WO2003042487B1 - Mono diameter wellbore casing - Google Patents

Mono diameter wellbore casing

Info

Publication number
WO2003042487B1
WO2003042487B1 PCT/US2002/036267 US0236267W WO03042487B1 WO 2003042487 B1 WO2003042487 B1 WO 2003042487B1 US 0236267 W US0236267 W US 0236267W WO 03042487 B1 WO03042487 B1 WO 03042487B1
Authority
WO
WIPO (PCT)
Prior art keywords
tubular member
expandable tubular
adjustable expansion
expansion
adjustable
Prior art date
Application number
PCT/US2002/036267
Other languages
French (fr)
Other versions
WO2003042487A3 (en
WO2003042487A2 (en
Inventor
Lev Ring
David Paul Brisco
Brock Wayne Watson
Kevin K Waddell
Original Assignee
Enventure Global Technlogy
Lev Ring
David Paul Brisco
Brock Wayne Watson
Kevin K Waddell
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Enventure Global Technlogy, Lev Ring, David Paul Brisco, Brock Wayne Watson, Kevin K Waddell filed Critical Enventure Global Technlogy
Priority to AU2002360373A priority Critical patent/AU2002360373A1/en
Priority to US10/495,344 priority patent/US7383889B2/en
Priority to GB0412876A priority patent/GB2400126B/en
Priority to CA2467381A priority patent/CA2467381C/en
Publication of WO2003042487A2 publication Critical patent/WO2003042487A2/en
Publication of WO2003042487A3 publication Critical patent/WO2003042487A3/en
Publication of WO2003042487B1 publication Critical patent/WO2003042487B1/en
Priority to US11/552,703 priority patent/US7546881B2/en
Priority to US11/838,782 priority patent/US20080142213A1/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E21B43/105—Expanding tools specially adapted therefor
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Geology (AREA)
  • Mining & Mineral Resources (AREA)
  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Earth Drilling (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Medicines That Contain Protein Lipid Enzymes And Other Medicines (AREA)
  • Manufacturing Of Micro-Capsules (AREA)
  • Orthopedics, Nursing, And Contraception (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
  • Analysing Materials By The Use Of Radiation (AREA)
  • Shaping Of Tube Ends By Bending Or Straightening (AREA)
  • Catalysts (AREA)
  • Solid-Sorbent Or Filter-Aiding Compositions (AREA)
  • Epoxy Compounds (AREA)
  • Piles And Underground Anchors (AREA)

Abstract

An apparatus (10) and method for forming a mono diameter wellbore casing (12).

Claims

AMENDED CLAIMS
[received by the International Bureau on 16 July 2004 (16.07.04); original claims 1-38 amended, claims 39-204 added]
Claims
What is claimed is:
1 , An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising: a float shoe adapted to mate with an end of the expandable tubular member; an adjustable expansion mandrel coupled to the float shoe adapted to be controllably expanded to a larger outside dimension for radial expansion of the expandable tubular member or collapsed to a smaller outside dimension; an actuator coupled to the adjustable expansion mandrel adapted to controllably displace the adjustable expansion mandrel relative to the expandable tubular member; a locking device coupled to the actuator adapted to controllably engage the expandable tubular member; and a support member coupled to the locking device.
2, A method for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising: positioning an adjustable expansion mandrel within the expandable tubular member; supporting the expandable tubular member and the adjustable expansion mandrel within the borehole; lowering the adjustable expansion mandrel out of the expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; and displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member.
3, A method for forming a mono diameter wellbore casing, comprising positioning an adjustable expansion mandrel within a first expandable tubular member; supporting the first expandable tubular member and the adjustable expansion mandrel within a borehole; lowering the adjustable expansion mandrel out of the first expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel;
S2A displacing the adjustable expansion mandrel upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; positioning the adjustable expansion mandrel within a second expandable tubular member; supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member; lowering the adjustable expansion mandrel out of the second expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; and displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole.
4. An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising: a float shoe adapted to mate with an end of the expandable tubular member; an adjustable expansion mandrel coupled to the float shoe adapted to be controllably expanded to a larger outside dimension for radial expansion of the expandable tubular member or collapsed to a smaller outside dimension; an actuator coupled to the adjustable expansion mandrel adapted to controllably displace the adjustable expansion mandrel relative to the expandable tubular member; a locking device coupled to the actuator adapted to controllably engage the expandable tubular member; a support member coupled to the locking device; and a sealing member for sealingly engaging the expandable tubular member adapted to define a pressure chamber above the adjustable expansion mandrel during radial expansion of the expandable tubular member.
5. A method for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising: positioning an adjustable expansion mandrel within the expandable tubular member;
53A supporting the expandable tubular member and the adjustable expansion mandrel within the borehole; lowering the adjustable expansion mandrel out of the expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the borehole; and pressurizing an interior region of the expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the expandable tubular member within the borehole.
A method for forming a mono diameter wellbore casing, comprising: positioning an adjustable expansion mandrel within a first expandable tubular member; supporting the first expandable tubular member and the adjustable expansion mandrel within a borehole; lowering the adjustable expansion mandrel out of the first expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; displacing the adjustable expansion mandrel upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; pressurizing an interior region of the first expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the first expandable tubular member within the borehole; positioning the adjustable expansion mandrel within a second expandable tubular member; supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member; lowering the adjustable expansion mandrel out of the second expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; displacing the adjustable expansion mandrel upwardly relative to the second
54A expandable tubular member n times to radially expand and plastically deform π portions of the second expandable tubular member within the borehole; and pressurizing an interior region of the second expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the second expandable tubular member within the borehole.
7. An apparatus for drilling a borehole within a subterranean formation and then radially expanding and plastically deforming an expandable tubular member within the drilled borehole, comprising: a float shoe adapted to mate with an end of the expandable tubular member; a drilling member coupled to the float shoe adapted to drill the borehole; an adjustable expansion mandrel coupled to the float shoe adapted to be controllably expanded to a larger outside dimension for radial expansion of the expandable tubular member or collapsed to a smaller outside dimension; an actuator coupled to the adjustable expansion mandrel adapted to controllably displace the adjustable expansion mandrel relative to the expandable tubular member; a locking device coupled to the actuator adapted to controllably engage the expandable tubular member; and a support member coupled to the locking device.
8. A method for drilling a borehole within a subterranean formation and then radially expanding and plastically deforming an expandable tubular member within the drilled borehole, comprising: positioning an adjustable expansion mandrel within the expandable tubular member; coupling a drilling member to an end of the expandable tubular member; drilling the borehole using the drilling member; positioning the adjustable expansion mandrel and the expandable tubular member within the drilled borehole; lowering the adjustable expansion mandrel out of the expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; and displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform π portions of the expandable tubular member within the drilled borehole.
S5A
9. A method for forming a mono diameter wellbore casing within a borehole, comprising: positioning an adjustable expansion mandrel within a first expandable tubular member; coupling a drilling member to an end of the first expandable tubular member; drilling a first section of the borehole using the drilling member; supporting the first expandable tubular member and the adjustable expansion mandrel within the drilled first section of the borehole; lowering the adjustable expansion mandrel out of the first expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; displacing the adjustable expansion mandrel upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the drilled first section of the borehole; positioning the adjustable expansion mandrel within a second expandable tubular member; coupling the drilling member to an end of the second expandable tubular member; drilling a second section of the borehole using the drilling member; supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member within the second drilled section of the borehole; lowering the adjustable expansion mandrel out of the second expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; and displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the drilled second section of the borehole.
10. An apparatus for drilling a borehole within a subterranean formation and then radially expanding and plastically deforming an expandable tubular member within the drilled borehole, comprising: a float shoe adapted to mate with an end of the expandable tubular member; a drilling member coupled to the float shoe adapted to drill the borehole; an adjustable expansion mandrel coupled to the float shoe adapted to be controllably expanded to a larger outside dimension for radial expansion of the expandable tubular member or collapsed to a smaller outside dimension; an actuator coupled to the adjustable expansion mandrel adapted to controllably displace the adjustable expansion mandrel relative to the expandable tubular member, a locking device coupled to the actuator adapted to controllably engage the expandable tubular member; a support member coupled to the locking device; and a sealing member for sealing engaging the expandable tubular member adapted to define a pressure chamber above the adjustable expansion mandrel during the radial expansion of the expandable tubular member.
11. A method for drilling a borehole within a subterranean formation and then radially expanding and plastically deforming an expandable tubular member within the drilled borehole, comprising: positioning an adjustable expansion mandrel within the expandable tubular member; coupling a drilling member to an end of the expandable tubular member; drilling the borehole using the drilling member; positioning the adjustable expansion mandrel and the expandable tubular member within the drilled borehole; lowering the adjustable expansion mandrel out of the expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform π portions of the expandable tubular member within the drilled borehole; and pressuring an interior portion of the expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the expandable tubular member within the drilled borehole.
12. A method for forming a mono diameter wellbore casing within a borehole, comprising:
57A positioning an adjustable expansion mandrel within a first expandable tubular member, coupling a drilling member to an end of the first expandable tubular member; drilling a first section of the borehole using the drilling member; supporting the first expandable tubular member and the adjustable expansion mandrel within the drilled first section of the borehole; lowering the adjustable expansion mandrel out of the first expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; displacing the adjustable expansion mandrel upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the drilled first section of the borehole; pressuring an interior portion of the first expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the first expandable tubular member within the first drilled section of the borehole; positioning the adjustable expansion mandrel within a second expandable tubular member; coupling the drilling member to an end of the second expandable tubular member, drilling a second section of the borehole using the drilling member; supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member within the second drilled section of the borehole; lowering the adjustable expansion mandrel out of the second expandable tubular member; increasing the outside dimension of the adjustable expansion mandrel; displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the drilled second section of the borehole; and pressuring an interior portion of the second expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic
59A deformation of the second expandable tubular member within the drilled second section of the borehole.
13. An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising: a float shoe adapted to mate with an end of the expandable tubular member; a first adjustable expansion mandrel coupled to the float shoe adapted to be controllably expanded to a first larger outside dimension for radial expansion of the expandable tubular member or collapsed to a first smaller outside dimension; a second adjustable expansion mandrel coupled to the first adjustable expansion mandrel adapted to be controllably expanded to a second larger outside dimension for radial expansion of the expandable tubular member or collapsed to a second smaller outside dimension; an actuator coupled to the first and second adjustable expansion mandrels adapted to controllably displace the first and second adjustable expansion mandrels relative to the expandable tubular member; a locking device coupled to the actuator adapted to controllably engage the expandable tubular member; and a support member coupled to the locking device; wherein the first larger outside dimension of ths first adjustable expansion mandrel is larger than the second larger outside dimension of the second adjustable expansion mandrel.
14. A method for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising: positioning first and second adjustable expansion mandrels within the expandable tubular member; supporting the expandable tubular member and the first and second adjustable expansion mandrels within the borehole; lowering the first adjustable expansion mandrel out of the expandable tubular member; increasing the outside dimension of the first adjustable expansion mandrel; displacing the first adjustable expansion mandrel upwardly relative to the expandable
S9A tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; displacing the first adjustable expansion mandrel and the second adjustable expansion mandrel downwardly relative to the expandable tubular member; decreasing the outside dimension of the first adjustable expansion mandrel and increasing the outside dimension of the second adjustable expansion mandrel; displacing the second adjustable expansion mandrel upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; wherein the outside dimension of the first adjustable expansion mandrel is greater than the outside dimension of the second adjustable expansion mandrel.
15. A method for forming a mono diameter wellbore casing, comprising: positioning first and second adjustable expansion mandrels within a first expandable tubular member, supporting the first expandable tubular member and the first and second adjustable expansion mandrels within a borehole; lowering the first adjustable expansion mandrel out of the first expandable tubular member; increasing the outside dimension of the first adjustable axpansion mandrel; displacing the first adjustable expansion mandrel upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; displacing the first adjustable expansion mandrel and the second adjustable expansion mandrel downwardly relative to the first expandable tubular member; decreasing the outside dimension of the first adjustable expansion mandrel and increasing the outside dimension of the second adjustable expansion mandrel; displacing the second adjustable expansion mandrel upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the
60A expandable tubular member; positioning first and second adjustable expansion mandrels within a second expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion mandrels within the borehole in overlapping relation to the first expandable tubular member; lowering the first adjustable expansion mandrel out of the second expandable tubular member; increasing the outside dimension of the first adjustable expansion mandrel; displacing the first adjustable expansion maπdrei upwardly relative to the second expandable tubular member to radially expand and plastically deform a lower portion of the second expandable tubular member; displacing the first adjustable expansion mandrel and the second adjustable expansion mandrel downwardly relative to the second expandable tubular member: decreasing the outside dimension of the first adjustable expansion mandrel and increasing the outside dimension of the second adjustable expansion mandrel; and displacing the second adjustable expansion maπdrei upwardly relative to the second expandable tubular member to radially expand and plastically deform portions of the second expandable tubular member above the lower portion of the second expandable tubular member; wherein the outside dimension of the first adjustable expansion mandrel is greater than the outside dimension of the second adjustable expansion maπdrei.
16. An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising: a float shoe adapted to mate with an end of the expandable tubular member; a first adjustable expansion mandrel coupled to the float shoe adapted to be controllably expanded to a first larger outside dimension for radial expansion of the expandable tubular member or collapsed to a first smaller outside dimension; a second adjustable expansion mandrel coupled to the first adjustable expansion mandrel adapted to be controllably expanded to a second larger outside
61A dimension for radial expansion of the expandable tubular member or collapsed to a second smaller outside dimension; an actuator coupled to the first and second adjustable expansion mandrels adapted to controllably displace the first and second adjustable expansion mandrels relative to the expandable tubular member; a locking device coupled to the actuator adapted to controllably engage the expandable tubular member; a support member coupled to the locking device; and a sealing member for sealingly engaging the expandable tubular adapted to define a pressure chamber above the first and second adjustable expansion mandrels during the radial expansion of the expandable tubular member; wherein the first larger outside dimension of the first adjustable expansion mandrel is larger than the second larger outside dimension of the second adjustable expansion mandrel.
17. A method for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising: positioning first and second adjustable expansion mandrels within the expandable tubular member; supporting the expandable tubular member and the first and second adjustable expansion mandrels within the borehole; lowering the first adjustable expansion mandrel out of the expandable tubular member; increasing the outside dimension of the first adjustable expansion mandrel; displacing the first adjustable expansion mandrel upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; pressurizing an interior region of the expandable tubular member above the first adjustable expansion mandrel during the radial expansion of the lower portion of the expandable tubular member by the first adjustable expansion maπdrei; displacing the first adjustable expansion mandrel and the second adjustable expansion mandrel downwardly relative to the expandable tubular member; decreasing the outside dimension of the first adjustable expansion mandrel and increasing the outside dimension of the second adjustable expansion
62A mandrel; displacing the second adjustable expansion mandrel upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member, and pressurizing an interior region of the expandable tubular member above the second adjustable expansion mandrel during the radial expansion of the portions of the expandable tubular member above the lower portion of the expandable tubular member by the second adjustable expansion mandrel; wherein the outside dimension of the first adjustable expansion mandrel is greater than the outside dimension of the second adjustable expansion mandrel.
18. A method for forming a mono diameter wellbore casing, comprising: positioning first and second adjustable expansion mandrels within a first expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion mandrels within a borehole; lowering the first adjustable expansion mandrel out of the first expandable tubular member; increasing the outside dimension of the first adjustable expansion maπdrei; displacing the first adjustable expansion mandrel upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; pressurizing an interior region of the first expandable tubular member above the first adjustable expansion maπdrei during the radial expansion of the lower portion of the first expandable tubular member by the first adjustable expansion mandrel; displacing the first adjustable expansion mandrel and the second adjustable expansion maπdrei downwardly relative to the first expandable tubular member; decreasing the outside dimension of the first adjustable expansion mandrel and increasing the outside dimension of the second adjustable expansion mandrel; displacing the second adjustable expansion mandrel upwardly relative to the first
63A expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; pressurizing an interior region of the first expandable tubular member above the second adjustable expansion mandrel during the radial expansion of the portions of the first expandable tubular member above the lower portion of the first expandable tubular member by the second adjustable expansion mandrel; positioning first and second adjustable expansion mandrels within a second expandable tubular member; supporting the first expandable tubular member and the first and second adjustable expansion mandrels within the borehole in overlapping relation to the first expandable tubular member; lowering the first adjustable expansion mandrel out of the second expandable tubular member; increasing the outside dimension of the first adjustable expansion mandrel; displacing the first adjustable expansion mandrel upwardly relative to the second expandable tubular member to radially expand and plastically deform a lower portion of the second expandable tubular member; pressurizing an interior region of the second expandable tubular member above the first adjustable expansion mandrel during the radial expansion of the lower portion of the second expandable tubular member by the first adjustable expansion mandrel; displacing the first adjustable expansion mandrel and the second adjustable expansion mandrel downwardly relative to the second expandable tubular member; decreasing the outside dimension of the first adjustable expansion mandrel and increasing the outside dimension of the second adjustable expansion mandrel; displacing the second adjustable expansion mandrel upwardly relative to the second expandable tubular member to radially expand and plastically deform portions of the second expandable tubular member above the lower portion of the second expandable tubular member; and pressurizing an interior region of the second expandable tubular member above the
64A second adjustable expansion mandrel during the radial expansion of the portions of the second expandable tubular member above the lower portion of the second expandable tubular member by the second adjustable expansion mandrel; wherein the outside dimension of the first adjustable expansion mandrel is greater than the outside dimension of the second adjustable expansion mandrel.
19. An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising: a support member, a locking device coupled to the support member and releasably coupled to the expandable tubular member; an adjustable expansion mandrel adapted to be controllably expanded to a larger outside dimension for radial expansion and plastic deformation of the expandable tubular member or collapsed to a smaller outside dimension; and an actuator coupled to the locking member and the adjustable expansion maπdrei adapted to displace the adjustable expansion maπdrei upwardly through the expandable tubular member to radially expand and plastically- deform a portion of the expandable tubular member.
20. The apparatus of claim 19, further comprising: a gripping assembly coupled to the support member and the actuator for controllably gripping at least one of the expandable tubular member or ' another tubular member.
21. The apparatus of claim 19, further comprising: one or more cup seals coupled to the support member for sealingly engaging the expandable tubular member above the adjustable expansion mandrel.
22. The apparatus of claim 19, further comprising: an expansion mandrel coupled to the adjustable expansion mandrel; and a float collar assembly coupled to the adjustable expansion mandrel comprising: a float valve assembly; and
S5A a sealing sleeve coupled to the float valve assembly adapted to be radially expanded and plastically deformed by the expansion mandrel.
23. A method for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising: supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion mandrel within the borehole; increasing the size of the adjustable expansion mandrel; and displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member.
24. The method of claim 23, further comprising; reducing the size of the adjustable expansion mandrel after the portion of the expandable tubular member has been radially expanded and plastically deformed.
25. The method of claim 24, further comprising: fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion mandrel.
26. The method of claim 25, further comprising: permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member.
27. The method of claim 26, further comprising: injecting a hardeπable fluidic sealing material into an anπulus between the expandable tubular member and a preexisting structure after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
28. The method of claim 26, further comprising: increasing the size of the adjustable expansion mandrel after permitting the position
66A of the expandable tubular member to float relative to the position of the hydraulic actuator.
29. The method of claim 28, further comprising: displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
30. The method of claim 29, further comprising: if the end of the other portion of the expandable tubular member overlaps with a preexisting structure, then not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the other portion of the expandable , tubular member that overlaps with the preexisting structure.
31. A method for forming a mono diameter weilbore casing within a borehole that includes a preexisting weilbore casing, comprising: supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion mandrel within the borehole; increasing the size of the adjustable expansion mandrel; displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting weilbore casing that overlaps with an end of the remaining portion of the expandable tubular member.
32. The method of claim 31 , further comprising: reducing the size of the adjustable expansion mandrel after the portion of the
Θ7A expandable tubular member has been radially expanded and plastically deformed.
33. The method of claim 32, further comprising: fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion mandrel.
34. The method of claim 33, further comprising: permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member.
35. The method of claim 34, further comprising: injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the borehole after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
36. The method of claim 34, further comprising: increasing the size of the adjustable expansion maπdrei after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
37. The method of claim 36, further comprising: displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member.
38. The method of claim 37, further comprising: not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and displacing the adjustable expansion cone upwardly relative tα the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the remaining portion of the expandable tubular member that
6BA overlaps with the preexisting weilbore casing after not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
39. An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising; a support member; an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and an actuator coupled to the support member for displacing the expansion device relative to the support member.
40. The apparatus of claim 39, further comprising: a gripping device for gripping the tubular member coupled to the support member.
41. The apparatus of claim 40, wherein the gripping device comprises a plurality of movable gripping elements.
42. The apparatus of claim 41 , wherein the gripping elements are moveable in a radial direction relative to the support member.
43. The apparatus of claim 39, further comprising: a sealing device for sealing an interface with the tubular member coupled to the support member.
44. The apparatus of claim 43, wherein the sealing device seals an annulus defines between the support member and the tubular member.
45. The apparatus of claim 39, further comprising: a locking device for locking the position of the tubular member relative to the support member.
46. The apparatus of claim 45, wherein the locking device comprises: a pressure sensor for controllably unlocking the locking device from engagement with the
69A tubular member when the operating pressure within the apparatus exceeds a predetermined amount.
47. The apparatus of claim 45, wherein the locking device comprises: a position sensor for controllably unlocking the locking device from engagement with the tubular member when the position of the actuator exceeds a predetermined amount.
48. The apparatus of claim 39, wherein the expansion device comprises: a support member; and a plurality of movable expansion elements coupled to the support member.
49. The apparatus of claim 48, further comprising: an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
50. The apparatus of claim 49, wherein the expansion elements comprise: a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements,
51. The apparatus of claim 50, wherein in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements.
52. The apparatus of claim 50, wherein in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
53. The apparatus of claim 39, wherein the expansion device comprises an adjustable expansion device.
54. The apparatus of claim 39, wherein the expansion device comprises a plurality of
70A expansion devices.
55. The apparatus of claim 54, wherein at least one of the expansion devices comprises an adjustable expansion device.
56. The apparatus of claim 55, wherein the adjustable expansion device comprises: a support member; and a plurality of movable expansion elements coupled to the support member.
57. The apparatus of claim 56, further comprising: an actuator coupled to the support member for moving the expansion elements
* between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
58. The apparatus of claim 57, wherein the expansion elements comprise: a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
59. The apparatus of claim 58, wherein in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements.
60. The apparatus of claim 58, wherein in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
61. An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising: a support member; an expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a sealing assembly for sealing an annulus defined between the support member and
71A the tubular member.
62. The apparatus of claim 6-1 , further comprising: a gripping device for gripping the tubular member coupled to the support member.
63. The apparatus of claim 62, wherein the gripping device comprises a plurality of movable gripping elements.
64. The apparatus of claim 63, wherein the gripping elements are moveable in a radial direction relative to the support member.
65. The apparatus of claim 61 , further comprising; a locking device for locking the position of the tubular member relative to the support member.
66. The apparatus of claim 65, wherein the locking device comprises: a pressure sensor for controllably unlocking the locking device from engagement with the tubular member when the operating pressure within the apparatus exceeds a predetermined amount.
67. The apparatus of claim 65, wherein the locking device comprises: a position sensor for controllably unlocking the locking device from engagement with the tubular member when the position of a portion of the apparatus exceeds a predetermined amount.
68. The apparatus of claim 61 , further comprising: an actuator for displacing the expansion device relative to the support member.
69. The apparatus of claim 68, wherein the actuator comprises means for transferring torsional loads between the support member and the expansion device.
70. The apparatus of claim 68, wherein the actuator comprises a plurality of pistons positioned within corresponding piston chambers.
72A
71. The apparatus of claim 6 , wherein the expansion device comprises: a support member; and a plurality of movable expansion elements coupled to the support member.
72. The apparatus of claim 71 , further comprising: an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
73. The apparatus of claim 72, wherein the expansion elements comprise: a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
74. The apparatus of claim 73, wherein in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements.
75. The apparatus of claim 73, wherein in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
76. The apparatus of claim 61 , wherein the expansion device comprises an adjustable expansion device.
77. The apparatus of claim 61, wherein the expansion device comprises a plurality of expansion devices.
78. The apparatus of claim 77, wherein at least one of the expansion devices comprises an adjustable expansion device.
79. The apparatus of claim 78, wherein the adjustable expansion device comprises: a support member, and
73A a plurality of movable expansion elements coupled to the support member.
80. The apparatus of claim 79, further comprising: an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
81. The apparatus of claim 80, wherein the expansion elements comprise: a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
82. The apparatus of claim 81 , wherein in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements.
83. The apparatus of claim 81 , wherein in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
84. An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising: a support member; a first expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; and a second expansion device for radially expanding and plastically deforming the tubular member coupled to the support member-
85. The apparatus of claim 84, further comprising: a gripping device for gripping the tubular member coupled to the support member.
86. The apparatus of claim 85, wherein the gripping device comprises a plurality of movable gripping elements.
74A
87. The apparatus of claim 86, wherein the gripping elements are moveable in a radial direction relative to the support member.
88. The apparatus of claim 84, further comprising: a sealing device for sealing an interface with the tubular member coupled to the support member.
89. The apparatus of claim 88, wherein the sealing device seals an aπnulus defines between the support member and the tubular member.
90. The apparatus of claim 84, further comprising: a locking device for locking the position of the tubular member relative to the support member-
91. The apparatus of claim 90, wherein the locking device comprises: a pressure sensor for controllably unlocking the locking device from engagement with the tubular member when the operating pressure within the apparatus exceeds a predetermined amount.
92. The apparatus of claim 90, wherein the locking device comprises: a position sensor for controllably unlocking the locking device from engagement with the tubular member when the position of a portion of the apparatus exceeds a predetermined amount.
93. The apparatus of claim 84, further comprising: an actuator for displacing the expansion device relative to the support member.
94. The apparatus of claim 93, wherein the actuator comprises means for transferring torsional loads between the support member and the expansion device.
95. The apparatus of claim 93, wherein the actuator comprises a plurality of pistons positioned within corresponding piston chambers.
76A
96. The apparatus of claim 84, wherein at least one of the first second expansion devices comprise: a support member; and a plurality of movable expansion elements coupled to the support member.
97. The apparatus of claim 96, further comprising: an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member,
98. The apparatus of claim 97, wherein the expansion elements comprise: a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
99. The apparatus of claim 98, wherein in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements.
100. The apparatus of claim 98, wherein in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
101. The apparatus of claim 84, wherein at least one of the first and second expansion devices comprise a plurality of expansion devices.
102. The apparatus of claim 101 , wherein at least one of the first and second expansion device comprise an adjustable expansion device.
103. The apparatus of claim 102, wherein the adjustable expansion device comprises: a support member; and a plurality of movable expansion elements coupled to the support member.
76A
104. The apparatus of claim 103, further comprising: an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
105. The apparatus of claim 104, wherein the expansion elements comprise: a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
106. The apparatus of claim 105, wherein in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements,
07. The apparatus of claim 105, wherein in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
108. An apparatus for radially expanding and plastically deforming an expandable tubular member, comprising: a support member; a gripping device for gripping the tubular member coupled to the support member; a sealing device for sealing an interface with the tubular member coupled to the support member; a locking device for locking the position of the tubular member relative to the support member; a first adjustable expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; a second adjustable expansion device for radially expanding and plastically deforming the tubular member coupled to the support member; a packer coupled to the support member; and an actuator for displacing one or more of the sealing assembly, first and second adjustable expansion devices, and packer relative to the support member.
77A
109. The apparatus of claim 108, wherein the locking device comprises: a pressure sensor for controllably unlocking the locking device from engagement with the tubular member when the operating pressure within the apparatus exceeds a predetermined amount.
110. The apparatus of claim 108, wherein the locking device comprises: a position sensor for controllably unlocking the locking device from engagement with the tubular member when the position of a portion of the apparatus exceeds a predetermined amount.
111. The apparatus of claim 108, wherein the gripping device comprises a plurality of movable gripping elements.
112. The apparatus of claim 111, wherein the gripping elements are moveable in a radial direction relative to the support member.
113. The apparatus of claim 108, wherein the sealing device seals an anπulus defines between the support member and the tubular member.
114. The apparatus of claim 108, wherein the actuator comprises means for transfemng torsional loads between the support member and the expansion device.
115. The apparatus of claim 108, wherein the actuator comprises a plurality of pistons positioned within corresponding piston chambers.
116. The apparatus of claim 108, wherein at least one of the adjustable expansion devices comprise: a support member; and a plurality of movable expansion elements coupled to the support member.
1 . The apparatus of claim 116, further comprising: an actuator coupled to the support member for moving the expansion elements between a first position and a second position;
7BA wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
118. The apparatus of claim 11 , wherein the expansion elements comprise: a first set of expansion elements; and a second set of expansion elements; wherein the first set of expansion elements are interleaved with the second set of expansion elements.
19. The apparatus of claim 118, wherein in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements.
120. The apparatus of claim 118, wherein in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
121. The apparatus of claim 108, wherein at least one of the adjustable expansion devices comprise a plurality of expansion devices.
122. The apparatus of claim 121 , wherein at least one of the adjustable expansion devices comprise: a support member; and a plurality of movable expansion elements coupled to the support member.
123. The apparatus of claim 122, further comprising: an actuator coupled to the support member for moving the expansion elements between a first position and a second position; wherein in the first position, the expansion elements do not engage the tubular member; and wherein in the second position, the expansion elements engage the tubular member.
124. The apparatus of claim 123, wherein the expansion elements comprise; a first set of expansion elements; and a second set of expansion elements;
79A wherein the first set of expansion elements are interleaved with the second set of expansion elements.
125. The apparatus of claim 124, wherein in the first position, the first set of expansion elements are not axially aligned with the second set of expansion elements.
126. The apparatus of claim 124. wherein in the second position, the first set of expansion elements are axially aligned with the second set of expansion elements.
127. An actuator, comprising; a tubular housing; a tubular piston rod movably coupled to and at least partially positioned within the housing; a plurality of annular piston chambers defined by the tubular housing and the tubular piston rod; and a plurality of tubular pistons coupled to the tubular piston rod, each tubular piston movably positioned within a corresponding annular piston chamber.
128. The actuator of claim 127, further comprising means for transmitting torsional loads between the tubular housing and the tubular piston rod. , i
129. A method of radially expanding and plastically deforming an expandable tubular member within a borehole having a preexisting weilbore rasing, comprising: positioning the tubular member within the borehole in overlapping relation to the weilbore casing; radially expanding and plastically deforming a portion of the tubular member to form a bell section; and radially expanding and plastically deforming a portion of the tubular member above the bell section comprising a portion of the tubular member that overlaps with the weilbore casing; wherein the inside diameter of the bell section is greater than the inside diameter of the radially expanded and plastically deformed portion of the tubular member above the bell section.
130. The method of claim 129, wherein radially expanding and plastically deforming a
BOA portion of the tubular member to form a bell section comprises: positioning an adjustable expansion device within the expandable tubular member; supporting the expandable tubular member and the adjustable expansion device within the borehole; lowering the adjustable expansion device out of the expandable tubular member; increasing the outside dimension of the adjustable expansion device; and displacing the adjustable expansion device upwardly relative to the expandable tubular member n times to radially expand and plastically deform π portions of the expandable tubular member, wherein n is greater than or equal to 1.
131. A method for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising: supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; increasing the size of the adjustable expansion device; and displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member.
132. The method of claim 131 , further comprising: reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed.
133. The method of claim 132, further comprising: fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device.
134. The method of claim 133, further comprising: permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member.
81A
135. The method of claim 134, further comprising: injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and a preexisting structure after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
136. The method of claim 134, further comprising: increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
37. The method of claim 136, further comprising displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
138. The method of claim 137, further comprising: if the end of the other portion of the expandable tubular member overlaps with a preexisting structure, then not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the other portion of the expandable tubular member that overlaps with the preexisting structure.
139. A method for forming a mono diameter weilbore casing within a borehole that includes a preexisting weilbore casing, comprising: supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; increasing the size of the adjustable expansion device; displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically
82A deform a portion of the expandable tubular member; and displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting weilbore casing that overlaps with an end of the remaining portion of the expandable tubular member.
140. The method of claim 139, further comprising: reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed,
141. The method of claim 140, further comprising: fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device.
142. The method of claim 141 , further comprising: permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member.
143. The method of claim 142, further comprising: injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the borehole after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator-
144. The method of claim 142, further comprising: increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
83A
145. The method of claim 144, further comprising: displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member.
146. The method of claim 145, further comprising: not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the remaining portion of the expandable tubular member that overlaps with the preexisting weilbore casing after not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
147. A method of radially expanding and plastically deforming a tubular member, comprising: positioning the tubular member within a preexisting structure; radially expanding and plastically deforming a lower portion of the tubular member to form a bell section; and radially expanding and plastically deforming a portion of the tubular member above the bell section.
148. The method of claim 147, wherein positioning the tubular member within a preexisting structure comprises: locking the tubular member to an expansion device.
149. The method of claim 148, wherein positioning the tubular member within a preexisting structure comprises: unlocking the tubular member from an expansion device if the operating pressure within the preexisting structure exceeds a predetermined amount.
150. The method of claim 148, wherein positioning the tubular member within a preexisting structure comprises;
&4A unlocking the tubular member from an expansion device if the position of an actuator coupled to the tubular member exceeds a predetermined amount.
151. The method of claim 147, wherein radially expanding and plastically deforming a lower portion of the tubular member to form a bell section comprises: lowering an expansion device out of an end of the tubular member; and pulling the expansion device through the end of the tubular member.
152. The method of claim 151 , wherein lowering an expansion device out of an end of the tubular member comprises: lowering the expansion device out of the end of the tubular member; and adjusting the size of the expansion device.
153. The method of claim 152, wherein the expansion device is adjustable to a plurality of sizes.
154. The method of claim 152, wherein the expansion device comprises a plurality of adjustable expansion devices.
155. The method of claim 154, wherein at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
156. The method of claim 151 , wherein pulling the expansion device through the end of the tubular member comprises: gripping the tubular member; and pulling an expansion device through an end of the tubular member.
157. The method of claim 156, wherein gripping the tubular member comprises: permitting axial displacement of the tubular member in a first direction; and not permitting axial displacement of the tubular member in a second direction.
158. The method of claim 156, wherein pulling the expansion device through the end of the tubular member comprises: pulling the expansion device through the end of the tubular member using an
85A actuator.
159. The method of claim 142, wherein radially expanding and plastically deforming a portion of the tubular member above the bell section comprises: lowering an expansion device out of an end of the tubular member; and pulling the expansion device through the end of the tubular member.
160. The method of claim 159, wherein lowering an expansion device out of an end of the tubular member comprises: lowering the expansion device out of the end of the tubular member; and adjusting the size of the expansion device.
161. The method of claim 160, wherein the expansion device is adjustable to a plurality of sizes,
162. The method of claim 160, wherein the expansion device comprises a plurality of adjustable expansion devices.
163. The method of claim 162, wherein at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
164. The method of claim 159, wherein pulling the expansion device through the end of the tubular member comprises; gripping the tubular member; and pulling an expansion device through an end of the tubular member.
165. The method of claim 164, wherein gripping the tubular member comprises: permitting axial displacement of the tubular member in a first direction; and not permitting axial displacement of the tubular member in a second direction.
166. The method of claim 164, wherein pulling the expansion device through the end of the tubular member comprises: pulling the expansion device through the end of the tubular member using an actuator.
86A
167. The method of claim 159, wherein pulling the expansion device through the end of the tubular member comprises: pulling the expansion device through the end of the tubular member using fluid pressure.
168. The method of claim 167, wherein pulling the expansion device through the end of the tubular member using fluid pressure comprises: pressurizing an annulus within the tubular member above the expansion device.
169. The method of claim 147, wherein radially expanding and plastically deforming a portion of the tubular member above the bell section comprises; fluidicly sealing an end of the tubular member; and pulling the expansion device through the tubular member.
170. The method of claim 169, wherein the expansion device is adjustable.
171. The method of claim 170, wherein the expansion device is adjustable to a plurality of sizes.
172. The method of claim 169, wherein the expansion device comprises a plurality of adjustable expansion devices.
173. The method of claim 172, wherein at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
174. The method of claim 169, wherein pulling the expansion device through the end of the tubular member comprises: gripping the tubular member; and pulling an expansion device through an end of the tubular member.
175. The method of claim 174, wherein pulling the expansion device through the end of the tubular member comprises: pulling the expansion device through the end of the tubular member using an a7A actuator.
176. The method of claim 169, wherein pulling the expansion device through the end of the tubular member comprises: pulling the expansion device through the end of the tubular member using fluid pressure.
177. The method of claim 176, wherein pulling the expansion device through the end of the tubular member using fluid pressure comprises: pressurizing an annulus within the tubular member above the expansion device.
178. The method of claim 147, wherein radially expanding and plastically deforming a portion of the tubular member above the bell section comprises: overlapping the portion of the tubular member above the bell section with an end of a preexisting tubular member; and pulling an expansion device through the overlapping portions of the tubular member and the preexisting tubular member.
179. The method of claim 178, wherein the expansion device is adjustable.
180. The method of claim 179, wherein the expansion device is adjustable to a plurality of sizes.
181. The method of claim 178, wherein the expansion device comprises a plurality of adjustable expansion devices.
182. The method of claim 181 , wherein at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
183. The method of claim 1 8, wherein pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member comprises; gripping the tubular member; and pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member.
88A
184. The method of claim 183, wherein pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member comprises: pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using an actuator.
185. The method of claim 178, wherein pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member comprises: pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure.
186. The method of claim 185, wherein pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure comprises; pressurizing an annulus within the tubular member above the expansion device.
187. The method of claim 147, further comprising: injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the preexisting structure.
188. A method of injecting a hardenable fluidic sealing material into an annulus between a tubular member and a preexisting structure, comprising: positioning the tubular member into the preexisting structure; sealing off an end of the tubular member; operating a valve within the end of the tubular member; and injecting a hardenable fluidic sealing material through the valve into the annulus between the tubular member and the preexisting structure.
189. A method of engaging a tubular member, comprising: positioning a plurality of elements within the tubular member; and bringing the elements into engagement with the tubular member.
190. The method of claim 189, wherein the elements comprise: a first group of elements; and
89A a second group of elements; wherein the first group of elements are interleaved with the second group of elements,
191. The method of claim 189, wherein bringing the elements into engagement with the tubular member comprises: bringing the elements into axial alignment.
192. The method of claim 189, wherein bringing the elements into engagement with the tubular member further comprises: pivoting the elements.
193. The method of claim 189, wherein bringing the elements into engagement with the tubular member further comprises: translating the elements.
194. The method of claim 189, wherein bringing the elements into engagement with the tubular member further comprises: pivoting the elements; and translating the elements.
195. The method of claim 189, wherein bringing the elements into engagement with the tubular member comprises: rotating the elements about a common axis.
196. The method of claim 189, wherein bringing the elements into engagement with the tubular member comprises: pivoting the elements about corresponding axes; translating the elements; and rotating the elements about a common axis.
197. The method of claim 189, further comprising; preventing the elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value.
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198. The method of claim 197, wherein preventing the elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value comprises: sensing the inside diameter of the tubular member.
199. A locking device for locking a tubular member to a support member, comprising: a radially movable locking device coupled to the support member for engaging an interior surface of the tubular member.
200. The device of claim 199, further comprising: a pressure sensor for controllably unlocking the locking device from engagement with the tubular member when an operating pressure exceeds a predetermined amount.
201. The device of claim 199, further comprising: a position sensor for controllably unlocking the locking device from engagement with the tubular member when a position exceeds a predetermined amount.
202. A method of locking a tubular member to a support member, comprising: locking a locking element in a position that engages an interior surface of the tubular member.
203. The method of claim 202, further comprising: controllably unlocking the locking element from engagement with the tubular member when an operating pressure exceeds a predetermined amount.
204. The method of claim 202, further comprising: controllably unlocking the locking element from engagement with the tubular member when a position exceeds a predetermined amount.
205. A system for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising: means for positioning an adjustable expansion maπdrei within the expandable tubular
91A member; means for supporting the expandable tubular member and the adjustable expansion mandrel within the borehole; means for lowering the adjustable expansion mandrel out of the expandable tubular member; means for increasing the outside dimension of the adjustable expansion mandrel; and means for displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform π portions of the expandable tubular member.
206. A system for forming a mono diameter weilbore casing, comprising: positioning an adjustable expansion mandrel within a first expandable tubular member; means for supporting the first expandable tubular member and the adjustable expansion mandrel within a borehole; means for lowering the adjustable expansion mandrel out of the first expandable tubular member; means for increasing the outside dimension of the adjustable expansion mandrel; means for displacing the adjustable expansion maπdrei upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; means for positioning the adjustable expansion mandrel within a second expandable tubular member; means for supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member; means for lowering the adjustable expansion mandrel out of the second expandable tubular member; means for increasing the outside dimension of the adjustable expansion maπdrei; and means for displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member π times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole.
92A
207. A system for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising: means for positioning an adjustable expansion mandrel within the expandable tubular member; means for supporting the expandable tubular member and the adjustable expansion mandrel within the borehole; means for lowering the adjustable expansion mandrel out of the expandable tubular member; means for increasing the outside dimension of the adjustable expansion mandrel; means for displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member π times to radially expand and plastically deform n portions of the expandable tubular member within the borehole; and means for pressurizing an interior region of the expandable tubular member above the adjustable expansion maπdrei during the radial expansion and plastic deformation of the expandable tubular member within the borehole.
208. A system for forming a mono diameter weilbore casing, comprising: means for positioning an adjustable expansion mandrel within a first expandable tubular member, means for supporting the first expandable tubular member and the adjustable expansion mandrel within a borehole; means for lowering the adjustable expansion mandrel out of the first expandable tubular member; means for increasing the outside dimension of the adjustable expansion mandrel; means for displacing the adjustable expansion mandrel upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the borehole; means for pressurizing an interior region of the first expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the first expandable tubular member within the borehole; means for positioning the adjustable expansion mandrel within a second expandable tubular member,
93A means for supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member; means for lowering the adjustable expansion mandrel out of the second expandable tubular member; means for increasing the outside dimension of the adjustable expansion mandrel; means for displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the borehole; and means for pressurizing an interior region of the second expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the second expandable tubular member within the borehole.
209. A system for drilling a borehole within a subterranean formation and then radially expanding and plastically deforming an expandable tubular member within the drilled borehole, comprising: means for positioning an adjustable expansion mandrel within the expandable tubular member; means for coupling a drilling member to an end of the expandable tubular member; means for drilling the borehole using the drilling member; means for positioning the adjustable expansion mandrel and the expandable tubular member within the drilled borehole; means for lowering the adjustable expansion mandrel out of the expandable tubular member; means for increasing the outside dimension of the adjustable expansion mandrel; and means for displacing the adjustable expansion maπdrei upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the drilled borehole.
210. A system for forming a mono diameter weilbore casing within a borehole, comprising: means for positioning an adjustable expansion mandrel within a first expandable
94A tubular member; means for coupling a drilling member to an end of the first expandable tubular member; means for drilling a first section of the borehole using the drilling member; means for supporting the first expandable tubular member and the adjustable expansion mandrel within the drilled first section of the borehole; means for lowering the adjustable expansion mandrel out of the first expandable tubular member; means for increasing the outside dimension of the adjustable expansion maπdrei; means for displacing the adjustable expansion mandrel upwardly relative to the first expandable tubular member m times to radially expand and plastically deform m portions of the first expandable tubular member within the drilled first section of the borehole; means for positioning the adjustable expansion mandrel within a second expandable tubular member; means for coupling the drilling member to an end of the second expandable tubular member; means for drilling a second section of the borehole using the drilling member; means for supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member within the second drilled section of the borehole; means for lowering the adjustable expansion mandrel out of the second expandable tubular member; means for increasing the outside dimension of the adjustable expansion maπdrei; and means for displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the drilled second section of the borehole.
211. A system for drilling a borehole within a subterranean formation and then radially expanding and plastically deforming an expandable tubular member within the drilled borehole, comprising: means for positioning an adjustable expansion mandrel within the expandable tubular
95A member; means for coupling a drilling member to an end of the expandable tubular member; means for drilling the borehole using the drilling member, means for positioning the adjustable expansion mandrel and the expandable tubular member within the drilled borehole; means for lowering the adjustable expansion mandrel out of the expandable tubular member; means for increasing the outside dimension of the adjustable expansion mandrel; means for displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member within the drilled borehole; and means for pressuring an interior portion of the expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the expandable tubular member within the drilled borehole.
-12- A system for forming a mono diameter weilbore casing within a borehole, comprising: means for positioning an adjustable expansion mandrel within a first expandable tubular member; means for coupling a drilling member to an end of the first expandable tubular member; means for drilling a first section of the borehole using the drilling member; means for supporting the first expandable tubular member and the adjustable expansion mandrel within the drilled first section of the borehole; means for lowering the adjustable expansion mandrel out of the first expandable tubular member; means for increasing the outside dimension of the adjustable expansion mandrel; means for displacing the adjustable expansion mandrel upwardly relative to the first expandable tubular member in times to radially expand and plastically deform m portions of the first expandable tubular member within the drilled first section of the borehole; means for pressuring an interior portion of the first expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the first expandable tubular member within the first drilled section of the borehole;
96A means for positioning the adjustable expansion mandrel within a second expandable tubular member; means for coupling the drilling member to an end of the second expandable tubular member; means for drilling a second section of the borehole using the drilling member; means for supporting the second expandable tubular member and the adjustable expansion mandrel within the borehole in overlapping relation to the first expandable tubular member within the second drilled section of the borehole; means for lowering the adjustable expansion maπdrei out of the second expandable tubular member; means for increasing the outside dimension of the adjustable expansion mandrel; means for displacing the adjustable expansion mandrel upwardly relative to the second expandable tubular member n times to radially expand and plastically deform n portions of the second expandable tubular member within the drilled second section of the borehole; and means for pressuring an interior portion of the second expandable tubular member above the adjustable expansion mandrel during the radial expansion and plastic deformation of the second expandable tubular member within the drilled second section of the borehole.
213. A system for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising: means for positioning first and second adjustable expansion mandrels within the expandable tubular member; means for supporting the expandable tubular member and the first and second adjustable expansion mandrels within the borehole; means for lowering the first adjustable expansion mandrel out of the expandable tubular member; means for increasing the outside dimension of the first adjustable expansion mandrel; means for displacing the first adjustable expansion mandrel upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; means for displacing the first adjustable expansion mandrel and the second
97A adjustable expansion mandrel downwardly relative to the expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion mandrel and increasing the outside dimension of the second adjustable expansion mandrel; means for displacing the second adjustable expansion mandrel upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; wherein the outside dimension of the first adjustable expansion mandrel is greater than the outside dimension of the second adjustable expansion mandrel.
A system for forming a mono diameter weilbore casing, comprising: means for positioning first and second adjustable expansion mandrels within a first expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion mandrels within a borehole; means for lowering the first adjustable expansion mandrel out of the first expandable tubular member; means for increasing the outside dimension of the first adjustable expansion mandrel; means for displacing the first adjustable expansion mandrel upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; means for displacing the first adjustable expansion mandrel and the second adjustable expansion mandrel downwardly relative to the first expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion mandrel and increasing the outside dimension of the second adjustable expansion mandrel; means for displacing the second adjustable expansion mandrel upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubutar member above the lower portion of the expandable tubular member;
99A means for positioning first and second adjustable expansion mandrels within a second expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion mandrels within the borehole in overlapping relation to the first expandable tubular member; means for lowering the first adjustable expansion mandrel out of the second expandable tubular member; means for increasing the outside dimension of the first adjustable expansion mandrel; means for displacing the first adjustable expansion mandrel upwardly relative to the second expandable tubular member to radially expand and plastically deform a lower portion of the second expandable tubular member; means for displacing the first adjustable expansion maπdrei and the second adjustable expansion maπdrei downwardly relative to the second expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion mandrel and increasing the outside dimension of the second adjustable expansion mandrel; and means for displacing the second adjustable expansion mandrel upwardly relative to the second expandable tubular member to radially expand and plastically deform portions of the second expandable tubular member above the lower portion of the second expandable tubular member; wherein the outside dimension of the first adjustable expansion mandrel is greater than the outside dimension of the second adjustable expansion mandrel.
215. A system for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising: means for positioning first and second adjustable expansion mandrels within the expandable tubular member; means for supporting the expandable tubular member and the first and second adjustable expansion mandrels within the borehole; means for lowering the first adjustable expansion mandrel out of the expandable tubular member; means for increasing the outside dimension of the first adjustable expansion
99A mandrel; means for displacing the first adjustable expansion mandrel upwardly relative to the expandable tubular member to radially expand and plastically deform a lower portion of the expandable tubular member; means for pressurizing an interior region of the expandable tubular member above the first adjustable expansion mandrel during the radial expansion of the lower portion of the expandable tubular member by the first adjustable expansion mandrel; means for displacing the first adjustable expansion mandrel and the second adjustable expansion mandrel downwardly relative to the expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion mandrel and increasing the outside dimension of the second adjustable expansion maπdrei; means for displacing the second adjustable expansion mandrel upwardly relative to the expandable tubular member to radially expand and plastically deform portions of the expandable tubular member above the lower portion of the expandable tubular member; and means for pressurizing an interior region of the expandable tubular member above the second adjustable expansion maπdrei during the radial expansion of the portions of the er-pandable tubular member above the lower portion of the expandable tuhular member by the second adjustable expansion mandrel; wherein the outside dimension of the first adjustable expansion mandrel is greater than the outside dimension of the second adjustable expansion mandrel.
A system for forming a mono diameter weilbore casing, comprising means for positioning first and second adjustable expansion mandrels within a first expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion mandrels within a borehole; means for lowering the first adjustable expansion mandrel out of the first expandable tubular member; means for increasing the outside dimension of the first adjustable expansion mandrel;
100A means for displacing the first adjustable expansion mandrel upwardly relative to the first expandable tubular member to radially expand and plastically deform a lower portion of the first expandable tubular member; means for pressurizing an interior region of the first expandable tubular member above the first adjustable expansion mandrel during the radial expansion of the lower portion of the first expandable tubular member by the first adjustable expansion mandrel; means for displacing the first adjustable expansion mandrel and the second adjustable expansion mandrel downwardly relative to the first expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion mandrel and increasing the outside dimension of the second adjustable expansion mandrel; means for displacing the second adjustable expansion mandrel upwardly relative to the first expandable tubular member to radially expand and plastically deform portions of the first expandable tubular member above the lower portion of the expandable tubular member; means for pressurizing an interior region of the first expandable tubular member above the second adjustable expansion mandrel during the radial expansion of the portions of the first expandable tubular member above the lower portion of the first expandable tubular member by the second adjustable expansion mandrel; means for positioning first and second adjustable expansion mandrels within a second expandable tubular member; means for supporting the first expandable tubular member and the first and second adjustable expansion mandrels within the borehole in overlapping relation to the first expandable tubular member; means for lowering the first adjustable expansion mandrel out of the second expandable tubular member; means for increasing the outside dimension of the first adjustable expansion mandrel; means for displacing the first adjustable expansion maπdrei upwardly relative to the second expandable tubular member to radially expand and plastically deform a lower portion of the second expandable tubular member;
101A means for pressurizing an interior region of the second expandable tubular member above the first adjustable expansion mandrel during the radial expansion of the lower portion of the second expandable tubular member by the first adjustable expansion mandrel; means for displacing the first adjustable expansion mandrel and the second adjustable expansion maπdrei downwardly relative to the second expandable tubular member; means for decreasing the outside dimension of the first adjustable expansion mandrel and increasing the outside dimension of the second adjustable expansion mandrel; means for displacing the second adjustable expansion maπdrei upwardly relative to the second expandable tubular member to radially expand and plastically deform portions of the second expandable tubular member above the lower portion of the second expandable tubular member; and means for pressurizing an interior region of the second expandable tubular member above the second adjustable expansion mandrel during the radial expansion of the portions of the second expandable tubular member above the lower portion of the second expandable tubular member by the second adjustable expansion mandrel; wherein the outside dimension of the first adjustable expansion mandrel is greater than the outside dimension of the second adjustable expansion mandrel.
217. A system for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising: means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion mandrel within the borehole; means for increasing the size of the adjustable expansion maπdrei; and means for displacing the adjustable expansion mandrel upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member.
218. The system of claim 217, further comprising:
102A means for reducing the size of the adjustable expansion mandrel after the portion of the expandable tubular member has been radially expanded and plastically deformed.
219. The system of claim 218, further comprising: means for fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion mandrel.
220. The system of claim 219, further comprising: means for permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member.
221. The system of claim 220, further comprising: means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and a preexisting structure after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
222. The system of claim 220, further comprising; means for increasing the size of the adjustable expansion mandrel after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
223. The system of claim 222, further comprising; means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member,
224. The system of claim 223, further comprising: if the end of the other portion of the expandable tubular member overlaps with a preexisting structure, then means for not permitting the position of the expandable tubular member to
103A float relative to the position of the hydraulic actuator; and means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the other portion of the expandable tubular member that overlaps with the preexisting structure.
225. A system for forming a mono diameter weilbore casing within a borehole that includes a preexisting weilbore casing, comprising: means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion mandrel within the borehole; means for increasing the size of the adjustable expansion mandrel; means for displacing the adjustable expansion maπdrei upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and means for displacing the adjustable expansion maπdrei upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting weilbore casing that overlaps with an end of the remaining portion of the expandable tubular member.
226. The system of claim 225, further comprising: means for reducing the size of the adjustable expansion mandrel after the portion of the expandable tubular member has been radially expanded and plastically deformed.
227. The system of claim 226, further comprising; means for fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion mandrel-
104A
228. The system of claim 227, further comprising: means for permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member.
229. The system of claim 228, further comprising: means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the borehole after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
230. The system of claim 228, further comprising: means for increasing the size of the adjustable expansion mandrel after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
231. The system of claim 230, further comprising: means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member.
232. The system of claim 23 , further comprising; means for not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the remaining portion of the expandable tubular member that overlaps with the preexisting weilbore casing after not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
233. A system of radially expanding and plastically deforming an expandable tubular member within a borehole having a preexisting weilbore casing, comprising;
105A means for positioning the tubular member within the borehole in overlapping relation to the weilbore casing; means for radially expanding and plastically deforming a portion of the tubular member to form a bell section; and means for radially expanding and plastically deforming a portion of the tubular member above the bell section comprising a portion of the tubular member that overlaps with the weilbore casing; wherein the inside diameter of the bell section is greater than the inside diameter of the radially expanded and plastically deformed portion of the tubular member above the bell section.
234. The system of claim 233, wherein radially expanding and plastically deforming a portion of the tubular member to form a belt section comprises: means for positioning an adjustable expansion device within the expandable tubular member; means for supporting the expandable tubular member and the adjustable expansion device within the borehole; means for lowering the adjustable expansion device out of the expandable tubular member; means for increasing the outside dimension of the adjustable expansion device; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member n times to radially expand and plastically deform n portions of the expandable tubular member, wherein π is greater than or equal to 1.
235. A system for radially expanding and plastically deforming an expandable tubular member within a borehole, comprising: means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; means for increasing the size of the adjustable expansion device; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member.
1Q6A
236. The system of claim 235, further comprising: means for reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed.
237. The system of claim 236, further comprising: means for fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device.
238. The system of claim 237, further comprising: means for permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member.
239. The system of claim 238, further comprising: means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and a preexisting structure after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
240. The system of claim 238, further comprising: means for increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
241. The system of claim 240, further comprising: means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
242. The system of claim 241 , further comprising: if the end of the other portion of the expandable tubular member overlaps with a preexisting structure, then
107A means for not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the other portion of the expandable tubular member that overlaps with the preexisting structure.
243. A system for forming a mono diameter weilbore casing within a borehole that includes a preexisting weilbore casing, comprising: means for supporting the expandable tubular member, an hydraulic actuator, and an adjustable expansion device within the borehole; means for increasing the size of the adjustable expansion device; means for displacing the adjustable expansion device upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform a portion of the expandable tubular member; and means for displacing the adjustable expansion device upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member and a portion of the preexisting weilbore casing that overlaps with an end of the remaining portion of the expandable tubular member.
244. The system of claim 243, further comprising: means for reducing the size of the adjustable expansion device after the portion of the expandable tubular member has been radially expanded and plastically deformed.
245. The system of claim 244, further comprising: means for fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member after reducing the size of the adjustable expansion device.
108A
246. The system of claim 245, further comprising: means for permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator after fluidicly sealing the radially expanded and plastically deformed end of the expandable tubular member,
247. The system of claim 246, further comprising: means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the borehole after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
248. The system of claim 246, further comprising: means for increasing the size of the adjustable expansion device after permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
249. The system of claim 248. further comprising: means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member to radially expand and plastically deform the remaining portion of the expandable tubular member.
250. The system of claim 249, further comprising means for not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator; and means for displacing the adjustable expansion cone upwardly relative to the expandable tubular member using the hydraulic actuator to radially expand and plastically deform the end of the remaining portion of the expandable tubular member that overlaps with the preexisting weilbore casing after not permitting the position of the expandable tubular member to float relative to the position of the hydraulic actuator.
251. A system for radially expanding and plastically deforming a tubular member, comprising: means for positioning the tubular member within a preexisting structure;
109A means for radially expanding and plastically deforming a lower portion of the tubular member to form a bell section; and means for radially expanding and plastically deforming a portion of the tubular member above the bell section.
252. The system of claim 251 , wherein positioning the tubular member within a preexisting structure comprises: means for locking the tubular member to an expansion device.
253. The system of claim 252, wherein positioning the tubular member within a preexisting structure comprises: means for unlocking the tubular member from an expansion device rf the operating pressure within the preexisting structure exceeds a predetermined amount.
254. The system of claim 252, wherein positioning the tubular member within a preexisting structure comprises: means for unlocking the tubular member from an expansion device if the position of an actuator coupled to the tubular member exceeds a predetermined amount.
255. The system of claim 251 , wherein radially expanding and plastically deforming a lower portion of the tubular member to form a bell section comprises: means for lowering an expansion device out of an end of the tubular member; and means for pulling the expansion device through the end of the tubular member.
256. The system of claim 255, wherein lowering an expansion device out of an end of the tubular member comprises: means for lowering the expansion device out of the end of the tubular member; and means for adjusting the size of the expansion device.
257. The system of claim 256, wherein the expansion device is adjustable to a plurality of sizes.
258. The system of claim 256, wherein the expansion device comprises a plurality of adjustable expansion devices.
110A
259. The system of claim 258. wherein at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
260. The system of claim 255, wherein means for pulling the expansion device through the end of the tubular member comprises: means for gripping the tubular member; and means for pulling an expansion device through an end of the tubular member.
26 . The system of claim 260, wherein means for gripping the tubular member comprises: means for permitting axial displacement of the tubular member in a first direction; and means for not permitting axial displacement of the tubular member in a second direction.
262. The system of claim 260, wherein means for pulling the expansion device through the end of the tubular member comprises: means for pulling the expansion device through the end of the tubular member using an actuator.
263. The system of claim 246, wherein means for radially expanding and plastically deforming a portion of the tubular member above the bell section comprises: means for lowering an expansion device out of an end of the tubular member; and means for pulling the expansion device through the end of the tubular member.
264. The system of claim 263, wherein means for lowering an expansion device out of an end of the tubular member comprises: means for lowering the expansion device out of the end of the tubular member; and means for adjusting the size of the expansion device.
265. The system of claim 264, wherein the expansion device is adjustable to a plurality of sizes.
266. The system of claim 264, wherein the expansion device comprises a plurality of adjustable expansion devices.
111A
267. The system of claim 266, wherein at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
268. The system of claim 263, wherein means for pulling the expansion device through the end of the tubular member comprises: means for gripping the tubular member; and means for pulling an expansion device through an end of the tubular member.
269. The system of claim 268, wherein means for gripping the tubular member comprises: means for permitting axial displacement of the tubular member in a first direction; and means for not permitting axial displacement of the tubular member in a second direction.
270. The system of claim 268, wherein means for pulling the expansion device through the end of the tubular member comprises: means for pulling the expansion device through the end of the tubular member using an actuator.
271. The system of claim 263, wherein means for pulling the expansion device through the end of the tubular member comprises: means for pulling the expansion device through the end of the tubular member using fluid pressure.
272. The system of claim 271 , wherein means for pulling the expansion device through the end of the tubular member using fluid pressure comprises: means for pressurizing an annulus within the tubular member above the expansion device.
273. The system of claim 251 , wherein means for radially expanding and plastically deforming a portion of the tubular member above the bell section comprises*. means for fluidicly sealing an end of the tubular member; and means for pulling the expansion device through the tubular member.
112A
274. The system of claim 273, wherein the expansion device is adjustable.
275. The system of claim 274, wherein the expansion device is adjustable to a plurality of sizes.
276. The system of claim 273, wherein the expansion device comprises a plurality of adjustable expansion devices.
277. The system of claim 276, wherein at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
278. The system of claim 273, wherein means for pulling the expansion device through the end of the tubular member comprises: means for gripping the tubular member; and means for pulling an expansion device through an end of the tubular member.
279. The system of claim 278, wherein means for pulling the expansion device through the end of the tubular member comprises: means for pulling the expansion device through the end of the tubular member using an actuator.
280. The system of claim 273, wherein means for pulling the expansion device through the end of the tubular member comprises: means for pulling the expansion device through the end of the tubular member using fluid pressure.
281. The system of claim 280, herein means for pulling the expansion device through the end of the tubular member using fluid pressure comprises: means for pressurizing an annulus within the tubular member above the expansion device.
282. The system of claim 251 , wherein means for radially expanding and plastically deforming a portion of the tubular member above the bell section comprises:
113A means for overlapping the portion of the tubular member above the bell section with an end of a preexisting tubular member; and means for pulling an expansion device through the overlapping portions of the tubular member and the preexisting tubular member,
283. The system of claim 282, wherein the expansion device is adjustable.
284. The system of claim 283, wherein the expansion device is adjustable to a plurality of sizes.
285. The system of claim 282, wherein the expansion device comprises a plurality of adjustable expansion devices.
286. The system of claim 285, wherein at least one of the adjustable expansion devices is adjustable to a plurality of sizes.
287. The system of claim 282, wherein means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member comprises; means for gripping the tubular member; and means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member.
288. The system of claim 287, wherein means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member comprises: means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using an actuator.
289. The system of claim 282, wherein means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member comprises; means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure.
114A
290. The system of claim 289, wherein means for pulling the expansion device through the overlapping portions of the tubular member and the preexisting tubular member using fluid pressure comprises; means for pressurizing an annulus within the tubular member above the expansion device.
29 . The system of claim 251 , further comprising: means for injecting a hardenable fluidic sealing material into an annulus between the expandable tubular member and the preexisting structure.
292. A system of injecting a hardenable fluidic sealing material into an annulus between a tubular member and a preexisting structure, comprising: means for positioning the tubular member into the preexisting structure; means for sealing off an end of the tubular member; means for operating a valve within the end of the tubular member; and means for injecting a hardenable fluidic sealing material through the valve into the annulus between the tubular member and the preexisting structure.
293. A system of engaging a tubular member, comprising: means for positioning a plurality of elements within the tubular member; and means for bringing the elements into engagement with the tubular member.
294. The system of claim 293, wherein the elements comprise: a first group of elements; and a second group of elements; wherein the first group of elements are interleaved with the second group of elements.
295. The system of claim 293, wherein means for bringing the elements into engagement with the tubular member comprises: means for bringing the elements into axial alignment.
115A
296. The system of claim 293, wherein means for bringing the elements into engagement with the tubular member further comprises: means for pivoting the elements.
297. The system of claim 189, wherein means for bringing the elements into engagement with the tubular member further comprises: means for translating the elements.
298. The system of claim 293, wherein means for bringing the elements into engagement with the tubular member further comprises: means for pivoting the elements; and means for translating the elements.
299. The system of claim 293, wherein means for bringing the elements into engagement with the tubular member comprises: means for rotating the elements about a common axis.
300. The system of claim 293, wherein means for bringing the elements into engagement with the tubular member comprises; means for pivoting the elements about corresponding axes; means for translating the elements; and means for rotating the elements about a common axis.
301. The system of claim 293, further comprising: means for preventing the elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value.
302. The system of claim 301 , wherein means for preventing the elements from coming into engagement with the tubular member if the inside diameter of the tubular member is less than a predetermined value comprises: means for sensing the inside diameter of the tubular member.
303. A system of locking a tubular member to a support member, comprising:
116A locking a locking element in a position that engages an interior surface of the tubular member.
304. The system of claim 303, further comprising: means for controllably unlocking the locking element from engagement with the tubular member when an operating pressure exceeds a predetermined amount.
305. The system of claim 303, further comprising: means for controllably unlocking the locking element from engagement with the tubular member when a position exceeds a predetermined amount.
117A
PCT/US2002/036267 2001-09-07 2002-11-12 Mono diameter wellbore casing WO2003042487A2 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
AU2002360373A AU2002360373A1 (en) 2001-11-12 2002-11-12 Mono diameter wellbore casing
US10/495,344 US7383889B2 (en) 2001-11-12 2002-11-12 Mono diameter wellbore casing
GB0412876A GB2400126B (en) 2001-11-12 2002-11-12 Mono diameter wellbore casing
CA2467381A CA2467381C (en) 2001-11-12 2002-11-12 Mono diameter wellbore casing
US11/552,703 US7546881B2 (en) 2001-09-07 2006-10-25 Apparatus for radially expanding and plastically deforming a tubular member
US11/838,782 US20080142213A1 (en) 2002-11-12 2007-08-14 Radial expansion of a wellbore casing against a formation

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
US33899601P 2001-11-12 2001-11-12
US33901301P 2001-11-12 2001-11-12
US60/339,013 2001-11-12
US60/338,996 2001-11-12
US36382902P 2002-03-13 2002-03-13
US60/363,829 2002-03-13
US38796102P 2002-06-12 2002-06-12
US60/387,961 2002-06-12

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US10495347 Continuation-In-Part 2002-11-12
US10495344 A-371-Of-International 2002-11-12
US10/495,344 A-371-Of-International US7383889B2 (en) 2001-09-07 2002-11-12 Mono diameter wellbore casing
PCT/US2003/004837 Continuation-In-Part WO2003078785A2 (en) 2001-09-07 2003-02-19 Collapsible expansion cone
US10507567 Continuation-In-Part 2003-02-19
US10/507,567 Continuation-In-Part US20050103502A1 (en) 2001-09-07 2003-02-19 Collapsible expansion cone

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