemplary embodiment,
a yield point
of an inner tubular portion of at least a portion of the tubular assembly is
less than a yield
point of an outer tubular portion of the portion of the tubular assembly. In
an exemplary
embodiment, yield point of the inner tubular portion of the tubular body
varies as a function
of the radial position within the tubular body. In an exemplary embodiment,
the yield point of
the inner tubular portion of the tubular body varies in an linear fashion as a
function of the
radial position within the tubular body. In an exemplary embodiment, the yield
point of the
inner tubular portion of the tubular body varies in an non-linear fashion as a
function of the
radial position within the tubular body. In an exemplary embodiment, the yield
point of the
outer tubular portion of the tubular body varies as a function of the radial
position within the
tubular body. In an exemplary embodiment, the yield point of the outer tubular
portion of the
tubular body varies in an linear fashion as a function of the radial position
within the tubular
body. In an exemplary embodiment, the yield point of the outer tubular portion
of the tubular
body varies in an non-linear fashion as a function of the radial position
within the tubular
body. In an exemplary embodiment, the yield point of the inner tubular portion
of the tubular
74
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
body varies as a function of the radial position within the tubular body; and
wherein the yield
point of the outer tubular portion of the tubular body varies as a function of
the radial position
within the tubular body. In an exemplary embodiment, the yield point of the
inner tubular
portion of the tubular body varies in a linear fashion as a function of the
radial position within
the tubular body; and wherein the yield point of the outer tubular portion of
the tubular body
varies in a linear fashion as a function of the radial position within the
tubular body. In an
exemplary embodiment, the yield point of the inner tubular portion of the
tubular body varies
in a linear fashion as a function of the radial position within the tubular
body; and wherein the
yield point of the outer tubular portion of the tubular body varies in a non-
linear fashion as a
function of the radial position within the tubular body. In an exemplary
embodiment, the yield
point of the inner tubular portion of the tubular body varies in a non-linear
fashion as a
function of the radial position within the tubular body; and wherein the yield
point of the outer
tubular portion of the tubular body varies in a linear fashion as a function
of the radial
position within the tubular body. In an exemplary embodiment, the yield point
of the inner
tubular portion of the tubular body varies in a non-linear fashion as a
function of the radial
position within the tubular body; and wherein the yield point of the outer
tubular portion of the
. tubular body varies in a non-linear fashion as a function of the radial
position within the
tubular body. In an exemplary embodiment, the rate of change of the yield
point of the inner
tubular portion of the tubular body is different than the rate of change of
the yield point of the
outer tubular portion of the tubular body. In an exemplary embodiment, the
rate of change of
the yield point of the inner tubular portion of the tubular body is different
than the rate of
change of the yield point of the outer tubular portion of the tubular body. In
an exemplary
embodiment, prior to the radial expansion and plastic deformation, at least a
portion of the
tubular assembly comprises a microstructure comprising a hard phase structure
and a soft
phase structure. In an exemplary embodiment, prior to the radial expansion and
plastic
deformation, at least a portion of the tubular assembly comprises a
microstructure
comprising a transitional phase structure. In an exemplary embodiment, the
hard phase
structure comprises martensite. In an exemplary embodiment, the soft phase
structure
comprises ferrite. In an exemplary embodiment, the transitional phase
structure comprises
retained austentite. In an exemplary embodiment, the hard phase structure
comprises
martensite; wherein the soft phase structure comprises ferrite; and wherein
the transitional
phase structure comprises retained austentite. In an exemplary embodiment, the
portion of
the tubular assembly comprising a microstructure comprising a hard phase
structure and a
soft phase structure comprises, by weight percentage, about 0.1 % C, about
1.2% Mn, and
about 0.3% Si.
[00352] An expandable tubular member has been described that includes a steel
alloy
including: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si, 0.01 % Cu,
0.01 % Ni,
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
and 0.02 % Cr. In an exemplary embodiment, a yield point of the tubular member
is at most
about 46.9 ksi prior to a radial expansion and plastic deformation; and a
yield point of the
tubular member is at least about 65.9 ksi after the radial expansion and
plastic deformation.
In an exemplary embodiment, the yield point of the tubular member after the
radial
expansion and plastic deformation is at least about 40 % greater than the
yield point of the
tubular member prior to the radial expansion and plastic deformation. In an
exemplary
embodiment, the anisotropy of the tubular member, prior to a radial expansion
and plastic
deformation, is about 1.48. In an exemplary embodiment, the tubular member
includes a
wellbore casing, a pipeline, or a structural support.
[00353] An expandable tubular member has been described that includes a steel
alloy
Including: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu,
0.01 % Ni,
and 0.03 % Cr. In an exemplary embodiment, a yield point of the tubular member
is at most
about 57.8 ksi prior to a radial expansion and plastic deformation; and the
yield point of the
tubular member is at least about 74.4 ksi after the radial expansion and
plastic deformation.
In an exemplary embodiment, a yield point of the of the tubular member after a
radial
expansion and plastic deformation is at least about 28 % greater than the
yield point of the
tubular member prior to the radial expansion and plastic deformation. In an
exemplary
embodiment, the anisotropy of the tubular member, prior to a radial expansion
and plastic
deformation, is about 1.04. In an exemplary embodiment, the tubular member
includes a
wellbore casing, a pipeline, or a structural support.
[00354] An expandable tubular member has been described that includes a steel
alloy
including: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Sl, 0.16 % Cu,
0.05 % Ni,
and 0.05 % Cr. In an exemplary embodiment, the anisotropy of the tubular
member, prior to
a radial expansion and plastic deformation, is about 1.92. In an exemplary
embodiment, the
tubular member includes a wellbore casing, a pipeline, or a structural
support.
[00355] An expandable tubular member has been described that includes a steel
alloy
including: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % NI, and
18.7 % Cr.
In an exemplary embodiment, the anisotropy of the tubular member, prior to a
radial
expansion and plastic deformation, is about 1.34. In an exemplary embodiment,
the tubular
member includes a wellbore casing, a pipeline, or a structural support.
[00356] An expandable tubular member has been described, wherein the yield
point of
the expandable tubular member is at most about 46.9 ksi prior to a radial
expansion and
plastic deformation; and wherein the yield point of the expandable tubular
member is at least
about 65.9 ksi after the radial expansion and plastic deformation. In an
exemplary
embodiment, the tubular member includes a wellbore casing, a pipeline, or a
structural
support.
[00357] An expandable tubular member has been described, wherein a yield point
of the
76
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
expandable tubular member after a radial expansion and plastic deformation is
at least about
40 % greater than the yield point of the expandable tubular member prior to
the radial
expansion and plastic deformation. In an exemplary embodiment, the tubular
member
includes a wellbore casing, a pipeline, or a structural support.
[00358] An expandable tubular member has been described, wherein the
anisotropy of
the expandable tubular member, prior to the radial expansion and plastic
deformation, is at
least about 1.48. In an exemplary embodiment, the tubular member includes a
wellbore
casing, a pipeline, or a structural support.
[00359] An expandable tubular member has been described, wherein the yield
point of
the expandable tubular member is at most about 57.8 ksi prior to the radial
expansion and
plastic deformation; and wherein the yield point of the expandable tubular
member is at least
about 74.4 ksi after the radial expansion and plastic deformation. In an
exemplary
embodiment, the tubular member includes a wellbore casing, a pipeline, or a
structural
support.
[00360] An expandable tubular member has been described, wherein the yield
point of
the expandable tubular member after a radial expansion and plastic deformation
is at least
about 28 % greater than the yield point of the expandable tubular member prior
to the radial
expansion and plastic deformation. In an exemplary embodiment, the tubular
member
includes a wellbore casing, a pipeline, or a structural support.
[00361] An expandable tubular member has been described, wherein the
anisotropy of
the expandable tubular member, prior to the radial expansion and plastic
deformation, is at
least about 1.04. In an exemplary embodiment, the tubular member includes a
wellbore
casing, a pipeline, or a structural support.
[00362] An expandable tubular member has been described, wherein the
anisotropy of
the expandable tubular member, prior to the radial expansion and plastic
deformation; is at
least about 1.92. In an exemplary embodiment, the tubular member includes a
wellbore
casing, a pipeline, or a structural support.
[00363] An expandable tubular member has been described, wherein the
anisotropy of
the expandable tubular member, prior to the radial expansion and plastic
deformation, is at
least about 1.34. In an exemplary embodiment, the tubular member includes a
weilbore
casing, a pipeline, or a structural support.
[00364] An expandable tubular member has been described, wherein the
anisotropy of
the expandable tubular member, prior to the radial expansion and plastic
deformation,
ranges from about 1.04 to about 1.92. In an exemplary embodiment, the tubular
member
includes a wellbore casing, a pipeline, or a structural support.
[00365] An expandable tubular member has been described, wherein the yield
point of
the expandable tubular member, prior to the radial expansion and plastic
deformation,
77
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the
tubular
member includes a weflbore casing, a pipeline, or a structural support.
[00366] An expandable tubular member has been described, wherein the
expandability
coefficient of the expandable tubular member, prior to the radial expansion
and plastic
deformation, is greater than 0.12. In an exemplary embodiment, the tubular
member
includes a wellbore casing, a pipeline, or a structural support.
[00367] An expandable tubular member has been described, wherein the
expandability
coefficient of the expandable tubular member is greater than the expandability
coefficient of
another portion of the expandable tubular member. In an exemplary embodiment,
the
tubular member includes a wellbore casing, a pipeline, or a structural
support.
[00368] An expandable tubular member has been described, wherein the tubular
member
has a higher ductility and a lower yield point prior to a radial expansion and
plastic
deformation than after the radial expansion and plastic deformation. In an
exemplary
embodiment, the tubular member includes a wellbore casing, a pipeline, or a
structural
support.
[00369] A method of radially expanding and plastically deforming a tubular
assembly
including a~first tubular member coupled to a second tubular member has been
described
that includes radially expanding and plastically deforming the tubular
assembly within a
preexisting structure; and using less power to radially expand each unit
length of the first
tubular member than to radially expand each unit length of the second tubular
member. In
an exemplary embodiment, the tubular member includes a wellbore casing, a
pipeline, or a
structural support.
[00370] A system for radially expanding and plastically deforming a tubular
assembly
including a first tubular member coupled to a second tubular member has been
described
that includes means for radially expanding the tubular assembly within a
preexisting
structure; and means for using less power to radially expand each unit length
of the first
tubular member than required to radially expand each unit length of the second
tubular
member. In an exemplary embodiment, the tubular member includes a wellbore
casing, a
pipeline, or a structural support.
[0037'l] A method of manufacturing a tubular member has been described that
includes
processing a tubular member until the tubular member is characterized by one
or more
intermediate characteristics; positioning the tubular member within a
preexisting structure;
and processing the tubular member within the preexisting structure until the
tubular member
is characterized one or more final characteristics. In an exemplary
embodiment, the tubular
member includes a wellbore casing, a pipeline, or a structural support. In an
exemplary
embodiment, the preexisting structure includes a wellbore that traverses a
subterranean
formation. In an exemplary embodiment, the characteristics are selected from a
group
78
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
consisting of yield point and ductility. In an exemplary embodiment,
processing the tubular
member within the preexisting structure until the tubular member is
characterized one or
more final characteristics includes: radially expanding and plastically
deforming the tubular
member within the preexisting structure.
[00372] An apparatus has been described that includes an expandable tubular
assembly;
and an expansion device coupled to the expandable tubular assembly; wherein a
predetermined portion of the expandable tubular assembly has a lower yield
point than
another portion of the expandable tubular assembly. In an exemplary
embodiment, the
expansion device includes a rotary expansion device, an axially displaceable
expansion
device, a reciprocating expansion device, a hydroforming expansion device,
and/or an
impulsive force expansion device. In an exemplary embodiment, the
predetermined portion
of the tubular assembly has a higher ductility and a lower yield point than
another portion of
the expandable tubular assembly. In an exemplary embodiment, the predetermined
portion
of the tubular assembly has a higher ductility than another portion of the
expandable tubular
assembly. In an exemplary embodiment, the predetermined portion of the tubular
assembly
has a lower yield point than another portion of the expandable tubular
assembly. In an
exemplary embodiment, the predetermined portion of the tubular assembly
includes an end
portion of the tubular assembly. In an exemplary embodiment, the predetermined
portion of
the tubular assembly includes a plurality of predetermined portions of the
tubular assembly.
In an exemplary embodiment, the predetermined portion of the tubular assembly
includes a
plurality of spaced apart predetermined portions of the tubular assembly. In
an exemplary
embodiment, the other portion of the tubular assembly includes an end portion
of the tubular
assembly. In an exemplary embodiment, the other portion of the tubular
assembly includes
a plurality of other portions of the tubular assembly. in an exemplary
embodiment, the other
portion of the tubular assembly includes a plurality of spaced apart other
portions of the
tubular assembly. In an exemplary embodiment, the tubular assembly includes a
plurality of
tubular members coupled to one another by corresponding tubular couplings. In
an
exemplary embodiment, the tubular couplings comprise the predetermined
portions of the
tubular assembly; and wherein the tubular members comprise the other portion
of the tubular
assembly. In an exemplary embodiment, one or more of the tubular couplings
comprise the
predetermined portions of the tubular assembly. In an exemplary embodiment,
one or more
of the tubular members comprise the predetermined portions of the tubular
assembly. In an
exemplary embodiment, the predetermined portion of the tubular assembly
defines one or
more openings. In an exemplary embodiment, one or more of the openings
comprise slots.
In an exemplary embodiment, the anisotropy for the predetermined portion of
the tubular
assembly is greater than 1 !n an exemplary embodiment, the anisotropy for the
predetermined portion of the tubular assembly is greater than 1. In an
exemplary
79
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
embodiment, the strain hardening exponent for the predetermined portion of the
tubular
assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for
the
predetermined portion of the tubular assembly is greater than 1; and wherein
the strain
hardening exponent for the predetermined portion of the tubular assembly is
greater than
0.12. in an exemplary embodiment, the predetermined portion of the tubular
assembly
includes a first steel alloy including: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002
% S, 0.24 % Si,
0.01 % Cu, 0.01 % Ni, and 0.02 % Cr. In an exemplary embodiment, the yield
point of the
predetermined portion of the tubular assembly is at most about 46.9 ksi. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the tubular
assembly is about
1.48. In an exemplary embodiment, the predetermined portion of the tubular
assembly
includes a second steel alloy including: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004
% S, 0.29
Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr. In an exemplary embodiment, the yield
point of
the predetermined portion of the tubular assembly is at most about 57.8 ksi.
In an
exemplary embodiment, the anisotropy of the predetermined portion of the
tubular assembly
is about 1.04. In an exemplary embodiment, the predetermined portion of the
tubular
assembly includes a third steel alloy including: 0.08 % C, 0.82 % Mn, 0.006 %
P, 0.003 % S,
0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr. In an exemplary embodiment,
the
anisotropy of the predetermined portion of the tubular assembly is about 1.92.
In an
exemplary embodiment, the predetermined portion of the tubular assembly
includes a fourth
steel alloy including: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si,
9.1 % Ni, and
18.7 % Cr. In an exemplary embodiment, the anisotropy of the predetermined
portion of the
tubular assembly is at least about 1.34. In an exemplary embodiment, the yield
point of the
predetermined portion of the tubular assembly is at most about 46.9 ksi. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the tubular
assembly is at least
about 1.48. In an exemplary embodiment, the yield point of the predetermined
portion of the
tubular assembly is at most about 57.8 ksi. In an exemplary embodiment, the
anisotropy of
the predetermined portion of the tubular assembly is at least about 1.04. In
an exemplary
embodiment, the anisotropy of the predetermined portion of the tubular
assembly is at least
about 1.92. In an exemplary embodiment, the anisotropy of the predetermined
portion of the
tubular assembly is at least about 1.34. In an exemplary embodiment, the
anisotropy of the
predetermined portion of the tubular assembly ranges from about 1.04 to about
1.92. In an
exemplary embodiment, the yield point of the predetermined portion of the
tubular assembly
ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the
expandability coefficient of the predetermined portion of the tubular assembly
is greater than
0.12. In an exemplary embodiment, the expandability coefficient of the
predetermined
portion of the tubular assembly is greater than the expandability coefficient
of the other
portion of the tubular assembly. In an exemplary embodiment, the tubular
assembly
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
includes a wellbore casing, a pipeline, or a structural support. In an
exemplary embodiment,
the carbon content of the predetermined portion of the tubular assembly is
less than or equal
to 0.12 percent; and wherein the carbon equivalent value for the predetermined
portion of
the tubular assembly is less than 0.21. In an exemplary embodiment, the carbon
content of
the predetermined portion of the tubular assembly is greater than 0.12
percent; and wherein
the carbon equivalent value for the predetermined portion of the tubular
assembly is less
than 0.36. In an exemplary embodiment, a yield point of an inner tubular
portion of at least a
portion of the tubular assembly is less than a yield point of an outer tubular
portion of the
portion of the tubular assembly. In an exemplary embodiment, the yield point
of the inner
tubular portion of the tubular body varies as a function of the radial
position within the tubular
body. In an exemplary embodiment, the yield point of the inner tubular portion
of the tubular
body varies in an linear fashion as a function of the radial position within
the tubular body. In
an exemplary embodiment, the yield point of the inner tubular portion of the
tubular body
varies in an non-linear fashion as a function of the radial position within
the tubular body. In
an exemplary embodiment, the yield point of the outer tubular portion of the
tubular body
varies as a function of the radial position within the tubular body. In an
exemplary
embodiment, the yield point of the outer tubular portion of the tubular body
varies in an linear
fashion as a function of the radial position within the tubular body. In an
exemplary
embodiment, the yield point of the outer tubular portion of the tubular body
varies in an non-
linear fashion as a function of the radial position within the tubular body.
In an exemplary
embodiment, the yield point of the inner tubular portion of the tubular body
varies as a
function of the radial position within the tubular body; and wherein the yield
point of the outer
tubular portion of the tubular body varies as a function of the radial
position within the tubular
body. In an exemplary embodiment, the yield point of the inner tubular portion
of the tubular
body varies in a linear fashion as a function of the radial position within
the tubular body; and
wherein the yield point of the outer tubular portion of the tubular body
varies in a linear
fashion as a function of the radial position within the tubular body. In an
exemplary
embodiment, the yield point of the inner tubular portion of the tubular body
varies in a linear
fashion as a function of the radial position within the tubular body; and
wherein the yield
point of the outer tubular portion of the tubular body varies in a non-linear
fashion as a
function of the radial position within the tubular body. In an exemplary
embodiment, the yield
point of the inner tubular portion of the tubular body varies in a non-linear
fashion as a
function of the radial position within the tubular body; and wherein the yield
point of the outer
tubular portion of the tubular body varies in a linear fashion as a function
of the radial
position within the tubular body. In an exemplary embodiment, the yield point
of the inner
tubular portion of the tubular body varies in a non-linear fashion as a
function of the radial
position within the tubular body; and wherein the yield point of the outer
tubular portion of the
81
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
tubular body varies in a non-linear fashion as a function of the radial
position within the
tubular body. In an exemplary embodiment, the rate of change of the yield
point of the inner
tubular portion of the tubular body is different than the rate of change of
the yield point of the
outer tubular portion of the tubular body. In an exemplary embodiment, the
rate of change of
the yield point of the inner tubular portion of the tubular body is different
than the rate of
change of the yield point of the outer tubular portion of the tubular body. In
an exemplary
embodiment, at least a portion of the tubular assembly comprises a
microstructure
comprising a hard phase structure and a soft phase structure. In an exemplary
embodiment,
prior to the radial expansion and plastic deformation, at least a portion of
the tubular
assembly comprises a microstructure comprising a transitional phase structure.
In an
exemplary embodiment, wherein the hard phase structure comprises martensite.
In an
exemplary embodiment, wherein the soft phase structure comprises ferrite. In
an exemplary
embodiment, wherein the transitional phase structure comprises retained
austentite. In an
exemplary embodiment, the hard phase structure comprises martensite; wherein
the soft
phase structure comprises ferrite; and wherein the transitional phase
structure comprises
retained austentite. In an exemplary embodiment, the portion of the tubular
assembly
comprising a microstructure comprising a hard phase structure and a soft phase
structure
comprises, by weight percentage, about 0.1 % C, about 1.2% Mn, and about 0.3%
Si. In an
exemplary embodiment, at least a portion of the tubular assembly comprises a
microstructure comprising a hard phase structure and a soft phase structure.
In an
exemplary embodiment, the portion of the tubular assembly comprises, by weight
percentage, 0.065% C, 1.44% Mn, 0.01 % P, 0.002% S, 0.24% Si, 0.01 % Cu, 0.01
% Ni,
0.02% Cr, 0.05% V, 0.01 % Mo, 0.01 % Nb, and 0.01 %Ti. In an exemplary
embodiment, the
portion of the tubular assembly comprises, by weight percentage, 0.18% C,
1.28% Mn,
0.017% P, 0.004% S, 0.29% Si, 0.01 % Cu, 0.01 % Ni, 0.03% Cr, 0.04% V, 0.01 %
Mo, 0.03%
Nb, and 0.01%Ti. In an exemplary embodiment, the portion of the tubular
assembly
comprises, by weight percentage, 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30%
Si,
0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01 % Nb, and 0.01 %Ti. In
an
exemplary embodiment, the portion of the tubular assembly comprises a
microstructure
comprising one or more of the following: martensite, pearlite, vanadium
carbide, nickel
carbide, or titanium carbide. In an exemplary embodiment, the portion of the
tubular
assembly comprises a microstructure comprising one or more of the following:
pearlite or
pearlite striation. In an exemplary embodiment, the portion of the tubular
assembly
comprises a microstructure comprising one or more of the following: grain
pearlite,
widmanstatten martensite, vanadium carbide, nickel carbide, or titanium
carbide. In an
exemplary embodiment, the portion of the tubular assembly comprises a
microstructure
comprising one or more of the following: ferrite, grain pearlite, or
martensite. In an
82
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
exemplary embodiment, the portion of the tubular assembly comprises a
microstructure
comprising one or more of the following: ferrite, martensite, or bainite. In
an exemplary
embodiment, the portion of the tubular assembly comprises a microstructure
comprising one
or more of the following: bainite, pearlite, or ferrite. In an exemplary
embodiment, the portion
of the tubular assembly comprises a yield strength of about 67ksi and a
tensile strength of
about 95 ksi. In an exemplary embodiment, the portion of the tubular assembly
comprises a
yield strength of about 82 ksi and a tensile strength of about 130 ksi. In an
exemplary
embodiment, the portion of the tubular assembly comprises a yield strength of
about 60 ksi
and a tensile strength of about 97 ksi.
(00373] An expandable tubular member has been described, wherein a yield point
of the
expandable tubular member after a radial expansion and plastic deformation is
at least about
5.8 % greater than the yield point of the expandable tubular member prior to
the radial
expansion and plastic deformation. In an exemplary embodiment, the tubular
member
includes a wellbore casing, a pipeline, or a structural support.
(00374] A method of determining the expandability of a selected tubular member
has
been described that includes determining an anisotropy value for the selected
tubular
member, determining a strain hardening value for the selected tubular member;
and
multiplying the anisotropy value times the strain hardening value to generate
an
expandability value for the selected tubular member. In an exemplary
embodiment, an
anisotropy value greater than 0.12 indicates that the tubular member is
suitable for radial
expansion and plastic deformation. In an exemplary embodiment, the tubular
member
includes a wellbore casing, a pipeline, or a structural support.
(00375] A method of radially expanding and plastically deforming tubular
members has
been described that includes selecting a tubular member; determining an
anisotropy value
for the selected tubular member; determining a strain hardening value for the
selected
tubular member; multiplying the anisotropy value times the strain hardening
value to
generate an expandability value for the selected tubular member; and if the
anisotropy value
is greater than 0.12, then radially expanding and plastically deforming the
selected tubular
member. In an exemplary embodiment, the tubular member includes a wellbore
casing, a
pipeline, or a structural support. In an exemplary embodiment, radially
expanding and
plastically deforming the selected tubular member includes: inserting the
selected tubular
member into a preexisting structure; and then radially expanding and
plastically deforming
the selected tubular member. In an exemplary embodiment, the preexisting
structure
includes a wellbore that traverses a subterranean formation.
(00376] A radially expandable multiple tubular member apparatus has been
described
that includes a first tubular member; a second tubular member engaged with the
first tubular
member forming a joint; a sleeve overlapping and coupling the first and second
tubular
~3
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
members at the joint; the sleeve having opposite tapered ends and a flange
engaged in a
recess formed in an adjacent tubular member; and one of the tapered ends being
a surface
formed on the flange. In an exemplary embodiment, the recess includes a
tapered wall in
mating engagement with the tapered end formed on the flange. In an exemplary
embodiment, the sleeve includes a flange at each tapered end and each tapered
end is
formed on a respective flange. In an exemplary embodiment, each tubular member
includes
a recess. In an exemplary embodiment, each flange is engaged in a respective
one of the
recesses. In an exemplary embodiment, each recess includes a tapered wall in
mating
engagement with the tapered end formed on a respective one of the flanges.
[00377] A method of joining radially expandable multiple tubular members has
also
been described that includes providing a first tubular member; engaging a
second tubular
member with the first tubular member to form a joint; providing a sleeve
having opposite
tapered ends and a flange, one of the tapered ends being a surface formed on
the flange;
and mounting the sleeve for overlapping and coupling the first and second
tubular members
at the joint, wherein the flange is engaged in a recess formed in an adjacent
one of the
tubular members. In an exemplary embodiment, the method further includes
providing a
tapered wall in the recess for mating engagement with the tapered end formed
on the flange.
In an exemplary embodiment, the method further includes providing a flange at
each tapered
end wherein each tapered end is formed on a respective flange. In an exemplary
embodiment, the method further includes providing a recess in each tubular
member. In an
exemplary embodiment, the method further includes engaging each flange in a
respective
one of the recesses. In an exemplary embodiment, the method further includes
providing a
tapered wall in each recess for mating engagement with the tapered end formed
on a
respective one of the flanges.
[00378] A radially expandable multiple tubular member apparatus has been
described
that includes a first tubular member; a second tubular member engaged with the
first tubular
member forming a joint; and a sleeve overlapping and coupling the first and
second tubular
members at the joint; wherein at least a portion of the sleeve is comprised of
a frangible
material.
[00379] A radially expandable multiple tubular member apparatus has been
described
that includes a first tubular member; a second tubular member engaged with the
first tubular
member forming a joint; and a sleeve overlapping and coupling the first and
second tubular
members at the joint; wherein the wall thickness of the sleeve is variable.
[00380] A method of joining radially expandable multiple tubular members has
been
described that includes providing a first tubular member; engaging a second
tubular member
with the first tubular member to form a joint; providing a sleeve comprising a
frangible
84
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
material; and mounting the sleeve for overlapping and coupling the first and
second tubular
members at the joint.
[00381] A method of joining radially expandable multiple tubular members has
been
described that includes providing a first tubular member; engaging a second
tubular member
with the first tubular member to form a joint; providing a sleeve comprising a
variable wall
thickness; and mounting the sleeve for overlapping and coupling the first and
second tubular
members at the joint.
[00382] An expandable tubular assembly has been described that includes a
first
tubular member; a second tubular member coupled to the first tubular member;
and means
for increasing the axial compression loading capacity of the coupling between
the first and
second tubular members before and after a radial expansion and plastic
deformation of the
first and second tubular members.
[00383] An expandable tubular assembly has been described that includes a
first
tubular member; a second tubular member coupled to the first tubular member;
and
means for increasing the axial tension loading capacity of the coupling
between the first and
second tubular members before and after a radial expansion and plastic
deformafiion of the
first and second tubular members.
[00384] An expandable tubular assembly has been described that includes a
first
tubular member; a second tubular member coupled to the first tubular member;
and means
for increasing the axial compression and tension loading capacity of the
coupling between
the first and second tubular members before and after a radial expansion and
plastic
deformation of the first and second tubular members.
[00385] An expandable tubular assembly has been described that includes a
first
tubular member; a second tubular member coupled to the first Tubular member;
and means
for avoiding stress risers in the coupling between the first and second
tubular members
before and after a radial expansion and plastic deformation of the first and
second tubular
members.
[00386] An expandable tubular assembly has been described that includes a
first
tubular member; a second tubular member coupled to the first tubular member;
and means
for inducing stresses at selected portions of the coupling between the first
and second
tubular members before and after a radial expansion and plastic deformation of
the first and
second tubular members.
[00387] In several exemplary embodiments of the apparatus described above, the
sleeve is circumferentially tensioned; and wherein the first and second
tubular members are
circumferentially compressed.
[00388] In several exemplary embodiments of the method described above, the
method further includes maintaining the sleeve in circumferential tension; and
maintaining
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
the first and second tubular members in circumferential compression before,
during, and/or
after the radial expansion and plastic deformation of the first and second
tubular members.
[00389] An expandable tubular assembly has been described that includes a
first
tubular member, a second tubular member coupled to the first tubular member, a
first
threaded connection for coupling a portion of the first and second tubular
members, a
second threaded connection spaced apart from the first threaded connection for
coupling
another portion of the first and second tubular members, a tubular sleeve
coupled to and
receiving end portions of the first and second tubular members, and a sealing
element
positioned between the first and second spaced apart threaded connections for
sealing an
interface between the first and second tubular member, wherein the sealing
element is
positioned within an annulus defined between the first and second tubular
members. in an
exemplary embodiment, the annulus is at least partially defined by an
irregular surface. In
an exemplary embodiment, the annulus is at least partially defined by a
toothed surface. In
an exemplary embodiment, the sealing element comprises an elastomeric
material. In an
exemplary embodiment, the sealing element comprises a metallic material. In an
exemplary
embodiment, the sealing element comprises an elastomeric and a metallic
material.
[00390] A method of joining radially expandable multiple tubular members has
been
described that includes providing a first tubular member, providing a second
tubular
member, providing a sleeve, mounting the sleeve for overlapping and coupling
the first and
second tubular members, threadably coupling the first and second tubular
members at a first
location, threadably coupling the first and second tubular members at a second
location
spaced apart from the first location, and sealing an interface between the
first and second
tubular members between the first and second locations using a compressible
sealing
element. In an exemplary embodiment, the sealing element includes an irregular
surface. In
an exemplary embodiment, the sealing element includes a toothed surface. In an
exemplary
embodiment, the sealing element comprises an elastomeric material. In an
exemplary
embodiment, the sealing element comprises a metallic material. In an exemplary
embodiment, the sealing element comprises an elastomeric and a metallic
material.
[00391] An expandable tubular assembly has been described that includes a
first
tubular member, a second tubular member coupled to the first tubular member, a
first
threaded connection for coupling a portion of the first and second tubular
members, a
second threaded connection spaced apart from the first threaded connection for
coupling
another portion of the first and second tubular members, and a plurality of
spaced apart
tubular sleeves coupled to and receiving end portions of the first and second
tubular
members. in an exemplary embodiment, at least one of the tubular sleeves is
positioned in
opposing relation to the first threaded connection; and wherein at least one
of the tubular
sleeves is positioned in opposing relation to the second threaded connection.
In an
86
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
exemplary embodiment, at least one of the tubular sleeves is not positioned in
opposing
relation to the first and second threaded connections.
[00392] A method of joining radially expandable multiple tubular members has
been
described that includes providing a first tubular member, providing a second
tubular
member, threadably coupling the first and second tubular members at a first
location,
threadably coupling the first and second tubular members at a second location
spaced apart
from the first location, providing a plurality of sleeves, and mounting the
sleeves at spaced
apart locations for overlapping and coupling the first and second tubular
members. in an
exemplary embodiment, at least one of the tubular sleeves is positioned in
opposing relation
to the first threaded coupling; and wherein at least one of the tubular
sleeves is positioned in
opposing relation to the second threaded coupling. In an exemplary embodiment,
at least
one of the tubular sleeves is not positioned in opposing relation to the first
and second
threaded couplings.
[00393] An expandable tubular assembly has been described that includes a
first
tubular member, a second tubular member coupled to the first tubular member,
and a
plurality of spaced apart tubular sleeves coupled to and receiving end
portions of the first
and second tubular members.
[00394] A method of joining radially expandable multiple tubular members has
been
described that includes providing a first tubular member, providing a second
tubular
member, providing a plurality of sleeves, coupling the first and second
tubular members, and
mounting the sleeves at spaced apart locations for overlapping and coupling
the first and
second tubular members.
[00395] An expandable tubular assembly has been described that includes a
first
tubular member, a second tubular member coupled to the first tubular member, a
threaded
connection for coupling a portion of the first and second tubular members, and
a tubular
sleeves coupled to and receiving end portions of the first and second tubular
members,
wherein at least a portion of the threaded connection is upset. in an
exemplary embodiment,
at least a portion of tubular sleeve penetrates the first tubular member.
[00396] A method of joining radially expandable multiple tubular members has
been
described that includes providing a first tubular member, providing a second
tubular
member, threadably coupling the first and second tubular members, and
upsetting the
threaded coupling. In an exemplary embodiment, the first tubular member
further comprises
an annular extension extending therefrom, and the flange of the sleeve defines
an annular
recess for receiving and mating with the annular extension of the first
tubular member. In an
exemplary embodiment, the first tubular member further comprises an annular
extension
extending therefrom; and the flange of the sleeve defines an annular recess
for receiving
and mating with the annular extension of the first tubular member.
87
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00397] A radially expandable multiple tubular member apparatus has been
described
that includes a first tubular member, a second tubular member engaged with the
first tubular
member forming a joint, a sleeve overlapping and coupling the first and second
tubular
members at the joint, and one or more stress concentrators for concentrating
stresses in the
joint. In an exemplary embodiment, one or more of the stress concentrators
comprises one
or more external grooves defined in the first tubular member. In an exemplary
embodiment,
one or more of the stress concentrators comprises one or more internal grooves
defined in
the second tubular member. In an exemplary embodiment, one or more of the
stress
concentrators comprises one or more openings defined in the sleeve. !n an
exemplary
embodiment, one or more of the stress concentrators comprises one or more
external
grooves defined in the first tubular member; and one or more of the stress
concentrators
comprises one or more internal grooves defined in the second tubular member.
In an
exemplary embodiment, one or more of the stress concentrators comprises one or
more
external grooves defined in the first tubular member; and one or more of the
stress
concentrators comprises one or more openings defined in the sleeve. In an
exemplary
embodiment, one or more of the stress concentrators comprises one or more
internal
grooves defined in the second tubular member; and one or more of the stress
concentrators
comprises one or more openings defined in the sleeve. In an exemplary
embodiment, one
or more of the stress concentrators comprises one or more external grooves
defined in the
first tubular member; wherein one or more of the stress concentrators
comprises one or
more internal grooves defined in the second tubular member; and wherein one or
more of
the stress concentrators comprises one or more openings defined in the sleeve.
j00398] A method of joining radially expandable multiple tubular members has
been
described that includes providing a first tubular member, engaging a second
tubular member
with the first tubular member to form a joint, providing a sleeve having
opposite tapered
ends and a flange, one of the tapered ends being a surface formed on the
flange, and
concentrating stresses within the joint. In an exemplary embodiment,
concentrating stresses
within the joint comprises using the first tubular member to concentrate
stresses within the
joint. In an exemplary embodiment, concentrating stresses within the joint
comprises using
the second tubular member to concentrate stresses within the joint. In an
exemplary
embodiment, concentrating stresses within the joint comprises using the sleeve
to
concentrate stresses within the joint. In an exemplary embodiment,
concentrating stresses
within the joint comprises using the first tubular member and the second
tubular member to
concentrate stresses within the joint. In an exemplary embodiment,
concentrating stresses
within the joint comprises using the first tubular member and the sleeve to
concentrate
stresses within the joint. In an exemplary embodiment, concentrating stresses
within the
joint comprises using the second tubular member and the sleeve to concentrate
stresses
88
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
within the joint. In an exemplary embodiment, concentrating stresses within
the joint
comprises using the first tubular member, the second tubular member, and the
sleeve to
concentrate stresses within the joint.
[00399] A system for radially expanding and plastically deforming a first
tubular
member coupled to a second tubular member by a mechanical connection has been
described that includes means for radially expanding the first and second
tubular members,
and means for maintaining portions of the first and second tubular member in
circumferential
compression following the radial expansion and plastic deformation of the
first and second
tubular members.
[00400] A system for radially expanding and plastically deforming a first
tubular
member coupled to a second tubular member by a mechanical connection has been
described that includes means for radially expanding the first and second
tubular members;
and means for concentrating stresses within the mechanical connection during
the radial
expansion and plastic deformation of the first and second tubular members.
[00401] A system for radially expanding and plastically deforming a first
tubular
member coupled to a second tubular member by a mechanical connection has been
described that includes means for radially expanding the first and second
tubular members;
means for maintaining portions of the first and second tubular member in
circumferential
compression following the radial expansion and plastic deformation of the
first and second
tubular members; and means for concentrating stresses within the mechanical
connection
during the radial expansion and plastic deformation of the first and second
tubular members.
[00402) A radially expandable tubular member apparatus has been described that
includes a first tubular member; a second tubular member engaged with the
first tubular
member forming a joint; and a sleeve overlapping and coupling the first and
second tubular
members at the joint; wherein, prior to a radial expansion and plastic
deformation of the
apparatus, a predetermined portion of the apparatus has a lower yield point
than another
portion of the apparatus. In an exemplary embodiment, the carbon content of
the
predetermined portion of the apparatus is less than or equal to 0.12 percent;
and wherein
the carbon equivalent value for the predetermined portion of the apparatus is
less than 0.21.
In an exemplary embodiment, the carbon content of the predetermined portion of
the
apparatus is greater than 0.12 percent; and wherein the carbon equivalent
value for the
predetermined portion of the apparatus is less than 0.36. In an exemplary
embodiment, the
apparatus further includes means for maintaining portions of the first and
second tubular
member in circumferential compression following the radial expansion and
plastic
deformation of the first and second tubular members. In an exemplary
embodiment, the
apparatus further includes means for concentrating stresses within the
mechanical
connection during the radial expansion and plastic deformation of the first
and second
89
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
tubular members. In an exemplary embodiment, the apparatus further includes
means for
maintaining portions of the first and second tubular member in circumferential
compression
following the radial expansion and plastic deformation of the first and second
tubular
members; and means for concentrating stresses within the mechanical connection
during
the radial expansion and plastic deformation of the first and second tubular
members. In an
exemplary embodiment, the apparatus further includes one or more stress
concentrators for
concentrating stresses in the joint. In an exemplary embodiment, one or more
of the stress
concentrators comprises one or more external grooves defined in the first
tubular member.
In an exemplary embodiment, one or more of the stress concentrators comprises
one or
more internal grooves defined in the second tubular member. In an exemplary
embodiment,
one or more of the stress concentrators comprises one or more openings defined
in the
sleeve. In an exemplary embodiment, one or more of the stress concentrators
comprises
one or more external grooves defined in the first tubular member; and wherein
one or more
of the stress concentrators comprises one or more internal grooves defined in
the second
tubular member. In an exemplary embodiment, one or more of the stress
concentrators
comprises one or more external grooves defined in the first tubular member;
and wherein
one or more of the stress concentrators comprises one or more openings defined
in the
sleeve. In an exemplary embodiment, one or more of the stress concentrators
comprises
one or more internal grooves defined in the second tubular member; and wherein
one or
more of the stress concentrators comprises one or more openings defined in the
sleeve. In
an exemplary embodiment, one or more of the stress concentrators comprises one
or more
external grooves defined in the first tubular member; wherein one or more of
the stress
concentrators comprises one or more internal grooves defined in the second
tubular
member; and wherein one or more of the stress concentrators comprises one or
more
openings defined in the sleeve. In an exemplary embodiment, the first tubular
member
further comprises an annular extension extending therefrom; and wherein the
flange of the
sleeve defines an annular recess for receiving and mating with the annular
extension of the
first tubular member. In an exemplary embodiment, the apparatus further
includes a
threaded connection for coupling a portion of the first and second tubular
members; wherein
at least a portion of the threaded connection is upset. In an exemplary
embodiment, at least
a portion of tubular sleeve penetrates the first tubular member. In an
exemplary
embodiment, the apparatus further includes means for increasing the axial
compression
loading capacity of the joint between the first and second tubular members
before and after
a radial expansion and plastic deformation of the first and second tubular
members. In an
exemplary embodiment, the apparatus further includes means for increasing the
axial
tension loading capacity of the joint between the first and second tubular
members before
and after a radial expansion and plastic deformation of the first and second
tubular
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
members. In an exemplary embodiment, the apparatus further includes means for
increasing the axial compression and tension loading capacity of the joint
between the first
and second tubular members before and after a radial expansion and plastic
deformation of
the first and second tubular members. In an exemplary embodiment, the
apparatus further
includes means for avoiding stress risers in the joint between the first and
second tubular
members before and after a radial expansion and plastic deformation of the
first and second
tubular members. In an exemplary embodiment, the apparatus further includes
means for
inducing stresses at selected portions of the coupling between the first and
second tubular
members before and after a radial expansion and plastic deformation of the
first and second
tubular members. In an exemplary embodiment, the sleeve is circumferentially
tensioned;
and wherein the first and second tubular members are circumferentially
compressed. In an
exemplary embodiment, the means for increasing the axial compression loading
capacity of
the coupling between the first and second tubular members before and after a
radial
expansion and plastic deformation of the first and second tubular members is
circumferentially tensioned; and wherein the first and second tubular members
are
circumferentially compressed. In an exemplary embodiment, the means for
increasing the
axial tension loading capacity of the coupling between the first and second
tubular members
before and after a radial expansion and plastic deformation of the first and
second tubular
members is circumferentially tensioned; and wherein the first and second
tubular members
are circumferentially compressed. In an exemplary embodiment, the means for
increasing
the axial compression and tension loading capacity of the coupling between the
first and
second tubular members before and after a radial expansion and plastic
deformation of the
first and second tubular members is circumferentially tensioned; and wherein
the first and
second tubular members are circumferentially compressed. In an exemplary
embodiment,
the means for avoiding stress risers in the coupling between the first and
second tubular
members before and after a radial expansion and plastic deformation of the
first and second
tubular members is circumferentially tensioned; and wherein the first and
second tubular
members are circumferentially compressed. In an exemplary embodiment, the
means for
inducing stresses at selected portions of the coupling between the first and
second tubular
members before and after a radial expansion and plastic deformation of the
first and second
tubular members is circumferentially tensioned; and wherein the first and
second tubular
members are circumferentially compressed. In an exemplary embodiment, at least
a portion
of the sleeve is comprised of a frangible material. In an exemplary
embodiment, the wall
thickness of the sleeve is variable. In an exemplary embodiment, the
predetermined portion
of the apparatus has a higher ductility and a lower yield point prior to the
radial expansion
and plastic deformation than after the radial expansion and plastic
deformation. In an
exemplary embodiment, the predetermined portion of the apparatus has a higher
ductility
91
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
prior to the radial expansion and plastic deformation than after the radial
expansion and
plastic deformation. In an exemplary embodiment, the predetermined portion of
the
apparatus has a lower yield point prior to the radial expansion and plastic
deformation than
after the radial expansion and plastic deformation. In an exemplary
embodiment, the
predetermined portion of the apparatus has a larger inside diameter after the
radial
expansion and plastic deformation than other portions of the tubular assembly.
In an
exemplary embodiment, the sleeve is circumferentially tensioned; and wherein
the first and
second tubular members are circumferentially compressed. In an exemplary
embodiment,
the sleeve is circumferentially tensioned; and wherein the first and second
tubular members
are circumferentially compressed. In an exemplary embodiment, the apparatus
further
includes positioning another apparatus within the preexisting structure in
overlapping relation
to the apparatus; and radially expanding and plastically deforming the other
apparatus within
the preexisting structure; wherein, prior to the radial expansion and plastic
deformation of the
apparatus, a predetermined portion of the other apparatus has a lower yield
point than
another portion of the other apparatus. In an exemplary embodiment, the inside
diameter of
the radially expanded and plastically deformed other portion of the apparatus
is equal to the
inside diameter of the radially expanded and plastically deformed other
portion of the other
apparatus. In an exemplary embodiment, the predetermined portion of the
apparatus
comprises an end portion of the apparatus. In an exemplary embodiment, the
predetermined portion of the apparatus comprises a plurality of predetermined
portions of
the apparatus. In an exemplary embodiment, the predetermined portion of the
apparatus
comprises a plurality of spaced apart predetermined portions of the apparatus.
In an
exemplary embodiment, the other portion of the apparatus comprises an end
portion of the
apparatus. In an exemplary embodiment, the other portion of the apparatus
comprises a
plurality of other portions of the apparatus. In an exemplary embodiment, the
other portion
of the apparatus comprises a plurality of spaced apart other portions of the
apparatus. In an
exemplary embodiment, the apparatus comprises a plurality of tubular members
coupled to
one another by corresponding tubular couplings. In an exemplary embodiment,
the tubular
couplings comprise the predetermined portions of the apparatus; and wherein
the tubular
members comprise the other portion of the apparatus. In an exemplary
embodiment, one or
more of the tubular couplings comprise the predetermined portions of the
apparatus. In an
exemplary embodiment, one or more of the tubular members comprise the
predetermined
portions of the apparatus. In an exemplary embodiment, the predetermined
portion of the
apparatus defines one or more openings. In an exemplary embodiment, one or
more of the
openings comprise slots. In an exemplary embodiment, the anisotropy for the
predetermined portion of the apparatus is greater than 1. In an exemplary
embodiment, the
anisotropy for the predetermined portion of the apparatus is greater than 1.
In an exemplary
92
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
embodiment, the strain hardening exponent for the predetermined portion of the
apparatus is
greater than 0.12. In an exemplary embodiment, the anisotropy for the
predetermined
portion of the apparatus is greater than 1; and wherein the strain hardening
exponent for the
predetermined portion of the apparatus is greater than 0.12. In an exemplary
embodiment,
the predetermined portion of the apparatus comprises a first steel alloy
comprising: 0.065
C, 1.44%Mn,0.01 %P,0.002%S,0.24%Si,0.01 %Cu,0.01 %Ni,and0.02%Cr. In an
exemplary embodiment, the yield point of the predetermined portion of the
apparatus is at
most about 46.9 ksi prior to the radial expansion and plastic deformation; and
wherein the
yield point of the predetermined portion of the apparatus is at least about
65.9 ksi after the
radial expansion and plastic deformation. In an exemplary embodiment, the
yield point of
the predetermined portion of the apparatus after the radial expansion and
plastic
deformation is at least about 40 % greater than the yield point of the
predetermined portion
of the apparatus prior to the radial expansion and plastic deformation. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the apparatus,
prior to the radial
expansion and plastic deformation, is about 1.48. In an exemplary embodiment,
the
predetermined portion of the apparatus comprises a second steel alloy
comprising: 0.18
C,1.28%Mn,0.017%P,0.004%S,0.29%Si,0.01 %Cu,0.01 %Ni,and0.03%Cr. In
an exemplary embodiment, the yield point of the predetermined portion of the
apparatus is at
most about 57.8 ksi prior to the radial expansion and plastic deformation; and
wherein the
yield point of the predetermined portion of the apparatus is at least about
74.4 ksi after the
radial expansion and plastic deformation. In an exemplary embodiment, the
yield point of
fihe predetermined portion of the apparatus affier the radial expansion and
plastic
deformation is at least about 28 % greater than the yield point of the
predetermined portion
of the apparatus prior to the radial expansion and plastic deformation. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the apparatus,
prior to the radial
expansion and plastic deformation, is about 1.04. In an exemplary embodiment,
the
predetermined portion of the apparatus comprises a third steel alloy
comprising: 0.08 % C,
0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 %
Cr. In an
exemplary embodiment, the anisotropy of the predetermined portion of the
apparatus, prior
to the radial expansion and plastic deformation, is about 1.92. In an
exemplary embodiment,
the predetermined portion of the apparatus comprises a fourth steel alloy
comprising: 0.02
C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the apparatus,
prior to the radial
expansion and plastic deformation, is about 1.34. In an exemplary embodiment,
the yield
point of the predetermined portion of the apparatus is at most about 46.9 ksi
prior to the
radial expansion and plastic deformation; and wherein the yield point of the
predetermined
portion of the apparatus is at least about 65.9 ksi after the radial expansion
and plastic
93
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
deformation. In an exemplary embodiment, the yield point of the predetermined
portion of
the apparatus after the radial expansion and plastic deformation is at least
about 40
greater than the yield point of the predetermined portion of the apparatus
prior to the radial
expansion and plastic deformation. In an exemplary embodiment, the anisotropy
of the
predetermined portion of the apparatus, prior to the radial expansion and
plastic
deformation, is at least about 1.48. In an exemplary embodiment, the yield
point of the
predetermined portion of the apparatus is at most about 57.8 ksi prior to the
radial expansion
and plastic deformation; and wherein the yield point of the predetermined
portion of the
apparatus is at least about 74.4 ksi after the radial expansion and plastic
deformation. In an
exemplary embodiment, the yield point of the predetermined portion of the
apparatus after
the radial expansion and plastic deformation is at least about 28 % greater
than the yield
point of the predetermined portion of the apparatus prior to the radial
expansion and plastic
deformation. In an exemplary embodiment, the anisotropy of the predetermined
portion of
the apparatus, prior to the radial expansion and plastic deformation, is at
least about 1.04.
In an exemplary embodiment, the anisotropy of the predetermined portion of the
apparatus,
prior to the radial expansion and plastic deformation, is at least about 1.92.
In an exemplary
embodiment, the anisotropy of the predetermined portion of the apparatus,
prior to the radial
expansion and plastic deformation, is at least about 1.34. In an exemplary
embodiment, the
anisotropy of the predetermined portion of the apparatus, prior to the radial
expansion and
plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary
embodiment,
the yield point of the predetermined portion of the apparatus, prior to the
radial expansion
and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an
exemplary
embodiment, the expandability coefficient of the predetermined portion of the
apparatus,
prior to the radial expansion and plastic deformation, is greater than 0.12.
In an exemplary
embodiment, the expandability coefficient of the predetermined portion of the
apparatus is
greater than the expandability coefficient of the other portion of the
apparatus. In an
exemplary embodiment, the apparatus comprises a wellbore casing. In an
exemplary
embodiment, the apparatus comprises a pipeline. !n an exemplary embodiment,
the
apparatus comprises a structural support.
[00403] A radially expandable tubular member apparatus has been described that
includes a first tubular member; a second tubular member engaged with the
first tubular
member forming a joint; a sleeve overlapping and coupling the first and second
tubular
members at the joint; the sleeve having opposite tapered ends and a flange
engaged in a
recess formed in an adjacent tubular member; and one of the tapered ends being
a surface
formed on the flange; wherein, prior to a radial expansion and plastic
deformation of the
apparatus, a predetermined portion of the apparatus has a lower yield point
than another
portion of the apparatus. In an exemplary embodiment, the recess includes a
tapered wall in
94
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
mating engagement with the tapered end formed on the flange. In an exemplary
embodiment, the sleeve includes a flange at each tapered end and each tapered
end is
formed on a respective flange. In an exemplary embodiment, each tubular member
includes
a recess. In an exemplary embodiment, each flange is engaged in a respective
one of the
recesses. In an exemplary embodiment, each recess includes a tapered wall in
mating
engagement with the tapered end formed on a respective one of the flanges. In
an
exemplary embodiment, the predetermined portion of the apparatus has a higher
ductility
and a lower yield point prior to the radial expansion and plastic deformation
than after the
radial expansion and plastic deformation. In an exemplary embodiment, the
predetermined
portion of the apparatus has a higher ductility prior to the radial expansion
and plastic
deformation than after the radial expansion and plastic deformation. In an
exemplary
embodiment, the predetermined portion of the apparatus has a lower yield point
prior to the
radial expansion and plastic deformation than after the radial expansion and
plastic
deformation. In an exemplary embodiment, the predetermined portion of the
apparatus has
a larger inside diameter after the radial expansion and plastic deformation
than other
portions of the tubular assembly. In an exemplary embodiment, the apparatus
further
includes positioning another apparatus within the preexisting structure in
overlapping relation
to the apparatus; and radially expanding and plastically deforming the other
apparatus within
the preexisting structure; wherein, prior to the radial expansion and plastic
deformation of the
apparatus, a predetermined portion of the other apparatus has a lower yield
point than
another portion of the other apparatus. In an exemplary embodiment, the inside
diameter of
the radially expanded and plastically deformed other portion of the apparatus
is equal to the
inside diameter of the radially expanded and plastically deformed other
portion of the other
apparatus. In an exemplary embodiment, the predetermined portion of fihe
apparatus
comprises an end portion of the apparatus. In an exemplary embodiment, the
predetermined portion of the apparatus comprises a plurality of predetermined
portions of
the apparatus. In an exemplary embodiment, the predetermined portion of the
apparatus
comprises a plurality of spaced apart predetermined portions of the apparatus.
In an
exemplary embodiment, the other portion of the apparatus comprises an end
portion of the
apparatus. In an exemplary embodiment, the other portion of the apparatus
comprises a
plurality of other portions of the apparatus. In an exemplary embodiment, the
other portion
of the apparatus comprises a plurality of spaced apart other portions of the
apparatus. In an
exemplary embodiment, the apparatus comprises a plurality of tubular members
coupled to
one another by corresponding tubular couplings. In an exemplary embodiment,
the tubular
couplings comprise the predetermined portions of the apparatus; and wherein
the tubular
members comprise the other portion of the apparatus. In an exemplary
embodiment, one or
more of the tubular couplings comprise the predetermined portions of the
apparatus. In an
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
exemplary embodiment, one or more of the tubular members comprise the
predetermined
portions of the apparatus. In an exemplary embodiment, the predetermined
portion of the
apparatus defines one or more openings. In an exemplary embodiment, one or
more of the
openings comprise slots. In an exemplary embodiment, the anisotropy for the
predetermined portion of the apparatus is greater than 1. In an exemplary
embodiment, the
anisotropy for the predetermined portion of the apparatus is greater than 1.
In an exemplary
embodiment, the strain hardening exponent for the predetermined portion of the
apparatus is
greater than 0.12. In an exemplary embodiment, the anisotropy for the
predetermined
portion of the apparatus is greater than 1; and wherein the strain hardening
exponent for the
predetermined portion of the apparatus is greater than 0.12. In an exemplary
embodiment,
the predetermined portion of the apparatus comprises a first steel alloy
comprising: 0.065
C, 1.44%Mn,0.01 %P,0.002%S,0.24%Si,0.01 %Cu,0.01 %Ni,and0.02%Cr. In an
exemplary embodiment, the yield point of the predetermined portion of the
apparatus is at
most about 46.9 ksi prior to the radial expansion and plastic deformation; and
wherein the
yield point of the predetermined portion of the apparatus is at least about
65.9 ksi after the
radial expansion and plastic deformation. In an exemplary embodiment, the
yield point of
the predetermined portion of the apparatus after the radial expansion and
plastic
deformation is at least about 40 % greater than the yield point of the
predetermined portion
of the apparatus prior to the radial expansion and plastic deformation. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the apparatus,
prior to the radial
expansion and plastic deformation, is about 1.48. In an exemplary embodiment,
the
predetermined portion of the apparatus comprises a second steel alloy
comprising: 0.18
C, 1.28%Mn,0.017%P,0.004%S,0.29%Si,0.01 %Cu,0.01 %Ni,and0.03%Cr. In
an exemplary embodiment, the yield point of the predetermined portion of the
apparatus is at
most about 57.8 ksi prior to the radial expansion and plastic deformation; and
wherein the
yield point of the predetermined portion of the apparatus is at least about
74.4 ksi after the
radial expansion and plastic deformation. In an exemplary embodiment, the
yield point of
the predetermined portion of the apparatus after the radial expansion and
plastic
deformation is at feast about 28 % greater than the yield point of the
predetermined portion
of the apparatus prior to the radial expansion and plastic deformation. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the apparatus,
prior to the radial
expansion and plastic deformation, is about 1.04. In an exemplary embodiment,
the
predetermined portion of the apparatus comprises a third steel alloy
comprising: 0.08 % C,
0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 %
Cr. In an
exemplary embodiment, the anisotropy of the predetermined portion of the
apparatus, prior
to the radial expansion and plastic deformation, is about 1.92. In an
exemplary embodiment,
the predetermined portion of the apparatus comprises a fourth steel alloy
comprising: 0.02
96
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the apparatus,
prior to the radial
expansion and plastic deformation, is about 1.34. In an exemplary embodiment,
the yield
point of the predetermined portion of the apparatus is at most about 46.9 ksi
prior to the
radial expansion and plastic deformation; and wherein the yield point of the
predetermined
portion of the apparatus is at least about 65.9 ksi after the radial expansion
and plastic
deformation. In an exemplary embodiment, the yield point of the predetermined
portion of
the apparatus after the radial expansion and plastic deformation is at least
about 40
greater than the yield point of the predetermined portion of the apparatus
prior to the radial
expansion and plastic deformation. In an exemplary embodiment, the anisotropy
of the
predetermined portion of the apparatus, prior to the radial expansion and
plastic
deformation, is at least about 1.48. In an exemplary embodiment, the yield
point of the
predetermined portion of the apparatus is at most about 57.8 ksi prior to the
radial expansion
and plastic deformation; and wherein the yield point of the predetermined
portion of the
apparatus is at least about 74.4 ksi after the radial expansion and plastic
deformation. In an
exemplary embodiment, the yield point of the predetermined portion of the
apparatus after
the radial expansion and plastic deformation is at least about 28 % greater
than the yield
point of the predetermined portion of the apparatus prior to the radial
expansion and plastic
deformation. In an exemplary embodiment, the anisotropy of the predetermined
portion of
the apparatus, prior to the radial expansion and plastic deformation, is at
least about 1.04.
In an exemplary embodiment, the anisotropy of the predetermined portion of the
apparatus,
prior to the radial expansion and plastic deformation, is at least about 1.92.
In an exemplary
embodiment, fihe anisotropy of the predetermined portion of the apparatus,
prior to the radial
expansion and plastic deformation, is at least about 1.34. In an exemplary
embodiment, the
anisotropy of the predetermined portion of the apparatus, prior to the radial
expansion and
plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary
embodiment,
the yield point of the predetermined portion of the apparatus, prior to the
radial expansion
and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an
exemplary
embodiment, the expandability coefficient of the predetermined portion of the
apparatus,
prior to the radial expansion and plastic deformation, is greater than 0.12.
In an exemplary
embodiment, the expandability coefficient of the predetermined portion of the
apparatus is
greater than the expandability coefficient of the other portion of the
apparatus. In an
exemplary embodiment, the apparatus comprises a wellbore casing. In an
exemplary
embodiment, the apparatus comprises a pipeline. In an exemplary embodiment,
the
apparatus comprises a structural support.
[00404] A method of joining radially expandable tubular members has been
provided
that includes: providing a first tubular member; engaging a second tubular
member with the
97
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
first tubular member to form a joint; providing a sleeve; mounting the sleeve
for overlapping
and coupling the first and second tubular members at the joint; wherein the
first tubular
member, the second tubular member, and the sleeve define a tubular assembly;
and radially
expanding and plastically deforming the tubular assembly; wherein, prior to
the radial
expansion and plastic deformation, a predetermined portion of the tubular
assembly has a
lower yield point than another portion of the tubular assembly. In an
exemplary embodiment,
the carbon content of the predetermined portion of the tubular assembly is
less than or equal
to 0.12 percent; and wherein the carbon equivalent value for the predetermined
portion of
the tubular assembly is less than 0.21. In an exemplary embodiment, the carbon
content of
the predetermined portion of the tubular assembly is greater than 0.12
percent; and wherein
the carbon equivalent value for the predetermined portion of the tubular
assembly is less
than 0.36. In an exemplary embodiment, the method further includes:
maintaining portions
of the first and second tubular member in circumferential compression
following a radial
expansion and plastic deformation of the first and second tubular members. In
an exemplary
embodiment, the method further includes: concentrating stresses within the
joint during a
radial expansion and plastic deformation of the first and second tubular
members. In an
exemplary embodiment, the method further includes: maintaining portions of the
first and
second tubular member in circumferential compression following a radial
expansion and
plastic deformation of the first and second tubular members; and concentrating
stresses
within the joint during a radial expansion and plastic deformation of the
first and second
tubular members. In an exemplary embodiment, the method further includes:
concentrating
stresses within the joint. In an exemplary embodiment, concentrating stresses
within the
joint comprises using the first tubular member to concentrate stresses within
the joint. In an
exemplary embodiment, concentrating stresses within the joint comprises using
the second
tubular member to concentrate stresses within the joint. In an exemplary
embodiment,
concentrating stresses within the joint comprises using the sleeve to
concentrate stresses
within the joint. In an exemplary embodiment, concentrating stresses within
the joint
comprises using the first tubular member and the second tubular member to
concentrate
stresses within the joint. In an exemplary embodiment, concentrating stresses
within the
joint comprises using the first tubular member and the sleeve to concentrate
stresses within
the joint. In an exemplary embodiment, concentrating stresses within the joint
comprises
using the second tubular member and the sleeve to concentrate stresses within
the joint. In
an exemplary embodiment, concentrating stresses within the joint comprises
using the first
tubular member, the second tubular member, and the sleeve to concentrate
stresses within
the joint. In an exemplary embodiment, at least a portion of the sleeve is
comprised of a
frangible material. In an exemplary embodiment, the sleeve comprises a
variable wall
Thickness. In an exemplary embodiment, the method further includes maintaining
the sleeve
98
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
in circumferential tension; and maintaining the first and second tubular
members in
circumferentiaf compression. In an exemplary embodiment, the method further
includes
maintaining the sleeve in circumferential tension; and maintaining the first
and second
tubular members in circumferential compression. In an exemplary embodiment;
the method
further includes: maintaining the sleeve in circumferential tension; and
maintaining the first
and second tubular members in circumferential compression. In an exemplary
embodiment,
the method further includes: threadably coupling the first and second tubular
members at a
first location; threadably coupling the first and second tubular members at a
second location
spaced apart from the first location; providing a plurality of sleeves; and
mounting the
sleeves at spaced apart locations for overlapping and coupling the first and
second tubular
members. In an exemplary embodiment, at least one of the tubular sleeves is
positioned in
opposing relation to the first threaded coupling; and wherein at least one of
the tubular
sleeves is positioned in opposing relation to the second threaded coupling. In
an exemplary
embodiment, at least one of the tubular sleeves is not positioned in opposing
relation to the
first and second threaded couplings. In an exemplary embodiment, the method
further
includes: threadably coupling the first and second tubular members; and
upsetting the
threaded coupling. In an exemplary embodiment, the first tubular member
further comprises
an annular extension extending therefrom; and wherein the flange of the sleeve
defines an
annular recess for receiving and mating with the annular extension of the
first tubular
member. In an exemplary embodiment, the predetermined portion of the tubular
assembly
has a higher ductility and a lower yield point prior to the radial expansion
and plastic
deformation than after the radial expansion and plastic deformation. In an
exemplary
embodiment, the predetermined portion of the tubular assembly has a higher
ductility prior to
the radial expansion and plastic deformation than after the radial expansion
and plastic
deformation. In an exemplary embodiment, the predetermined portion of the
tubular
assembly has a lower yield point prior to the radial expansion and plastic
deformation than
after the radial expansion and plastic deformation. In an exemplary
embodiment, the
predetermined portion of the tubular assembly has a larger inside diameter
after the radial
expansion and plastic deformation than the other portion of the tubular
assembly. In an
exemplary embodiment, the method further includes: positioning another tubular
assembly
within the preexisting structure in overlapping relation to the tubular
assembly; and radially
expanding and plastically deforming the other tubular assembly within the
preexisting
structure; wherein, prior to the radial expansion and plastic deformation of
the tubular
assembly, a predetermined portion of the other tubular assembly has a lower
yield point than
another portion of the other tubular assembly. In an exemplary embodiment, the
inside
diameter of the radially expanded and plastically deformed other portion of
the tubular
assembly is equal to the inside diameter of the radially expanded and
plastically deformed
99
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
other portion of the other tubular assembly. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises an end portion of the
tubular
assembly. In an exemplary embodiment, the predetermined portion of the tubular
assembly
comprises a plurality of predetermined portions of the tubular assembly. In an
exemplary
embodiment, the predetermined portion of the tubular assembly comprises a
plurality of
spaced apart predetermined portions of the tubular assembly. In an exemplary
embodiment,
the other portion of the tubular assembly comprises an end portion of the
tubular assembly.
In an exemplary embodiment, the other portion of the tubular assembly
comprises a plurality
of other portions of the tubular assembly. In an exemplary embodiment, the
other portion of
the tubular assembly comprises a plurality of spaced apart other portions of
the tubular
assembly. In an exemplary embodiment, the tubular assembly comprises a
plurality of
tubular members coupled to one another by corresponding tubular couplings. In
an
exemplary embodiment, the tubular couplings comprise the predetermined
portions of the
tubular assembly; and wherein the tubular members comprise the other portion
of the tubular
assembly. In an exemplary embodiment, one or more of the tubular couplings
comprise the
predetermined portions of the tubular assembly. In an exemplary embodiment,
one or more
of the tubular members comprise the predetermined portions of the tubular
assembly. In an
exemplary embodiment, the predetermined portion of the tubular assembly
defines one or
more openings. In an exemplary embodiment, one or more of the openings
comprise slots.
In an exemplary embodiment, the anisotropy for the predetermined portion of
the tubular
assembly is greater than 1. In an exemplary embodiment, the anisotropy for the
predetermined portion of the tubular assembly is greater than 1. In an
exemplary
embodiment, the strain hardening exponent for the predetermined portion of the
tubular
assembly is greater than 0.12. in an exemplary embodiment, the anisotropy for
the
predetermined portion of the tubular assembly is greater than 1; and wherein
the strain
hardening exponent for the predetermined portion of the tubular assembly is
greater than
0.12. In an exemplary embodiment, the predetermined portion of the tubular
assembly
comprises a first steel alloy comprising: 0.065 % C, 1.44 % Mn, 0.01 % P,
0.002 % S, 0.24
Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr. In an exemplary embodiment, the yield
point of
the predetermined portion of the tubular assembly is at most about 46.9 ksi
prior to the radial
expansion and plastic deformation; and wherein the yield point of the
predetermined portion
of the tubular assembly is at least about 65.9 ksi after the radial expansion
and plastic
deformation. In an exemplary embodiment, the yield point of the predetermined
portion of
the tubular assembly after the radial expansion and plastic deformation is at
least about 40
greater than the yield point of the predetermined portion of the tubular
assembly prior to
the radial expansion and plastic deformation. In an exemplary embodiment, the
anisotropy
of the predetermined portion of the tubular assembly, prior to the radial
expansion and
100
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
plastic deformation, is about 1.48. In an exemplary embodiment, the
predetermined portion
of the tubular assembly comprises a second steel alloy comprising: 0.18 % C,
1.28 % Mn,
0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr. In an
exemplary
embodiment, the yield point of the predetermined portion of the tubular
assembly is at most
about 57.8 ksi prior to the radial expansion and plastic deformation; and
wherein the yield
point of the predetermined portion of the tubular assembly is at least about
74.4 ksi after the
radial expansion and plastic deformation. In an exemplary embodiment, the
yield point of
the predetermined portion of the tubular assembly after the radial expansion
and plastic
deformation is at least about 28 % greater than the yield point of the
predetermined portion
of the tubular assembly prior to the radial expansion and plastic deformation.
In an
exemplary embodiment, the anisotropy of the predetermined portion of the
tubular assembly,
prior to the radial expansion and plastic deformation, is about 1.04. In an
exemplary
embodiment, the predetermined portion of the tubular assembly comprises a
third steel alloy
comprising: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % St, 0.16 % Cu,
0.05 % Ni,
and 0.05 % Cr. In an exemplary embodiment, the anisotropy of the predetermined
portion of
the tubular assembly, prior to the radial expansion and plastic deformation,
is about 1.92. In
an exemplary embodiment, the predetermined portion of the tubular assembly
comprises a
fourth steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45
% Si, 9.1
Ni, and 18.7 % Cr. In an exemplary embodiment, the anisotropy of the
predetermined
portion of the tubular assembly, prior to the radial expansion and plastic
deformation, is
about 1.34. In an exemplary embodiment, the yield point of the predetermined
portion of the
tubular assembly is at most about 46.9 ksi prior to the radial expansion and
plastic
deformation; and wherein the yield point of the predetermined portion of the
tubular
assembly is at least about 65.9 ksi after fihe radial expansion and plastic
deformation. In an
exemplary embodiment, the yield point of the predetermined portion of the
tubular assembly
after the radial expansion and plastic deformation is at least about 40 %
greater than the
yield point of the predetermined portion of the tubular assembly prior to the
radial expansion
and plastic deformation. In an exemplary embodiment, the anisotropy of the
predetermined
portion of the tubular assembly, prior to the radial expansion and plastic
deformation, is at
least about 1.48. In an exemplary embodiment, the yield point of the
predetermined portion
of the tubular assembly is at most about 57.8 ksi prior to the radial
expansion and plastic
deformation; and wherein the yield point of the predetermined portion of the
tubular
assembly is at least about 74.4 ksi after the radial expansion and plastic
deformation. In an
exemplary embodiment, the yield point of the predetermined portion of the
tubular assembly
after the radial expansion and plastic deformation is at least about 28 %
greater than the
yield point of the predetermined portion of the tubular assembly prior to the
radial expansion
and plastic deformation. In an exemplary embodiment, the anisotropy of the
predetermined
101
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
portion of the tubular assembly, prior to the radial expansion and plastic
deformation, is at
least about 1.04. In an exemplary embodiment, the anisotropy of the
predetermined portion
of the tubular assembly, prior to the radial expansion and plastic
deformation, is at least
about 1.92. In an exemplary embodiment, the anisotropy of the predetermined
portion of the
tubular assembly, prior to the radial expansion and plastic deformation, is at
least about
1.34. In an exemplary embodiment, the anisotropy of the predetermined portion
of the
tubular assembly, prior to the radial expansion and plastic deformation,
ranges from about
1.04 to about 1.92. In an exemplary embodiment, the yield point of the
predetermined
portion of the tubular assembly, prior to the radial expansion and plastic
deformation, ranges
from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the
expandability
coefficient of the predetermined portion of the tubular assembly, prior to the
radial expansion
and plastic deformation, is greater than 0.12. In an exemplary embodiment, the
expandability coefficient of the predetermined portion of the tubular assembly
is greater than
the expandability coefficient of the other portion of the tubular assembly. In
an exemplary
embodiment, the tubular assembly comprises a wellbore casing. In an exemplary
embodiment, the tubular assembly comprises a pipeline. In an exemplary
embodiment, the
tubular assembly comprises a structural support.
[00405] A method of joining radially expandable tubular members has been
described
that includes: providing a first tubular member; engaging a second tubular
member with the
first tubular member to form a joint; providing a sleeve having opposite
tapered ends and a
flange, one of the tapered ends being a surface formed on the flange; mounting
the sleeve
for overlapping and coupling the first and second tubular members at the
joint, wherein the
flange is engaged in a recess formed in an adjacent one of the tubular
members; wherein
the first tubular member, the second tubular member, and the sleeve define a
tubular
assembly; and radially expanding and plastically deforming the tubular
assembly; wherein,
prior to the radial expansion and plastic deformation, ~a predetermined
portion of the tubular
assembly has a lower yield point than another portion of the tubular assembly.
In an
exemplary embodiment, the method further includes: providing a tapered wall in
the recess
for mating engagement with the tapered end formed on the flange. In an
exemplary
embodiment, the method further includes: providing a flange at each tapered
end wherein
each tapered end is formed on a respective flange. In an exemplary embodiment,
the
method further includes: providing a recess in each tubular member. In an
exemplary
embodiment, the method further includes: engaging each flange in a respective
one of the
recesses. In an exemplary embodiment, the method further includes: providing a
tapered
wall in each recess for mating engagement with the tapered end formed on a
respective one
of the flanges. In an exemplary embodiment, the predetermined portion of the
tubular
assembly has a higher ductility and a lower yield point prior to the radial
expansion and
102
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
plastic deformation than after the radial expansion and plastic deformation.
In an exemplary
embodiment, the predetermined portion of the tubular assembly has a higher
ductility prior to
the radial expansion and plastic deformation than after the radial expansion
and plastic
deformation. In an exemplary embodiment, the predetermined portion of the
tubular
assembly has a lower yield point prior to the radial expansion and plastic
deformation than
after the radial expansion and plastic deformation. In an exemplary
embodiment, the
predetermined portion of the tubular assembly has a larger inside diameter
after the radial
expansion and plastic deformation than the other portion of the tubular
assembly. In an
exemplary embodiment, the method further includes: positioning another tubular
assembly
within the preexisting structure in overlapping relation to the tubular
assembly; and radially
expanding and plastically deforming the other tubular assembly within the
preexisting
structure; wherein, prior to the radial expansion and plastic deformation of
the tubular
assembly, a predetermined portion of the other tubular assembly has a lower
yield point than
another portion of the other tubular assembly. In an exemplary embodiment, the
inside
diameter of the radially expanded and plastically deformed other portion of
the tubular
assembly is equal to the inside diameter of the radially expanded and
plastically deformed
other portion of the other tubular assembly. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises an end portion of the
tubular
assembly. In an exemplary embodiment, the predetermined portion of the tubular
assembly
comprises a plurality of predetermined portions of the tubular assembly. In an
exemplary
embodiment, the predetermined portion of the tubular assembly comprises a
plurality of
spaced apart predetermined portions of the tubular assembly. In an exemplary
embodiment,
the other portion of the tubular assembly comprises an end portion of the
tubular assembly.
In an exemplary embodiment, the other portion of the tubular assembly
comprises a plurality
of other portions of the tubular assembly. In an exemplary embodiment, the
other porfiion of
the tubular assembly comprises a plurality of spaced apart other portions of
the tubular
assembly. In an exemplary embodiment, the tubular assembly comprises a
plurality of
tubular members coupled to one another by corresponding tubular couplings. In
an
exemplary embodiment, the tubular couplings comprise the predetermined
portions of the
tubular assembly; and wherein the tubular members comprise the other portion
of the tubular
assembly. In an exemplary embodiment, one or more of the tubular couplings
comprise the
predetermined portions of the tubular assembly. In an exemplary embodiment,
one or more
of the tubular members comprise the predetermined portions of the tubular
assembly. In an
exemplary embodiment, the predetermined portion of the tubular assembly
defines one or
more openings. In an exemplary embodiment, one or more of the openings
comprise slots.
In an exemplary embodiment, the anisotropy for the predetermined portion of
the tubular
assembly is greater than 1. In an exemplary embodiment, the anisotropy for the
103
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
predetermined portion of the tubular assembly is greater than 1. In an
exemplary
embodiment, the strain hardening exponent for the predetermined portion of the
tubular
assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for
the
predetermined portion of the tubular assembly is greater than 1; and wherein
the strain
hardening exponent for the predetermined portion of the tubular assembly is
greater than
0.12. In an exemplary embodiment, the predetermined portion of the tubular
assembly
comprises a first steel alloy comprising: 0.065 % C, 1.44 % Mn, 0.01 % P,
0.002 % S, 0.24
Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr. In an exemplary embodiment, the yield
point of
the predetermined portion of the tubular assembly is at most about 46.9 ksi
prior to the radial
expansion and plastic deformation; and wherein the yield point of the
predetermined portion
of the tubular assembly is at least about 65.9 ksi after the radial expansion
and plastic
deformation. In an exemplary embodiment, the yield point of the predetermined
portion of
the tubular assembly after the radial expansion and plastic deformation is at
least about 40
greater than the yield point of the predetermined portion of the tubular
assembly prior to
the radial expansion and plastic deformation. In an exemplary embodiment, the
anisotropy
of the predetermined portion of the tubular assembly, prior to the radial
expansion and
plastic deformation, is about 1.48. In an exemplary embodiment, the
predetermined portion
of the tubular assembly comprises a second steel alloy comprising: 0.18 % C,
1.28 % Mn,
0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr. In an
exemplary
embodiment, the yield point of the predetermined portion of the tubular
assembly is at most
about 57.8 ksi prior to the radial expansion and plastic deformation; and
wherein the yield
point of the predetermined portion of the tubular assembly is at least about
74.4 ksi after the
radial expansion and plastic deformation. In an exemplary embodiment, the
yield point of
the predetermined portion of the tubular assembly after the radial expansion
and plastic
deformation is at feast about 28 % greater than the yield point of the
predetermined portion
of the tubular assembly prior to the radial expansion and plastic deformation.
In an
exemplary embodiment, the anisotropy of the predetermined portion of the
tubular assembly,
prior to the radial expansion and plastic deformation, is about 1.04. In an
exemplary
embodiment, the predetermined portion of the tubular assembly comprises a
third steel alloy
comprising: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu,
0.05 % Ni,
and 0.05 % Cr. In an exemplary embodiment, the anisotropy of the predetermined
portion of
the tubular assembly, prior to the radial expansion and plastic deformation,
is about 1.92. In
an exemplary embodiment, the predetermined portion of the tubular assembly
comprises a
fourth steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45
% Si, 9.1
Ni, and 18.7 % Cr. In an exemplary embodiment, the anisotropy of the
predetermined
portion of the tubular assembly, prior to the radial expansion and plastic
deformation, is
about 1.34. In an exemplary embodiment, the yield point of the predetermined
portion of the
104
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
tubular assembly is at most about 46.9 ksi prior to the radial expansion and
plastic
deformation; and wherein the yield point of the predetermined portion of the
tubular
assembly is at least about 65.9 ksi after the radial expansion and plastic
deformation. In an
exemplary embodiment, the yield point of the predetermined portion of the
tubular assembly
after the radial expansion and plastic deformation is at least about 40 %
greater than the
yield point of the predetermined portion of the tubular assembly prior to the
radial expansion
and plastic deformation. In an exemplary embodiment, the anisotropy of the
predetermined
portion of the tubular assembly, prior to the radial expansion and plastic
deformation, is at
least about 1.48. In an exemplary embodiment, the yield point of the
predetermined portion
of the tubular assembly is at most about 57.8 ksi prior to the radial
expansion and plastic
deformation; and wherein the yield point of the predetermined portion of the
tubular
assembly is at least about 74.4 ksi after the radial expansion and plastic
deformation. In an
exemplary embodiment, the yield point of the predetermined portion of the
tubular assembly
after the radial expansion and plastic deformation is at least about 28 %
greater than the
yield point of the predetermined portion of the tubular assembly prior to the
radial expansion
and plastic deformation. In an exemplary embodiment, the anisotropy of the
predetermined
portion of the tubular assembly, prior to fihe radial expansion and plastic
deformation, is at
least about 1.04. In an exemplary embodiment, the anisotropy of the
predetermined portion
of the tubular assembly, prior to the radial expansion and plastic
deformation, is at least
about 1.92. In an exemplary embodiment, the anisotropy of the predetermined
portion of the
tubular assembly, prior to the radial expansion and plastic deformation, is at
least about
1.34. In an exemplary embodiment, the anisotropy of the predetermined portion
of the
tubular assembly, prior to the radial expansion and plastic deformation,
ranges from about
1.04 to about 1.92. In an exemplary embodiment, the yield point of the
predetermined
portion of the tubular assembly, prior to the radial expansion and plastic
deformation, ranges
from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the
expandability
coefficient of the predetermined portion of the tubular assembly, prior to the
radial expansion
and plastic deformation, is greater than 0.12. In an exemplary embodiment, the
expandability coefficient of the predetermined portion of the tubular assembly
is greater than
the expandability coefficient of the other portion of the tubular assembly. In
an exemplary
embodiment, the tubular assembly comprises a wellbore casing. In an exemplary
embodiment, the tubular assembly comprises a pipeline. In an exemplary
embodiment, the
tubular assembly comprises a structural support.
[00406] An expandable tubular assembly has been described that includes a
first
tubular member; a second tubular member coupled to the first tubular member; a
first
threaded connection for coupling a portion of the first and second tubular
members; a
second threaded connection spaced apart from the first threaded connection for
coupling
105
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
another portion of the first and second tubular members; a tubular sleeve
coupled to and
receiving end portions of the first and second tubular members; and a sealing
element
positioned between the first and second spaced apart threaded connections for
sealing an
interface between the first and second tubular member; wherein the sealing
element is
positioned within an annulus defined between the first and second tubular
members; and
wherein, prior to a radial expansion and plastic deformation of the assembly,
a
predetermined portion of the assembly has a lower yield point than another
portion of the
apparatus. In an exemplary embodiment, the predetermined portion of the
assembly has a
higher ductility and a lower yield point prior to the radial expansion and
plastic deformation
than after the radial expansion and plastic deformation. In an exemplary
embodiment, the
predetermined portion of the assembly has a higher ductility prior to the
radial expansion and
plastic deformation than after the radial expansion and plastic deformation.
In an exemplary
embodiment, the predetermined portion of the assembly has a lower yield point
prior to the
radial expansion and plastic deformation than after the radial expansion and
plastic
deformation. In an exemplary embodiment, the predetermined portion of the
assembly has a
larger inside diameter after the radial expansion and plastic deformation than
other portions
of the tubular assembly. In an exemplary embodiment, the assembly further
includes:
positioning another assembly within the preexisting structure in overlapping
relation to the
assembly; and radially expanding and plastically deforming the other assembly
within the
preexisting structure; wherein, prior to the radial expansion and plastic
deformation of the
assembly, a predetermined portion of the other assembly has a lower yield
point than
another portion of the other assembly. In an exemplary embodiment, the inside
diameter of
the radially expanded and plastically deformed other portion of the assembly
is equal to the
inside diameter of the radially expanded and plastically deformed other
portion of the other
assembly. In an exemplary embodiment, the predetermined portion of the
assembly
comprises an end portion of the assembly. In an exemplary embodiment, the
predetermined
portion of the assembly comprises a plurality of predetermined portions of the
assembly. In
an exemplary embodiment, the predetermined portion of the assembly comprises a
plurality
of spaced apart predetermined portions of the assembly. In an exemplary
embodiment, the
other portion of the assembly comprises an end portion of the assembly. In an
exemplary
embodiment, the other portion of the assembly comprises a plurality of other
portions of the
assembly. in an exemplary embodiment, the other portion of the assembly
comprises a
plurality of spaced apart other portions of the assembly. In an exemplary
embodiment, the
assembly comprises a plurality of tubular members coupled to one another by
corresponding
tubular couplings. In an exemplary embodiment, the tubular couplings comprise
the
predetermined portions of the assembly; and wherein the tubular members
comprise the
other portion of the assembly. In an exemplary embodiment, one or more of the
tubular
106
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
couplings comprise the predetermined portions of the assembly. In an exemplary
embodiment, one or more of the tubular members comprise the predetermined
portions of
the assembly. In an exemplary embodiment, the predetermined portion of the
assembly
defines one or more openings. In an exemplary embodiment, one or more of the
openings
comprise slots. In an exemplary embodiment, the anisotropy for the
predetermined portion
of the assembly is greater than 1. In an exemplary embodiment, the anisotropy
for the
predetermined portion of the assembly is greater than 1. In an exemplary
embodiment, the
strain hardening exponent for the predetermined portion of the assembly is
greater than
0.12. In an exemplary embodiment, the anisotropy for the predetermined portion
of the
assembly is greater than 1; and wherein the strain hardening exponent for the
predetermined portion of the assembly is greater than 0.12. In an exemplary
embodiment,
the predetermined portion of the assembly comprises a first steel alloy
comprising: 0.065
C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si, 0.01 % Cu, 0.01 % Ni, and 0.02 %
Cr. In an
exemplary embodiment, the yield point of the predetermined portion of the
assembly is at
most about 46.9 ksi prior to the radial expansion and plastic deformation; and
wherein the
yield point of the predetermined portion of the assembly is at feast about
65.9 ksi affier the
radial expansion and plastic deformation. In an exemplary embodiment, the
yield point of
the predetermined portion of the assembly after the radial expansion and
plastic deformation
is at least about 40 % greater than the yield point of the predetermined
portion of the
assembly prior to the radial expansion and plastic deformation. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the assembly, prior
to the radial
expansion and plastic deformation, is about 1.48. In an exemplary embodiment,
the
predetermined portion of the assembly comprises a second steel alloy
comprising: 0.18 % C,
1.28%Mn,0.017%P,0.004%S,0.29%Si,0.01 %Cu,0.01 %Ni,and0.03%Cr. In an
exemplary embodiment, the yield point of the predetermined portion of the
assembly is at
most about 57.8 ksi prior to the radial expansion and plastic deformation; and
wherein the
yield point of the predetermined portion of the assembly is at least about
74.4 ksi after the
radial expansion and plastic deformation. In an exemplary embodiment, the
yield point of
the predetermined portion of the assembly after the radial expansion and
plastic deformation
is at least about 28 % greater than the yield point of the predetermined
portion of the
assembly prior to the radial expansion and plastic deformation. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the assembly, prior
to the radial
expansion and plastic deformation, is about 1.04. In an exemplary embodiment,
the
predetermined portion of the assembly comprises a third steel alloy
comprising: 0.08 % C,
0.82%Mn,0.006%P,0.003%S,0.30%Si,0.16%Cu,0.05%Ni,and0.05%Cr.lnan
exemplary embodiment, the anisotropy of the predetermined portion of the
assembly, prior to
the radial expansion and plastic deformation, is about 1.92. In an exemplary
embodiment,
107
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
the predetermined portion of the assembly comprises a fourth steel alloy
comprising: 0.02 °lo
C, 1.31 % Mn, 0.02 % P, 0.001 % S; 0.45 % Si, 9.1 % Ni, and 18.7 % Cr. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the assembly, prior
to the radial
expansion and plastic deformation, is about 1.34. In an exemplary embodiment,
the yield
point of the predetermined portion of the assembly is at most about 46.9 ksi
prior to the
radial expansion and plastic deformation; and wherein the yield point of the
predetermined
portion of the assembly is at least about 65.9 ksi after the radial expansion
and plastic
deformation. In an exemplary embodiment, the yield point of the predetermined
portion of
the assembly after the radial expansion and plastic deformation is at least
about 40
greater than the yield point of the predetermined portion of the assembly
prior to the radial
expansion and plastic deformation. In an exemplary embodiment, the anisotropy
of the
predetermined portion of the assembly, prior to the radial expansion and
plastic deformation,
is at least about 1.48. In an exemplary embodiment, the yield point of the
predetermined
portion of the assembly is at most about 57.8 ksi prior to the radial
expansion and plastic
deformation; and wherein the yield point of the predetermined portion of the
assembly is at
least about 74.4 ksi after the radial expansion and plastic deformation. In an
exemplary
embodiment, the yield point of the predetermined portion of the assembly after
the radial
expansion and plastic deformation is at least about 28 % greater than the
yield point of the
predetermined portion of the assembly prior to the radial expansion and
plastic deformation.
In an exemplary embodiment, the anisotropy of the predetermined portion of the
assembly,
prior to the radial expansion and plastic deformation, is at least about 1.04.
In an exemplary
embodiment, the anisotropy of the predetermined portion of the assembly, prior
to the radial
expansion and plastic deformation, is at feast about 1.92. fn an exemplary
embodiment, the
anisotropy of the predetermined portion of the assembly, prior to the radial
expansion and
plastic deformation, is at least about 1.34. In an exemplary embodiment, the
anisotropy of
the predetermined portion of the assembly, prior to the radial expansion and
plastic
deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment,
the yield
point of the predetermined portion of the assembly, prior to the radial
expansion and plastic
deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary
embodiment, the
expandability coefficient of the predetermined portion of the assembly, prior
to the radial
expansion and plastic deformation, is greater than 0.12. In an exemplary
embodiment, the
expandability coefficient of the predetermined portion of the assembly is
greater than the
expandability coefficient of the other portion of the assembly. In an
exemplary embodiment,
the assembly comprises a wefibore casing. In an exemplary embodiment, the
assembly
comprises a pipeline. In an exemplary embodiment, the assembly comprises a
structural
support. In an exemplary embodiment, the annulus is at least partially defined
by an
irregular surface. fn an exemplary embodiment, the annulus is at least
partially defined by a
108
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
toothed surface. In an exemplary embodiment, the sealing element comprises an
elastomeric material. In an exemplary embodiment, the sealing element
comprises a
metallic material. In an exemplary embodiment, the sealing element comprises
an
elastomeric and a metallic material.
[00407] A method of joining radially expandable tubular members is provided
that
includes providing a first tubular member; providing a second tubular member;
providing a
sleeve; mounting the sleeve for overlapping and coupling the first and second
tubular
members; threadably coupling the first and second tubular members at a first
location;
threadably coupling the first and second tubular members at a second location
spaced apart
from the first location; sealing an interface between the first and second
tubular members
between the first and second locations using a compressible sealing element,
wherein the
first tubular member, second tubular member, sleeve, and the sealing element
define a
tubular assembly; and radially expanding and plastically deforming the tubular
assembly;
wherein, prior to the radial expansion and plastic deformation, a
predetermined portion of the
tubular assembly has a lower yield point than another portion of the tubular
assembly. In an
exemplary embodiment, the sealing element includes an irregular surface. In an
exemplary
embodiment, the sealing element includes a toothed surface. In an exemplary
embodiment,
the sealing element comprises an elastomeric material. In an exemplary
embodiment, the
sealing element comprises a metallic material. In an exemplary embodiment, the
sealing
element comprises an elastomeric and a metallic material. In an exemplary
embodiment,
the predetermined portion of the tubular assembly has a higher ductility and a
lower yield
point prior to the radial expansion and plastic deformation than after the
radial expansion
and plastic deformation. In an exemplary embodiment, the predetermined portion
of the
tubular assembly has a higher ductility prior to the radial expansion and
plastic deformation
than after the radial expansion and plastic deformation. In an exemplary
embodiment, the
predetermined portion of the tubular assembly has a lower yield point prior to
the radial
expansion and plastic deformation than after the radial expansion and plastic
deformation.
In an exemplary embodiment, the predetermined portion of the tubular assembly
has a
larger inside diameter after the radial expansion and plastic deformation than
the other
portion of the tubular assembly. In an exemplary embodiment, the method
further includes:
positioning another tubular assembly within the preexisting structure in
overlapping relation
to the tubular assembly; and radially expanding and plastically deforming the
other tubular
assembly within the preexisting structure; wherein, prior to the radial
expansion and plastic
deformation of the tubular assembly, a predetermined portion of the other
tubular assembly
has a lower yield point than another portion of the other tubular assembly. In
an exemplary
embodiment, the inside diameter of the radially expanded and plastically
deformed other
portion of the tubular assembly is equal to the inside diameter of the
radially expanded and
109
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
plastically deformed other portion of the other tubular assembly. In an
exemplary
embodiment, the predetermined portion of the tubular assembly comprises an end
portion of
the tubular assembly. In an exemplary embodiment, the predetermined portion of
the
tubular assembly comprises a plurality of predetermined portions of the
tubular assembly. In
an exemplary embodiment, the predetermined portion of the tubular assembly
comprises a
plurality of spaced apart predetermined portions of the tubular assembly. In
an exemplary
embodiment, the other portion of the tubular assembly comprises an end portion
of the
tubular assembly. In an exemplary embodiment, the other portion of the tubular
assembly
comprises a plurality of other portions of the tubular assembly. In an
exemplary
embodiment, the other portion of the tubular assembly comprises a plurality of
spaced apart
other portions of the tubular assembly. In an exemplary embodiment, the
tubular assembly
comprises a plurality of tubular members coupled to one another by
corresponding tubular
couplings. in an exemplary embodiment, the tubular couplings comprise the
predetermined
portions of the tubular assembly; and wherein the tubular members comprise the
other
portion of the tubular assembly. In an exemplary embodiment, one or more of
the tubular
couplings comprise the predetermined portions of the tubular assembly. In an
exemplary
embodiment, one or more of the tubular members comprise the predetermined
portions of
the tubular assembly. In an exemplary embodiment, the predetermined portion of
the
tubular assembly defines one or more openings. in an exemplary embodiment, one
or more
of the openings comprise slots. In an exemplary embodiment, the anisotropy for
the
predetermined portion of the tubular assembly is greater than 1. In an
exemplary
embodiment, the anisotropy for the predetermined portion of the tubular
assembly is greater
than 1. In an exemplary embodiment, the strain hardening exponent for the
predetermined
portion of the tubular assembly is greater than 0.12. In an exemplary
embodiment, the
anisotropy for the predetermined portion of the tubular assembly is greater
than 1; and
wherein the strain hardening exponent for the predetermined portion of the
tubular assembly
is greater than 0.12. In an exemplary embodiment, the predetermined portion of
the tubular
assembly comprises a first steel alloy comprising: 0.065 % C, 1.44 % Mn, 0.01
% P, 0.002
S, 0.24 % Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr. In an exemplary embodiment,
the yield
point of the predetermined portion of the tubular assembly is at most about
46.9 ksi prior to
the radial expansion and plastic deformation; and wherein the yield point of
the
predetermined portion of the tubular assembly is at least about 65.9 ksi after
the radial
expansion and plastic deformation. 1n an exemplary embodiment, the yield point
of the
predetermined portion of the tubular assembly after the radial expansion and
plastic
deformation is at least about 40 % greater than the yield point of the
predetermined portion
of the tubular assembly prior to the radial expansion and plastic deformation.
In an
exemplary embodiment, the anisotropy of the predetermined portion of the
tubular assembly,
110
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
prior to the radial expansion and plastic deformation, is about 1.48. In an
exemplary
embodiment, the predetermined portion of the tubular assembly comprises a
second steel
alloy comprising: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 % St, 0.01 %
Cu, 0.01
Ni, and 0.03 % Cr. In an exemplary embodiment, the yield point of the
predetermined
portion of the tubular assembly is at most about 57.8 ksi prior to the radial
expansion and
plastic deformation; and wherein the yield point of the predetermined portion
of the tubular
assembly is at least about 74.4 ksi after the radial expansion and plastic
deformation. In an
exemplary embodiment, the yield point of the predetermined portion of the
tubular assembly
after the radial expansion and plastic deformation is at least about 28 %
greater than the
yield point of the predetermined portion of the tubular assembly prior to the
radial expansion
and plastic deformation. In an exemplary embodiment, the anisotropy of the
predetermined
portion of the tubular assembly, prior to the radial expansion and plastic
deformation, is
about 1.04. In an exemplary embodiment, the predetermined portion of the
tubular
assembly comprises a third steel alloy comprising: 0.08 % C, 0.82 % Mn, 0.006
% P, 0.003
S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr. In an exemplary embodiment,
the
anisotropy of the predetermined portion of the tubular assembly, prior to the
radial expansion
and plastic deformation, is about 1.92. In an exemplary embodiment, the
predetermined
portion of the tubular assembly comprises a fourth steel alloy comprising:
0.02 % C, 1.31
Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr. In an exemplary
embodiment, the anisotropy of the predetermined portion of the tubular
assembly, prior to
the radial expansion and plastic deformation, is about 1.34. In an exemplary
embodiment,
the yield point of the predetermined portion of the tubular assembly is at
most about 46.9 ksi
prior to the radial expansion and plastic deformation; and wherein the yield
point of the
predetermined portion of the tubular assembly is at least about 65.9 ksi after
the radial
expansion and plastic deformation. In an exemplary embodiment, the yield point
of the
predetermined portion of the tubular assembly after the radial expansion and
plastic
deformation is at least about 40 % greater than the yield point of the
predetermined portion
of the tubular assembly prior to the radial expansion and plastic deformation.
In an
exemplary embodiment, the anisotropy of the predetermined portion of the
tubular assembly,
prior to the radial expansion and plastic deformation, is at least about 1.48.
In an exemplary
embodiment, the yield point of the predetermined portion of the tubular
assembly is at most
about 57.8 ksi prior to the radial expansion and plastic deformation; and
wherein the yield
point of the predetermined portion of the tubular assembly is at least about
74.4 ksi after the
radial expansion and plastic deformation. In an exemplary embodiment, the
yield point of
the predetermined portion of the tubular assembly after the radial expansion
and plastic
deformation is at least about 28 % greater than the yield point of the
predetermined portion
of the tubular assembly prior to the radial expansion and plastic deformation.
In an
111
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
exemplary embodiment, the anisotropy of the predetermined portion of the
tubular assembly,
prior to the radial expansion and plastic deformation, is at least about 1.04.
In an exemplary
embodiment, the anisotropy of the predetermined portion of the tubular
assembly, prior to
the radial expansion and plastic deformation, is at least about 1.92. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the tubular
assembly, prior to
the radial expansion and plastic deformation, is at least about 1.34. In an
exemplary
embodiment, the anisotropy of the predetermined portion of the tubular
assembly, prior to
the radial expansion and plastic deformation, ranges from about 1.04 to about
1.92. In an
exemplary embodiment, the yield point of the predetermined portion of the
tubular assembly,
prior to the radial expansion and plastic deformation, ranges from about 47.6
ksi to about
61.7 ksi. In an exemplary embodiment, the expandability coefficient of the
predetermined
portion of the tubular assembly, prior to the radial expansion and plastic
deformation, is
greater than 0.12. In an exemplary embodiment, the expandability coefficient
of the
predetermined portion of the tubular assembly is greater than the
expandability coefficient of
the other portion of the tubular assembly. In an exemplary embodiment, the
tubular
assembly comprises a wellbore casing. In an exemplary embodiment, the tubular
assembly
comprises a pipeline. !n an exemplary embodiment, the tubular assembly
comprises a
structural support. In an exemplary embodiment, the sleeve comprises: a
plurality of spaced
apart tubular sleeves coupled to and receiving end portions of the first and
second tubular
members. In an exemplary embodiment, the first tubular member comprises a
first threaded
connection; wherein the second tubular member comprises a second threaded
connection;
wherein the first and second threaded connections are coupled to one another;
wherein at
least one of the tubular sleeves is positioned in opposing relation to the
first threaded
connection; and wherein at least one of the tubular sleeves is positioned in
opposing relation
to the second threaded connection. In an exemplary embodiment, the first
tubular member
comprises a first threaded connection; wherein the second tubular member
comprises a
second threaded connection; wherein the first and second threaded connections
are coupled
to one another; and wherein at least one of the tubular sleeves is not
positioned in opposing
relation to the first and second threaded connections. In an exemplary
embodiment, the
carbon content of the tubular member is less than or equal to 0.12 percent;
and wherein the
carbon equivalent value for the tubular member is less than 0.21. In an
exemplary
embodiment, the tubular member comprises a wellbore casing.
[00408] An expandable tubular member has been described, wherein the carbon
content of the tubular member is greater than 0.12 percent; and wherein the
carbon
equivalent value for the tubular member is less than 0.36. In an exemplary
embodiment, the
tubular member comprises a wellbore casing.
112
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00409] A method of selecting tubular members for radial expansion and plastic
deformation has been described that includes: selecting a tubular member from
a collection
of tubular member; determining a carbon content of the selected tubular
member;
determining a carbon equivalent value for the selected tubular member; and if
the carbon
content of the selected tubular member is less than or equal to 0.12 percent
and the carbon
equivalent value for the selected tubular member is less than 0.21, then
determining that the
selected tubular member is suitable for radial expansion and plastic
deformation.
[00410] A method of selecting tubular members for radial expansion and plastic
deformation has been described that includes: selecting a tubular member from
a collection
of tubular member; determining a carbon content of the selected tubular
member;
determining a carbon equivalent value for the selected tubular member; and if
the carbon
content of the selected tubular member is greater than 0.12 percent and the
carbon
equivalent value for the selected tubular member is less than 0.36, then
determining that the
selected tubular member is suitable for radial expansion and plastic
deformation.
[00411] . An expandable tubular member has been described that includes: a
tubular
body; wherein a yield point of an inner tubular portion of the tubular body is
less than a yield
point of an outer tubular portion of the tubular body. In an exemplary
embodiment, the yield
point of the inner tubular portion of the tubular body varies as a function of
the radial position
within the tubular body. In an exemplary embodiment, the yield point of the
inner tubular
portion of the tubular body varies in an linear fashion as a function of the
radial position
within the tubular body. In an exemplary embodiment, the yield point of the
inner tubular
portion of the tubular body varies in an non-linear fashion as a function of
the radial position
within the tubular body. In an exemplary embodiment, the yield point of the
outer tubular
portion of the tubular body varies as a function of the radial position within
the tubular body.
In an exemplary embodiment, the yield point of the outer tubular portion of
the tubular body
varies in an linear fashion as a function of the radial position within the
tubular body. In an
exemplary embodiment, the yield point of the outer tubular portion of the
tubular body varies
in an non-linear fashion as a function of the radial position within the
tubular body. In an
exemplary embodiment, the yield point of the inner tubular portion of the
tubular body varies
as a function of the radial position within the tubular body; and wherein the
yield point of the
outer tubular portion of the tubular body varies as a function of the radial
position within the
tubular body. In an exemplary embodiment, the yield point of the inner tubular
portion of the
tubular body varies in a linear fashion as a function of the radial position
within the tubular
body; and wherein the yield point of the outer tubular portion of the tubular
body varies in a
linear fashion as a function of the radial position within the tubular body.
In an exemplary
embodiment, the yield point of the inner tubular portion of the tubular body
varies in a linear
fashion as a function of the radial position within the tubular body; and
wherein the yield
113
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
point of the outer tubular portion of the tubular body varies in a non-linear
fashion as a
function of the radial position within the tubular body. In an exemplary
embodiment, the yield
point of the inner tubular portion of the tubular body varies in a non-linear
fashion as a
function of the radial position within the tubular body; and wherein the yield
point of the outer
tubular portion of the tubular body varies in a linear fashion as a function
of the radial
position within the tubular body. In an exemplary embodiment, the yield point
of the inner
tubular portion of the tubular body varies in a non-linear fashion as a
function of the radial
position within the tubular body; and wherein the yield point of the outer
tubular portion of the
tubular body varies in a non-linear fashion as a function of the radial
position within the
tubular body. In an exemplary embodiment, the rate of change of the yield
point of the inner
tubular portion of the tubular body is different than the rate of change of
the yield point of the
outer tubular portion of the tubular body. In an exemplary embodiment, the
rate of change of
the yield point of the inner tubular portion of the tubular body is different
than the rate of
change of the yield point of the outer tubular portion of the tubular body.
[00412] A method of manufacturing an expandable tubular member has been
described that includes: providing a tubular member; heat treating the tubular
member; and
quenching the tubular member; wherein following the quenching, the tubular
member
comprises a microstructure comprising a hard phase structure and a soft phase
structure. In
an exemplary embodiment, the provided tubular member comprises, by weight
percentage,
0.065% C, 1.44% Mn, 0.01 % P, 0.002% S, 0.24% Si, 0.01 % Cu, 0.01 % NI, 0.02%
Cr, 0.05%
V, 0.01 % Mo, 0.01 % Nb, and 0.01 %Ti. In an exemplary embodiment, the
provided tubular
member comprises, by weight percentage, 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,
0.29% Si, 0.01 % Cu, 0.01 % Ni, 0.03% Cr, 0.04% V, 0.01 % Mo, 0.03% Nb, and
0.01 %Ti. In
an exemplary embodiment, the provided tubular member comprises, by weight
percentage,
0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr,
0.03%
V, 0.03% Mo, 0.01 % Nb, and 0.01 %Ti. In an exemplary embodiment, the provided
tubular
member comprises a microstructure comprising one or more of the following:
martensite,
pearlite, vanadium carbide, nickel carbide, or titanium carbide. In an
exemplary
embodiment, the provided tubular member comprises a microstructure comprising
one or
more of the following: pearlite or pearlite striation. In an exemplary
embodiment, the
provided tubular member comprises a microstructure comprising one or more of
the
following: grain pearlite, widmanstatten martensite, vanadium carbide, nickel
carbide, or
titanium carbide. In an exemplary embodiment, the heat treating comprises
heating the
provided tubular member for about 10 minutes at 790 °C. In an exemplary
embodiment, the
quenching comprises quenching the heat treated tubular member in water. In an
exemplary
embodiment, following the quenching, the tubular member comprises a
microstructure
comprising one or more of the following: ferrite, grain pearlite, or
martensite. In an
114
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
exemplary embodiment, following the quenching, the tubular member comprises a
microstructure comprising one or more of the following: ferrite, martensite,
or bainite. In an
exemplary embodiment, following the quenching, the tubular member comprises a
microstructure comprising one or more of the following: bainite, pearlite, or
ferrite. In an
exemplary embodiment, following the quenching, the tubular member comprises a
yield
strength of about 67ksi and a tensile strength of about 95 ksi. In an
exemplary embodiment,
following the quenching, the tubular member comprises a yield strength of
about 82 ksi and
a tensile strength of about 130 ksi. In an exemplary embodiment, following the
quenching,
the tubular member comprises a yield strength of about 60 ksi and a tensile
strength of
about 97 ksi. In an exemplary embodiment, the method further includes:
positioning the
quenched tubular member within a preexisting structure; and radially expanding
and
plastically deforming the tubular member within the preexisting structure.
[00413] An expandable tubular member has been described that includes: a steel
alloy comprising: 0.07% Carbon, 1.64% Manganese, 0.011 % Phosphor, 0.001 %
Sulfur,
0.23% Silicon, 0.5%Nickel, 0.51 % Chrome, 0.31 % Molybdenum, 0.15% Copper,
0.021
Aluminum, 0.04% Vanadium, 0.03% Niobium, and 0.007% Titanium.
[00414] An expandable tubular member has been described that includes: a
collapse
strength of approximately 70 ksi and comprising: 0.07% Carbon, 1.64%
Manganese, 0.011
Phosphor, 0.001 % Sulfur, 0.23% Silicon, 0.5%Nickel, 0.51 % Chrome, 0.31 %
Molybdenum,
0.15% Copper, 0.021 % Aluminum, 0.04% Vanadium, 0.03% Niobium, and 0.007%
Titanium, wherein, upon radial expansion and plastic deformation, the collapse
strength
increases to approximately 110 ksi.
[00415] An expandable tubular member has been described that includes: an
outer
surface and means for increasing the collapse strength of a tubular assembly
when the
expandable tubular member is radially expanded and plastically deformed
against a
preexisting structure, the means coupled to the outer surface. In an exemplary
embodiment,
the means comprises a coating comprising a soft metal. In an exemplary
embodiment, the
means comprises a coating comprising aluminum. In an exemplary embodiment, the
means
comprises a coating comprising aluminum and zinc. In an exemplary embodiment,
the
means comprises a coating comprising plastic. In an exemplary embodiment, the
means
comprises a material wrapped around the outer surface of the tubular member.
In an
exemplary embodiment, the material comprises a soft metal. In an exemplary
embodiment,
the material comprises aluminum. !n an exemplary embodiment, the means
comprises a
coating of varying thickness. In an exemplary embodiment, the means comprises
a non
uniform coating. In an exemplary embodiment, the means comprises a coating
having
multiple layers. In an exemplary embodiment, the multiple layers are selected
from the
group consisting of a soft metal, a plastic, a composite material, and
combinations thereof.
115
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00476] A preexisting structure for accepting an expandable tubular member has
been
described that includes; a passage defined by the structure, an inner surface
on the passage
and means for increasing the collapse strength of a tubular assembly when an
expandable
tubular member is radially expanded and plastically deformed against the
preexisting
structure, the means coupled to the inner surface. In an exemplary embodiment,
the means
comprises a coating comprising a soft metal. In an exemplary embodiment, the
means
comprises a coating comprising aluminum. In an exemplary embodiment, the
coating
comprises aluminum and zinc. In an exemplary embodiment, the means comprises a
coating comprising a plastic. In an exemplary embodiment, the means comprises
a coating
comprising a material lining the inner surface of the tubular member. In an
exemplary
embodiment, the material comprises a soft metal. In an exemplary embodiment,
the
material comprises aluminum. In an exemplary embodiment, the means comprises a
coating of varying thickness. fn an exemplary embodiment, the means comprises
a non
uniform coating. In an exemplary embodiment, the means comprises a coating
having
multiple layers. In an exemplary embodiment, the multiple layers are selected
from the
group consisting of a soft metal, a plastic, a composite material, and
combinations thereof.
[004'17] An expandable tubular assembly has been described that includes: a
structure defining a passage therein, an expandable tubular member positioned
in the
passage and means for increasing the coNapse strength of the assembly when the
expandable tubular member is radially expanded and plastically deformed
against the
structure, the means positioned between the expandable tubular member and the
structure.
In an exemplary embodiment, the structure comprises a wellbore casing. In an
exemplary
embodiment, the structure comprises a tubular member. In an exemplary
embodiment, the
means comprises an interstitial layer comprising a soft metal. (n an exemplary
embodiment,
the means comprises an interstitial layer comprising aluminum. In an exemplary
embodiment, the means comprises an interstitial layer comprising aluminum and
zinc. In an
exemplary embodiment, the means comprises an interstitial layer comprising a
plastic. In an
exemplary embodiment, the means comprises an interstitial layer comprising a
material
wrapped around an outer surface of the expandable tubular member. In an
exemplary
embodiment, the material comprises a soft metal. In an exemplary embodiment,
the
material comprises aluminum. In an exemplary embodiment, the means comprises
an
interstitial layer comprising a material lining an inner surface of the
structure. In an
exemplary embodiment, the material comprises a soft metal. In an exemplary
embodiment,
the material comprises aluminum. In an exemplary embodiment, the means
comprises an
interstitial layer of varying thickness. In an exemplary embodiment, the means
comprises a
non uniform interstitial layer. In an exemplary embodiment, the means
comprises an
interstitial layer having multiple layers. In an exemplary embodiment, the
multiple layers are
116
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
selected from the group consisting of a soft metal, a plastic, a composite
material, and
combinations thereof. In an exemplary embodiment, the structure is in
circumferential
tension. ,
[0041 ~] A tubular assembly has been described that includes: a structure
defining a
passage therein, an expandable tubular member positioned in the passage and an
interstitial
layer positioned between the structure and expandable tubular member, wherein
the
collapse strength of the assembly with the interstitial layer is at least 20%
greater than the
collapse strength without the interstitial layer. In an exemplary embodiment,
the structure
comprises a wellbore casing. In an exemplary embodiment, the structure
comprises a
tubular member. In an exemplary embodiment, the interstitial layer comprises
aluminum. In
an exemplary embodiment, the interstitial layer comprises aluminum and zinc.
In an
exemplary embodiment, the interstitial layer comprises plastic. In an
exemplary
embodiment, the interstitial layer has a varying thickness. In an exemplary
embodiment, the
interstitial layer is non uniform. In an exemplary embodiment, the
interstitial layer comprises
multiple layers. In an exemplary embodiment, the multiple layers are selected
from the
group consisting of a soft metal, a plastic, a composite material, and
combinations thereof.
In an exemplary embodiment, the structure is in circumferential tension.
[00419] A tubular assembly has been described that includes: a structure
defining a
passage therein, an expandable tubular member positioned in the passage and an
interstitial
layer positioned between the structure and expandable tubular member, wherein
the
collapse strength of the assembly with the interstitial layer is at least 30%
greater than the
collapse strength without the interstitial layer. In an exemplary embodiment,
the structure
comprises a wellbore casing. In an exemplary embodiment, the structure
comprises a
tubular member. In an exemplary embodiment, the interstitial layer comprises
aluminum. In
an exemplary embodiment, the interstitial layer comprises aluminum and zinc.
In an
exemplary embodiment, the interstitial layer comprises plastic. In an
exemplary
embodiment, the interstitial layer has a varying thickness. In an exemplary
embodiment, the
interstitial layer is non uniform. In an exemplary embodiment, the
interstitial layer comprises
multiple layers. In an exemplary embodiment, the multiple layers are selected
from the
group consisting of a soft metal, a plastic, a composite material, and
combinations thereof.
In an exemplary embodiment, the structure is in circumferential tension.
[00420] A tubular assembly has been described that includes: a structure
defining a
passage therein, an expandable tubular member positioned in the passage and an
interstitial
layer positioned between the structure and expandable tubular member, wherein
the
collapse strength of the assembly with the interstitial layer is at least 40%
greater than the
collapse strength without the interstitial layer. In an exemplary embodiment,
the structure
comprises a wellbore casing. In an exemplary embodiment, the structure
comprises a
197
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
tubular member. In an exemplary embodiment, the interstitial layer comprises
aluminum. In
an exemplary embodiment, the interstitial layer comprises aluminum and zinc.
In an
exemplary embodiment, the interstitial layer comprises plastic. In an
exemplary
embodiment, the interstitial layer has a varying thickness. In an exemplary
embodiment, the
interstitial layer is non uniform. In an exemplary embodiment, the
interstitial layer comprises
multiple layers. In an exemplary embodiment, the multiple layers are selected
from the
group consisting of a soft metal, a plastic, a composite material, and
combinations thereof.
In an exemplary embodiment, the structure is in circumferential tension.
[00421] A tubular assembly has been described that includes: a structure
defining a
passage therein, an expandable tubular member positioned in the passage and an
interstitial
layer positioned between the structure and expandable tubular member, wherein
the
collapse strength of the assembly with the interstitial layer is at least 50%
greater than the
collapse strength without the interstitial layer. In an exemplary embodiment,
the structure
comprises a wellbore casing. In an exemplary embodiment, the structure
comprises a
tubular member. In an exemplary embodiment, the interstitial layer comprises
aluminum. In
an exemplary embodiment, the interstitial layer comprises aluminum and zinc.
In an
exemplary embodiment, the interstitial layer comprises plastic. In an
exemplary
embodiment, the interstitial layer has a varying thickness. In an exemplary
embodiment, the
interstitial layer is non uniform. fn an exemplary embodiment, the
interstitial layer comprises
multiple layers. In an exemplary embodiment, the multiple layers are selected
from the
group consisting of a soft metal, a plastic, a composite material, and
combinations thereof.
In an exemplary embodiment, the structure is in circumferential tension.
[00422] An expandable tubular assembly has been described that includes: an
outer
tubular member comprising a steel alloy and defining a passage, an inner
tubular member
comprising a steel alloy and positioned in the passage and an interstitial
layer between the
inner tubular member and the outer tubular member, the interstitial layer
comprising an
aluminum material lining an inner surface of the outer tubular member, whereby
the collapse
strength of the assembly with the interstitial layer is greater than the
collapse strength of the
assembly without the interstitial layer.
[00423] A method for increasing the collapse strength of a tubular assembly
has been
described that includes: providing a preexisting structure defining a passage
therein,
providing an expandable tubular member, coating the expandable tubular member
with an
interstitial material, positioning the expandable tubular member in the
passage defined by
the preexisting structure and expanding the expandable tubular member such
that the
interstitial material engages the preexisting structure, whereby the collapse
strength of the
preexisting structure and expandable tubular member with the interstitial
material is greater
than the collapse strength of the preexisting structure and expandable tubular
member
118
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
without the interstitial material. In an exemplary embodiment, the preexisting
structure
comprises a wellbore casing. In an exemplary embodiment, the preexisting
structure
comprises a tubular member. In an exemplary embodiment, the coating comprises
applying
a soft metal layer on an outer surface of the expandable tubular member. In an
exemplary
embodiment, the coating comprises applying an aluminum layer on an outer
surface of the
expandable tubular member. In an exemplary embodiment, the coating comprises
applying
an aluminum/zinc layer on an outer surface of the expandable tubular member.
In an
exemplary embodiment, the coating comprises applying a plastic layer on an
outer surface
of the expandable tubular member. In an exemplary embodiment, the coating
comprises
wrapping a material around an outer surface of the expandable tubular member.
In an
exemplary embodiment, the material comprises a soft metal. In an exemplary
embodiment,
the material comprises aluminum. In an exemplary embodiment, the expanding
results in
the expansion of the preexisting structure. In an exemplary embodiment, the
expansion
places the preexisting structure in circumferential tension.
[00424] A method°for increasing the collapse strength of a tubular
assembly has been
described that includes: providing a preexisting structure defining a passage
therein,
providing an expandable tubular member, coating the preexisting structure with
an interstitial
material, positioning the expandable tubular member in the passage defined by
the
preexisting structure and expanding the expandable tubular member such that
the interstitial
material engages the expandable tubular member, whereby the collapse strength
of the
preexisting structure and expandable tubular member with the interstitial
material is greater
than the collapse strength of the preexisting structure and expandable tubular
member
without the interstitial material. In an exemplary embodiment, the preexisting
structure is a
wellbore casing. In an exemplary embodiment, the preexisting structure is a
tubular
member. In an exemplary embodiment, the coating comprises applying a soft
metal layer on
a surface of the passage in the preexisting structure. In an exemplary
embodiment, the
coating comprises applying an aluminum layer on a surface of the passage in
the preexisting
structure. In an exemplary embodiment, the coating comprises applying an
aluminum/zinc
layer on a surface of the passage in the preexisting structure. In an
exemplary embodiment,
the coating comprises applying a plastic layer on a surface of the passage in
the preexisting
structure. In an exemplary embodiment, the coating comprises lining a material
around a
surface of the passage in the preexisting structure. In an exemplary
embodiment, the
material comprises a soft metal. In an exemplary embodiment, the material
comprises
aluminum. In an exemplary embodiment, the expanding results in the expansion
of the
preexisting structure. In an exemplary embodiment, the expanding places the
preexisting
structure in circumferential tension.
119
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00425] An expandable tubular member has been described that includes: an
outer
surface and an interstitial layer on the outer surface, wherein the
interstitial layer comprises
an aluminum material resulting in a required expansion operating pressure of
approximately
3900 psi for the tubular member. In an exemplary embodiment, the expandable
tubular
member comprises an expanded 7 5/8 inch diameter tubular member.
[00426] An expandable tubular assembly has been described that includes: an
outer
surFace and an interstitial layer on the outer surface, wherein the
interstitial layer comprises
an aluminum/zinc material resulting in a required expansion operating pressure
of
approximately 3700 psi for the tubular member. In an exemplary embodiment, the
expandable tubular member comprises an expanded 7 5/8 inch diameter tubular
member.
[00427] An expandable tubular assembly has been described that includes: an
outer
surface and an interstitial layer on the outer surface, wherein the
interstitial layer comprises
an plastic material resulting in a required expansion operating pressure of
approximately
3600 psi for the tubular member. In an exemplary embodiment, the expandable
tubular
member comprises an expanded 7 5/8 inch diameter tubular member.
[00428] An expandable tubular assembly has been described that includes: a
structure defining a passage therein, an expandable tubular member positioned
in the
passage and an interstitial layer positioned between the expandable tubular
member and the
structure, wherein the interstitial layer has a thickness of approximately
0.05 inches to 0.15
inches. In an exemplary embodiment, the interstitial layer comprises aluminum.
[00429] An expandable tubular assembly has been described that includes: a
structure defining a passage therein, an expandable tubular member positioned
in the
passage and an interstitial layer positioned between the expandable tubular
member and the
structure, wherein the interstitial layer has a thickness of approximately
0.07 inches to 0.13
inches. In an exemplary embodiment, the interstitial layer comprises aluminum
and zinc.
[00430] An expandable tubular assembly has been described that includes: a
structure defining a passage therein, an expandable tubular member positioned
in the
passage and an interstitial layer positioned between the expandable tubular
member and the
structure, wherein the interstitial layer has a thickness of approximately
0.06 inches to 0.14
inches. In an exemplary embodiment, the interstitial layer comprises plastic.
[00431] An expandable tubular assembly has been described that includes: a
structure defining a passage therein, an expandable tubular member positioned
in the
passage and an interstitial layer positioned between the expandable tubular
member and the
structure, wherein the interstitial layer has a thickness of approximately 1.6
mm to 2.5 mm
between the structure and the expandable tubular member. In an exemplary
embodiment,
the interstitial layer comprises plastic.
120
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
[00432] An expandable tubular assembly has been described that includes: a
structure defining a passage therein, an expandable tubular member positioned
in the
passage and an interstitial layer positioned between the expandable tubular
member and the
structure, wherein the interstitial layer has a thickness of approximately 2.6
mm to 3.1 mm
between the structure and the expandable tubular member. In an exemplary
embodiment,
the interstitial layer comprises aluminum.
j00433] An expandable tubular assembly has been described that includes: a
structure defining a passage therein, an expandable tubular member positioned
in the
passage and an interstitial layer positioned between the expandable tubular
member and the
structure, wherein the interstitial layer has a thickness of approximately 1.9
mm to 2.5 mm
between the structure and the expandable tubular member. In an exemplary
embodiment,
the interstitial layer comprises aluminum and zinc.
[00434] An expandable tubular assembly has been described that includes: a
structure defining a passage therein, an expandable tubular member positioned
in the
passage, an interstitial layer positioned between the expandable tubular
member and the
structure and a collapse strength greater than approximately 20000 psi. In an
exemplary
embodiment, the structure comprises a tubular member comprising a diameter of
approximately 9 5/8 inches. In an exemplary embodiment, the expandable tubular
member
comprises diameter of approximately 7 5/8 inches. In an exemplary embodiment,
the
expandable tubular member has been expanded by at least 13%. In an exemplary
embodiment, the interstitial layer comprises a soft metal. In an exemplary
embodiment, the
interstitial layer comprises aluminum. In an exemplary embodiment, the
interstitial layer
comprises aluminum and zinc.
[00435] An expandable tubular assembly has been described that includes: a
structure defining a passage therein, an expandable tubular member positioned
in the
passage, an interstitial layer positioned between the expandable tubular
member and the
structure and a collapse strength greater than approximately 14000 psi. In an
exemplary
embodiment, the structure comprises a tubular member comprising a diameter of
approximately 9 5/8 inches. In an exemplary embodiment, the expandable tubular
member
comprises diameter of approximately 7 5/8 inches. In an exemplary embodiment,
the
expandable tubular member has been expanded by at least 13%. In an exemplary
embodiment, the interstitial layer comprises a plastic.
[00436] A method for determining the collapse resistance of a tubular assembly
has
been described that includes: measuring the collapse resistance of a first
tubular member,
measuring the collapse resistance of a second tubular member, determining the
value of a
reinforcement factor for a reinforcement of the first and second tubular
members and
121
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
multiplying the reinforcement factor by the sum of the collapse resistance of
the first tubular
member and the collapse resistance of the second tubular member.
[00437] An expandable tubular assembly has been described that includes: a
structure defining a passage therein, an expandable tubular member positioned
in the
passage and means for modifying the residual stresses in at least one of the
structure and
the expandable tubular member when the expandable tubular member is radially
expanded
and plastically deformed against the structure, the means positioned between
the
expandable tubular member and the structure. In an exemplary embodiment, the
structure
comprises a wellbore casing. In an exemplary embodiment, the structure
comprises a
tubular member. In an exemplary embodiment, the means comprises an
interstitial layer
comprising a soft metal. In an exemplary embodiment, the means comprises an
interstitial
layer comprising aluminum. In an exemplary embodiment, the means comprises an
interstitial layer comprising aluminum and zinc. In an exemplary embodiment,
the means
comprises an interstitial layer comprising a plastic. fn an exemplary
embodiment, the means
comprises an interstitial layer comprising a material wrapped around an outer
surFace of the
expandable tubular member. In an exemplary embodiment, the material comprises
a soft
metal. In an exemplary embodiment, the material comprises aluminum. In an
exemplary
embodiment, the means comprises an interstitial layer comprising a material
lining an inner
surface of the structure. In an exemplary embodiment, the material comprises a
soft metal.
In an exemplary embodiment, the material comprises aluminum. In an exemplary
embodiment, the means comprises an interstitial layer of varying thickness. In
an exemplary
embodiment, the means comprises a non uniform interstitial layer. In an
exemplary
embodiment, the means comprises an interstitial layer having multiple layers.
In an
exemplary embodiment, the multiple layers are selected from the group
consisting of a soft
metal, a plastic, a composite material, and combinations thereof. In an
exemplary
embodiment, the structure is in circumferential tension.
[00438] It is understood that variations may be made in the foregoing without
departing from the scope of the invention. For example, the teachings of the
present
illustrative embodiments may be used to provide a wellbore casing, a pipeline,
or a structural
support. Furthermore, the elements and teachings of the various illustrative
embodiments
may be combined in whole or in part in some or all of the illustrative
embodiments. In
addition, one or more of the elements and teachings of the various
illustrative embodiments
may be omitted, at least in part, and/or combined, at feast in part, with one
or more of the
other elements and teachings of the various illustrative embodiments.
[00439] 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
122
CA 02537242 2006-02-27
WO 2005/086614 PCT/US2004/028887
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.
123
