WO2005024170A2 - Radial expansion system - Google Patents

Radial expansion system Download PDF

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Publication number
WO2005024170A2
WO2005024170A2 PCT/US2004/028831 US2004028831W WO2005024170A2 WO 2005024170 A2 WO2005024170 A2 WO 2005024170A2 US 2004028831 W US2004028831 W US 2004028831W WO 2005024170 A2 WO2005024170 A2 WO 2005024170A2
Authority
WO
WIPO (PCT)
Prior art keywords
tubular
tubular member
assembly
plastic deformation
radial expansion
Prior art date
Application number
PCT/US2004/028831
Other languages
French (fr)
Other versions
WO2005024170A3 (en
Inventor
Mark Shuster
Malcolm Gray
Grigoriy Grinberg;
Scott Costa
Russel Wasson
David Paul Brisco
Brock Wayne Watson
Original Assignee
Enventure Global Technology, Llc
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 Technology, Llc filed Critical Enventure Global Technology, Llc
Priority to GB0604360A priority Critical patent/GB2420811B/en
Priority to JP2006525483A priority patent/JP2007521430A/en
Publication of WO2005024170A2 publication Critical patent/WO2005024170A2/en
Publication of WO2005024170A3 publication Critical patent/WO2005024170A3/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B21D39/04—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of tubes with tubes; of tubes with rods
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B21D39/08—Tube expanders
    • B21D39/20—Tube expanders with mandrels, e.g. expandable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B21D39/08—Tube expanders
    • B21D39/20—Tube expanders with mandrels, e.g. expandable
    • B21D39/203—Tube expanders with mandrels, e.g. expandable expandable by fluid or elastic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B7/00—Presses characterised by a particular arrangement of the pressing members
    • B30B7/04—Presses characterised by a particular arrangement of the pressing members wherein pressing is effected in different directions simultaneously or in turn
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/08—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for tubular bodies or pipes
    • 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
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/02—Couplings; joints
    • E21B17/04—Couplings; joints between rod or the like and bit or between rod and rod or the like
    • 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
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/02—Couplings; joints
    • E21B17/04—Couplings; joints between rod or the like and bit or between rod and rod or the like
    • E21B17/042—Threaded
    • 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
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/02—Couplings; joints
    • E21B17/08—Casing joints
    • 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
    • E21B23/00—Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells
    • 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
    • E21B29/00—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
    • 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
    • E21B29/00—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
    • E21B29/10—Reconditioning of well casings, e.g. straightening
    • 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
    • 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
    • E21B43/08—Screens or liners
    • E21B43/084—Screens comprising woven materials, e.g. mesh or cloth
    • 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
    • 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
    • E21B43/106—Couplings or joints 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
    • E21B43/108—Expandable screens or perforated liners
    • 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
    • E21B43/14—Obtaining from a multiple-zone well
    • 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
    • E21B43/30—Specific pattern of wells, e.g. optimizing the spacing of wells
    • E21B43/305—Specific pattern of wells, e.g. optimizing the spacing of wells comprising at least one inclined or horizontal well
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L55/00—Devices or appurtenances for use in, or in connection with, pipes or pipe systems
    • F16L55/16—Devices for covering leaks in pipes or hoses, e.g. hose-menders
    • F16L55/162—Devices for covering leaks in pipes or hoses, e.g. hose-menders from inside the pipe
    • F16L55/163—Devices for covering leaks in pipes or hoses, e.g. hose-menders from inside the pipe a ring, a band or a sleeve being pressed against the inner surface of the pipe
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16N—LUBRICATING
    • F16N7/00—Arrangements for supplying oil or unspecified lubricant from a stationary reservoir or the equivalent in or on the machine or member to be lubricated
    • F16N7/30—Arrangements for supplying oil or unspecified lubricant from a stationary reservoir or the equivalent in or on the machine or member to be lubricated the oil being fed or carried along by another fluid
    • F16N7/32—Mist lubrication
    • F16N7/34—Atomising devices for oil
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N17/00—Investigating resistance of materials to the weather, to corrosion, or to light
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49908—Joining by deforming
    • Y10T29/49938—Radially expanding part in cavity, aperture, or hollow body
    • Y10T29/4994—Radially expanding internal tube

Definitions

  • patent number 6,568,471 which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (50)
  • PCT/US2004/009434 attorney docket number 25791.260.02, filed on 3/26/2004
  • PCT patent application serial number PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712 attorney docket number 25791.272.02, filed on 4/6/2004
  • PCT patent application serial number PCT/US2004/010762 attorney docket number 25791.273.02, filed on 4/6/2004
  • a method of forming a tubular liner within a preexisting structure includes positioning a tubular assembly within the preexisting structure; and radially expanding and plastically deforming the tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • an expandable tubular member that includes a steel alloy including: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr.
  • an expandable tubular member that includes a steel alloy including: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr.
  • an expandable tubular member that includes a steel alloy including: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr.
  • an expandable tubular member that includes a steel alloy including: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr.
  • an expandable tubular member wherein the yield point of the expandable tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • an expandable tubular member wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 40 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.48.
  • an expandable tubular member wherein the yield point of the expandable tubular member is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • an expandable tubular member wherein the yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 28 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.04.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.92.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.34.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
  • an expandable tubular member is provided, wherein the yield point of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
  • an expandable tubular member is provided, wherein the expandability coefficient of the expandable tubular member, prior to the radial expansion and plastic deformation, is greater than 0.12.
  • an expandable tubular member is provided, wherein the expandability coefficient of the expandable tubular member is greater than the expandability coefficient of another portion of the expandable tubular member.
  • an expandable tubular member is provided, wherein the tubular member has a higher ductility and a lower yield point prior to a radial expansion and plastic deformation than after the radial expansion and plastic deformation.
  • a method of radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member includes radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member.
  • a system for radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member includes means for radially expanding the tubular assembly within a preexisting structure; and means for using less power to radially expand each unit length of the first tubular member than required to radially expand each unit length of the second tubular member.
  • a method of manufacturing a tubular member includes processing a tubular member until the tubular member is characterized by one or more intermediate characteristics; positioning the tubular member within a preexisting structure; and processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics.
  • an apparatus that includes an expandable tubular assembly; and an expansion device coupled to the expandable tubular assembly; wherein a predetermined portion of the expandable tubular assembly has a lower yield point than another portion of the expandable tubular assembly.
  • an expandable tubular member wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 5.8 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
  • a method of determining the expandability of a selected tubular member includes determining an anisotropy value for the selected tubular member, determining a strain hardening value for the selected tubular member; and multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member.
  • a method of radially expanding and plastically deforming tubular members includes selecting a tubular member; determining an anisotropy value for the selected tubular member; determining a strain hardening value for the selected tubular member; multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member; and if the anisotropy value is greater than 0.12, then radially expanding and plastically deforming the selected tubular member.
  • a radially expandable tubular member apparatus includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.
  • a radially expandable tubular member apparatus includes: a first tubular member; a second tubular member engaged with the first tubular member forming a joint; a sleeve overlapping and coupling the first and second tubular members at the joint; the sleeve having opposite tapered ends and a flange engaged in a recess formed in an adjacent tubular member; and one of the tapered ends being a surface formed on the flange; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.
  • a method of joining radially expandable tubular members includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • a method of joining radially expandable tubular members includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint, wherein the flange is engaged in a recess formed in an adjacent one of the tubular members; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • an expandable tubular assembly includes a first tubular member; a second tubular member coupled to the first tubular member; a first threaded connection for coupling a portion of the first and second tubular members; a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members; a tubular sleeve coupled to and receiving end portions of the first and second tubular members; and a sealing element positioned between the first and second spaced apart threaded connections for sealing an interface between the first and second tubular member; wherein the sealing element is positioned within an annulus defined between the first and second tubular members; and wherein, prior to a radial expansion and plastic deformation of the assembly, a predetermined portion of the assembly has a lower yield point than another portion of the apparatus.
  • a method of joining radially expandable tubular members includes: providing a first tubular member; providing a second tubular member; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members; threadably coupling the first and second tubular members at a first location; threadably coupling the first and second tubular members at a second location spaced apart from the first location; sealing an interface between the first and second tubular members between the first and second locations using a compressible sealing element, wherein the first tubular member, second tubular member, sleeve, and the sealing element define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • an expandable tubular member is provided, wherein the carbon content of the tubular member is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.21.
  • an expandable tubular member is provided, wherein the carbon content of the tubular member is greater than 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.36.
  • a method of selecting tubular members for radial expansion and plastic deformation includes selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is less than or equal to 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.21 , then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
  • a method of selecting tubular members for radial expansion and plastic deformation includes selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is greater than 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.36, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
  • an expandable tubular member that includes a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body.
  • a method of manufacturing an expandable tubular member includes: providing a tubular member; heat treating the tubular member; and quenching the tubular member; wherein following the quenching, the tubular member comprises a microstructure comprising a hard phase structure and a soft phase structure.
  • a method of radially expanding a tubular assembly includes radially expanding and plastically deforming a lower portion of the tubular assembly by pressurizing the interior of the lower portion of the tubular assembly; and then, radially expanding and plastically deforming the remaining portion of the tubular assembly by contacting the interior of the tubular assembly with an expansion device.
  • a system for radially expanding a tubular assembly includes means for radially expanding and plastically deforming a lower portion of the tubular assembly by pressurizing the interior of the lower portion of the tubular assembly; and then, means for radially expanding and plastically deforming the remaining portion of the tubular assembly by contacting the interior of the tubular assembly with an expansion device.
  • a method of repairing a tubular assembly includes positioning a tubular patch within the tubular assembly; and radially expanding and plastically deforming a tubular patch into engagement with the tubular assembly by pressurizing the interior of the tubular patch.
  • a system for repairing a tubular assembly includes means for positioning a tubular patch within the tubular assembly; and means for radially expanding and plastically deforming a tubular patch into engagement with the tubular assembly by pressurizing the interior of the tubular patch.
  • a method of radially expanding a tubular member includes accumulating a supply of pressurized fluid; and controliably injecting the pressurized fluid into the interior of the tubular member.
  • a system for radially expanding a tubular member includes means for accumulating a supply of pressurized fluid; and means for controliably injecting the pressurized fluid into the interior of the tubular member.
  • an apparatus for radially expanding a tubular member includes a fluid reservoir; a pump for pumping fluids out of the fluid reservoir; an accumulator for receiving and accumulating the fluids pumped from the reservoir; a flow control valve for controliably releasing the fluids accumulated within the reservoir; and an expansion element for engaging the interior of the tubular member to define a pressure chamber within the tubular member and receiving the released accumulated fluids into the pressure chamber.
  • an apparatus for radially expanding a tubular member includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device; and an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
  • an apparatus for radially expanding a tubular member includes: an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device; an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member; means for transmitting torque between the expandable tubular member and the tubular support member; means for sealing the interface between the expandable tubular member and the tubular support member; another tubular support member received within the tubular support member releasably coupled to the expandable tubular member; means for transmitting torque between the expandable tubular member and the other tubular support member; means for transmitting torque between the other tubular support member and the tubular support member; means for sealing the interface between the other tubular support member and the tubular support member; means for sealing the interface between the expandable tubular member and the tubular support member; means for sensing the operating
  • a method for radially expanding a tubular member includes positioning a tubular member and an adjustable expansion device within a preexisting structure; radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; increasing the size of the adjustable expansion device; and radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member.
  • a system for radially expanding a tubular member includes means for positioning a tubular member and an adjustable expansion device within a preexisting structure; means for radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; means for increasing the size of the adjustable expansion device; and means for radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member.
  • a method of radially expanding and plastically deforming an expandable tubular member includes limiting the amount of radial expansion of the expandable tubular member.
  • an apparatus for radially expanding a tubular member includes an expandable tubular member; an expansion device coupled to the expandable tubular member for radially expanding and plastically deforming the expandable tubular member; and an tubular expansion limiter coupled to the expandable tubular member for limiting the degree to which the expandable tubular member may be radially expanded and plastically deformed.
  • an apparatus for radially expanding a tubular member includes: an expandable tubular member; an expansion device coupled to the expandable tubular member for radially expanding and plastically deforming the expandable tubular member; an tubular expansion limiter coupled to the expandable tubular member for limiting the degree to which the expandable tubular member may be radially expanded and plastically deformed; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device and the expansion device; means for transmitting torque between the expandable tubular member and the tubular support member; means for sealing the interface between the expandable tubular member and the tubular support member; means for sensing the operating pressure within the tubular support member; and means for pressurizing the interior of the tubular support member; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the
  • a method for radially expanding a tubular member includes positioning a tubular member and an adjustable expansion device within a preexisting structure; radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; limiting the extent to which the portion of the tubular member is radially expanded and plastically deformed by pressurizing the interior of the tubular member; increasing the size of the adjustable expansion device; and radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member.
  • a system for radially expanding a tubular member includes means for positioning a tubular member and an adjustable expansion device within a preexisting structure; means for radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; means for limiting the extent to which the portion of the tubular member is radially expanded and plastically deformed by pressurizing the interior of the tubular member; means for increasing the size of the adjustable expansion device; and means for radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member.
  • an apparatus for radially expanding an expandable tubular member includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; a first expansion device coupled to the tubular support member; a second expansion device coupled to the tubular support member; and an expandable tubular sleeve coupled to the second expansion device.
  • a method for radially expanding a tubular member includes positioning an expandable tubular member and an expandable tubular sleeve within a preexisting structure; radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve; and radially expanding and plastically deforming at least a portion of the expandable tubular sleeve.
  • a system for radially expanding a tubular member includes means for positioning an expandable tubular member and an expandable tubular sleeve within a preexisting structure; means for radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve; and means for radially expanding and plastically deforming at least a portion of the expandable tubular sleeve.
  • an apparatus for radially expanding an expandable tubular member includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; an adjustable expansion device coupled to the tubular support member; a non-adjustable expansion device coupled to the tubular support member; and an expandable tubular sleeve coupled to the non-adjustable expansion device.
  • a method for radially expanding a tubular member includes positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; increasing the size of the adjustable expansion device; radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve using the adjustable expansion device; and radially expanding and plastically deforming at least a portion of the expandable tubular sleeve.
  • a system for radially expanding a tubular member includes means for positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; means for increasing the size of the adjustable expansion device; means for radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve using the adjustable expansion device; and means for radially expanding and plastically deforming at least a portion of the expandable tubular sleeve.
  • an apparatus for radially expanding an expandable tubular member includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; and an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member.
  • a method for radially expanding a tubular member includes positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; increasing the size of the adjustable expansion device to radially expand and plastically deform at least a portion of at least one of the expandable tubular member and the expandable tubular sleeve; and radially expanding and plastically deforming at least another portion of the expandable tubular member using the adjustable expansion device.
  • a system for radially expanding a tubular member includes means for positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; means for increasing the size of the adjustable expansion device to radially expand and plastically deform at least a portion of at least one of the expandable tubular member and the expandable tubular sleeve; and means for radially expanding and plastically deforming at least another portion of the expandable tubular member using the adjustable expansion device.
  • FIG. 1 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
  • Fig. 2 is a fragmentary cross sectional view of the expandable tubular member of Fig.
  • FIG. 3 is a fragmentary cross sectional view of the expandable tubular member of Fig.
  • Fig. 4 is a fragmentary cross sectional view of the expandable tubular member of Fig.
  • Fig. 5 is a graphical illustration of exemplary embodiments of the stress/strain curves for several portions of the expandable tubular member of Figs. 1-4.
  • Fig. 6 is a graphical illustration of the an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member of Figs. 1-4.
  • FIG. 7 is a fragmentary cross sectional illustration of an embodiment of a series of overlapping expandable tubular members.
  • FIG. 8 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
  • Fig. 9 is a fragmentary cross sectional view of the expandable tubular member of Fig.
  • FIG. 10 is a fragmentary cross sectional view of the expandable tubular member of
  • FIG. 11 is a fragmentary cross sectional view of the expandable tubular member of
  • Fig. 12 is a graphical illustration of exemplary embodiments of the stress/strain curves for several portions of the expandable tubular member of Figs. 8-11.
  • Fig. 13 is a graphical illustration of an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member of Figs. 8-11.
  • Fig. 14 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
  • Fig. 15 is a fragmentary cross sectional view of the expandable tubular member of
  • Fig. 16 is a fragmentary cross sectional view of the expandable tubular member of
  • Fig. 15 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.
  • Fig. 17 is a fragmentary cross sectional view of the expandable tubular member of
  • Fig. 18 is a flow chart illustration of an exemplary embodiment of a method of processing an expandable tubular member.
  • Fig. 19 is a graphical illustration of the an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member during the operation of the method of Fig. 18.
  • Fig. 20 is a graphical illustration of stress/strain curves for an exemplary embodiment of an expandable tubular member.
  • Fig. 21 is a graphical illustration of stress/strain curves for an exemplary embodiment of an expandable tubular member.
  • Fig. 22 is a fragmentary cross-sectional view illustrating an embodiment of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, an embodiment of a tubular sleeve supported by the end portion of the first tubular member, and a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member and engaged by a flange of the sleeve.
  • the sleeve includes the flange at one end for increasing axial compression loading.
  • FIG. 23 is a fragmentary cross-sectional view illustrating an embodiment of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes flanges at opposite ends for increasing axial tension loading.
  • Fig. 24 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes flanges at opposite ends for increasing axial compression/tension loading.
  • FIG. 25 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes flanges at opposite ends having sacrificial material thereon.
  • Fig. 26 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes a thin walled cylinder of sacrificial material.
  • Fig. 27 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes a variable thickness along the length thereof.
  • Fig. 28 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes a member coiled onto grooves formed in the sleeve for varying the sleeve thickness.
  • Fig. 29 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.
  • Figs. 30a-30c are fragmentary cross-sectional illustrations of exemplary embodiments of expandable connections.
  • Fig. 31 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.
  • FIGs. 32a and 32b are fragmentary cross-sectional illustrations of the formation of an exemplary embodiment of an expandable connection.
  • Fig. 33 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.
  • Figs. 34a, 34b and 34c are fragmentary cross-sectional illustrations of an exemplary embodiment of an expandable connection.
  • Fig. 35a is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable tubular member.
  • Fig. 35b is a graphical illustration of an exemplary embodiment of the variation in the yield point for the expandable tubular member of Fig. 35a.
  • Fig. 36a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • Fig. 36b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
  • Fig. 36c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
  • Fig. 37a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • Fig. 37b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
  • Fig. 37c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
  • Fig. 38a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • Fig. 38b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
  • Fig. 38c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
  • Fig. 39a is a fragmentary cross sectional illustration of an exemplary embodiment of expandable tubular members positioned within a preexisting structure.
  • Fig. 39b is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 39a after placing an adjustable expansion device and a hydroforming expansion device within the expandable tubular members.
  • Fig. 39c is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 39b after operating the hydroforming expansion device to radially expand and plastically deform at least a portion of the expandable tubular members.
  • Fig. 39d is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 39c after operating the hydroforming expansion device to disengage from the expandable tubular members.
  • Fig. 39e is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 39d after positioning the adjustable expansion device within the radially expanded portion of the expandable tubular members and then adjusting the size of the adjustable expansion device.
  • Fig. 39f is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 39e after operating the adjustable expansion device to radially expand another portion of the expandable tubular members.
  • Fig. 40a is a fragmentary cross sectional illustration of an exemplary embodiment of expandable tubular members positioned within a preexisting structure.
  • Fig. 40b is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 40a after placing a hydroforming expansion device within a portion of the expandable tubular members.
  • Fig. 40c is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 40b after operating the hydroforming expansion device to radially expand and plastically deform at least a portion of the expandable tubular members.
  • Fig. 40d is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 40c after placing the hydroforming expansion device within another portion of the expandable tubular members.
  • Fig. 40e is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 40d after operating the hydroforming expansion device to radially expand and plastically deform at least another portion of the expandable tubular members.
  • Fig. 40f is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 40e after placing the hydroforming expansion device within another portion of the expandable tubular members.
  • Fig. 40g is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 40f after operating the hydroforming expansion device to radially expand and plastically deform at least another portion of the expandable tubular members.
  • Fig. 41a is a fragmentary cross sectional illustration of an exemplary embodiment of expandable tubular members positioned within a preexisting structure, wherein the bottom most tubular member includes a valveable passageway.
  • Fig. 41b is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41a after placing a hydroforming expansion device within the lower most expandable tubular member.
  • Fig. 41c is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41b after operating the hydroforming expansion device to radially expand and plastically deform at least a portion of the lower most expandable tubular member.
  • Fig. 41 d is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41c after disengaging hydroforming expansion device from the lower most expandable tubular member.
  • Fig. 41 e is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41 d after positioning the adjustable expansion device within the radially expanded and plastically deformed portion of the lower most expandable tubular member.
  • Fig. 41f is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41 e after operating the adjustable expansion device to engage the radially expanded and plastically deformed portion of the lower most expandable tubular member.
  • Fig. 41 g is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41f after operating the adjustable expansion device to radially expand and plastically deform at least another portion of the expandable tubular members.
  • Fig. 41 h is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41g after machining away the lower most portion of the lower most expandable tubular member.
  • Fig. 42a is a fragmentary cross sectional illustration of an exemplary embodiment of tubular members positioned within a preexisting structure, wherein one of the tubular members includes one or more radial passages.
  • Fig. 42b is a fragmentary cross sectional illustration of the tubular members of
  • FIG. 42c is a fragmentary cross sectional illustration of the tubular members of
  • Fig. 41 d is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41c after disengaging the hydroforming expansion device from the tubular member having the radial passages.
  • Fig. 41e is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41 d after removing the hydroforming expansion device from the tubular member having the radial passages.
  • Fig. 43 is a schematic illustration of an exemplary embodiment of a hydroforming expansion device.
  • Figs. 44a-44b are flow chart illustrations of an exemplary method of operating the hydroforming expansion device of Fig. 43.
  • Fig. 45a is a fragmentary cross sectional illustration of an exemplary embodiment of a radial expansion system positioned within a cased section of a wellbore.
  • Fig. 45b is a fragmentary cross sectional illustration of the system of Fig. 45a following the placement of a ball within the throat passage of the system.
  • Fig. 45c is a fragmentary cross sectional illustration of the system of Fig. 45b during the injection of fluidic materials to burst the burst disc of the system.
  • Fig. 45d is a fragmentary cross sectional illustration of the system of Fig. 45c during the continued injection of fluidic materials to radially expand and plastically deform at least a portion of the tubular liner hanger.
  • Fig. 45e is a fragmentary cross sectional illustration of the system of Fig. 45d during the continued injection of fluidic materials to adjust the size of the adjustable expansion device assembly.
  • Fig. 45f is a fragmentary cross sectional illustration of the system of Fig. 45e during the displacement of the adjustable expansion device assembly to radially expand another portion of the tubular liner hanger.
  • Fig. 45g is a fragmentary cross sectional illustration of the system of Fig. 45f following the removal of the system from the wellbore.
  • Fig. 46a is a fragmentary cross sectional illustration of an exemplary embodiment of a radial expansion system positioned within a cased section of a wellbore.
  • Fig. 46b is a fragmentary cross sectional illustration of the system of Fig. 46a following the placement of a plug within the throat passage of the system.
  • Fig. 46c is a fragmentary cross sectional illustration of the system of Fig. 46b during the injection of fluidic materials to burst the burst disc of the system.
  • Fig. 46d is a fragmentary cross sectional illustration of the system of Fig. 46c during the continued injection of fluidic materials to radially expand and plastically deform at least a portion of the tubular liner hanger.
  • Fig. 46e is a fragmentary cross sectional illustration of the system of Fig. 46d during the continued injection of fluidic materials to adjust the size of the adjustable expansion device assembly.
  • Fig. 46f is a fragmentary cross sectional illustration of the system of Fig. 46e during the displacement of the adjustable expansion device assembly to radially expand another portion of the tubular liner hanger.
  • Fig. 46g is a top view of a portion of an exemplary embodiment of an expansion limiter sleeve prior to the radial expansion and plastic deformation of the expansion limiter sleeve.
  • Fig. 46h is a top view of a portion of the expansion limiter sleeve of Fig. 46g after the radial expansion and plastic deformation of the expansion limiter sleeve.
  • Fig. 46i is a top view of a portion of an exemplary embodiment of an expansion limiter sleeve prior to the radial expansion and plastic deformation of the expansion limiter sleeve.
  • Fig. 46ia is a fragmentary cross sectional view of the expansion limiter sleeve of Fig. 46i.
  • Fig. 46j is a top view of a portion of the expansion limiter sleeve of Fig. 46i after the radial expansion and plastic deformation of the expansion limiter sleeve.
  • Fig. 47a is a fragmentary cross sectional illustration of an exemplary embodiment of a system for radially expanding and plastically deforming a tubular member during the injection of a hardenable fluidic sealing material into the system.
  • Fig. 47b is a fragmentary cross sectional illustration of the system of Fig. 47a during the subsequent placement of a plug within the flow passages of the system to permit the passages of the system to be pressurized.
  • Fig. 47c is a fragmentary cross sectional illustration of the system of Fig. 47b during the subsequent pressurization of the flow passages of the system to operate and displace the expansion cone of the system to radially expand and plastically deform a portion of the expandable tubular casing.
  • Fig. 47d is a fragmentary cross sectional illustration of the system of Fig. 47c during the subsequent continued pressurization of the flow passages of the system to operate and displace the expansion cones of the system to radially expand and plastically deform further portions of the expandable tubular casing and a portion of the expandable tubular sleeve.
  • Fig. 47e is a fragmentary cross sectional illustration of the system of Fig. 47d during the subsequent pressurization of the flow passages of the system to operate and displace the expansion cone of the system to radially expand and plastically deform further portions of the expandable tubular casing.
  • FIG. 48a is a fragmentary cross sectional illustration of an exemplary embodiment of a system for radially expanding and plastically deforming a tubular member during the injection of a hardenable fluidic sealing material into the system.
  • Fig. 48b is a fragmentary cross sectional illustration of the system of Fig. 48a during the subsequent placement of a plug within the flow passages of the system to permit the passages of the system to be pressurized.
  • Fig. 48c is a fragmentary cross sectional illustration of the system of Fig. 48b during the subsequent pressurization of the flow passages of the system to operate and adjust the size of the adjustable expansion device of the system.
  • Fig. 48d is a fragmentary cross sectional illustration of the system of Fig. 48c during the subsequent pressurization of the flow passages of the system to operate and displace the expansion device of the system to radially expand and plastically deform a portion of the expandable tubular casing.
  • Fig. 48e is a fragmentary cross sectional illustration of the system of Fig. 48d during the subsequent continued pressurization of the flow passages of the system to operate and displace the expansion device of the system to radially expand and plastically deform further portions of the expandable tubular casing and a portion of the expandable tubular sleeve.
  • Fig. 48f is a fragmentary cross sectional illustration of the system of Fig. 48e during the subsequent pressurization of the flow passages of the system to operate and displace the expansion cone of the system to radially expand and plastically deform further portions of the expandable tubular casing.
  • Fig. 49a is a fragmentary cross sectional illustration of an exemplary embodiment of a system for radially expanding and plastically deforming a tubular member during the injection of a hardenable fluidic sealing material into the system.
  • Fig. 49b is a fragmentary cross sectional illustration of the system of Fig. 49a during the subsequent placement of a plug within the flow passages of the system to permit the passages of the system to be pressurized.
  • Fig. 49c is a fragmentary cross sectional illustration of the system of Fig. 49b during the subsequent pressurization of the flow passages of the system to operate and adjust the size of the adjustable expansion device of the system.
  • Fig. 49d is a fragmentary cross sectional illustration of the system of Fig. 49c during the subsequent pressurization of the flow passages of the system to operate and displace the expansion device of the system to radially expand and plastically deform a portion of the expandable tubular casing.
  • Fig. 49e is a fragmentary cross sectional illustration of the system of Fig. 49d during the subsequent continued pressurization of the flow passages of the system to operate and displace the expansion device of the system to radially expand and plastically deform further portions of the expandable tubular casing and a portion of the expandable tubular sleeve.
  • Fig. 49f is a fragmentary cross sectional illustration of the system of Fig. 49e during the subsequent pressurization of the flow passages of the system to operate and displace the expansion cone of the system to radially expand and plastically deform further portions of the expandable tubular casing.
  • Fig. 50a is a fragmentary cross sectional illustration of an exemplary embodiment of a system for radially expanding and plastically deforming a tubular member during the injection of a hardenable fluidic sealing material into the system.
  • Fig. 50b is a fragmentary cross sectional illustration of the system of Fig. 50a during the subsequent placement of a plug within the flow passages of the system to permit the passages of the system to be pressurized.
  • Fig. 50c is a fragmentary cross sectional illustration of the system of Fig. 50b during the subsequent pressurization of the flow passages of the system to operate and adjust the size of the adjustable expansion device of the system to radially expand and plastically deform a portion of the expandable sleeve.
  • Fig. 50d is a fragmentary cross sectional illustration of the system of Fig. 50c during the subsequent pressurization of the flow passages of the system to operate and displace the expansion device of the system to radially expand and plastically deform a portion of the expandable tubular casing and release the expandable tubular casing from engagement with the casing lock assembly.
  • Fig. 50e is a fragmentary cross sectional illustration of the system of Fig. 50d during the subsequent continued pressurization of the flow passages of the system to operate and displace the expansion device of the system to radially expand and plastically deform further portions of the expandable tubular casing.
  • Fig. 50f is a fragmentary cross sectional illustration of the system of Fig. 50b during an emergency release of the expandable tubular casing from engagement with the locking dogs of the casing lock assembly.
  • an exemplary embodiment of an expandable tubular assembly 10 includes a first expandable tubular member 12 coupled to a second expandable tubular member 14.
  • the ends of the first and second expandable tubular members, 12 and 14, are coupled using, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection.
  • the first expandable tubular member 12 has a plastic yield point YP-i
  • the second expandable tubular member 14 has a plastic yield point YP .
  • the expandable tubular assembly 10 is positioned within a preexisting structure such as, for example, a wellbore 16 that traverses a subterranean formation 18.
  • an expansion device 20 may then be positioned within the second expandable tubular member 14.
  • the expansion device 20 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services,
  • the expansion device 20 is positioned within the second expandable tubular member 14 before, during, or after the placement of the expandable tubular assembly 10 within the preexisting structure 16.
  • the expansion device 20 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member
  • the expansion device 20 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 14 and at least a portion of the first expandable tubular member 12.
  • at least a portion of at least a portion of at least one of the first and second expandable tubular members, 12 and 14, are radially expanded into intimate contact with the interior surface of the preexisting structure 16.
  • the plastic yield point YPi is greater than the plastic yield point YP 2 .
  • the amount of power and/or energy required to radially expand the second expandable tubular member 14 is less than the amount of power and/or energy required to radially expand the first expandable tubular member 12.
  • the first expandable tubular member 12 and/or the second expandable tubular member 14 have a ductility D PE and a yield strength YS PE prior to radial expansion and plastic deformation, and a ductility D AE and a yield strength YS AE after radial expansion and plastic deformation.
  • D PE is greater than D AE .
  • YS AE is greater than YS PE . In this manner, the first expandable tubular member 12 and/or the second expandable tubular member 14 are transformed during the radial expansion and plastic deformation process.
  • the amount of power and/or energy required to radially expand each unit length of the first and/or second expandable tubular members, 12 and 14, is reduced. Furthermore, because the YS AE is greater than YS PE , the collapse strength of the first expandable tubular member 12 and/or the second expandable tubular member 14 is increased after the radial expansion and plastic deformation process. [00188] In an exemplary embodiment, as illustrated in Fig. 7, following the completion of the radial expansion and plastic deformation of the expandable tubular assembly 10 described above with reference to Figs. 1-4, at least a portion of the second expandable tubular member 14 has an inside diameter that is greater than at least the inside diameter of the first expandable tubular member 12.
  • a bell-shaped section is formed using at least a portion of the second expandable tubular member 14.
  • Another expandable tubular assembly 22 that includes a first expandable tubular member 24 and a second expandable tubular member 26 may then be positioned in overlapping relation to the first expandable tubular assembly 10 and radially expanded and plastically deformed using the methods described above with reference to Figs. 1-4.
  • at least a portion of the second expandable tubular member 26 has an inside diameter that is greater than at least the inside diameter of the first expandable tubular member 24.
  • a bell-shaped section is formed using at least a portion of the second expandable tubular member 26.
  • a mono- diameter tubular assembly is formed that defines an internal passage 28 having a substantially constant cross-sectional area and/or inside diameter.
  • first expandable tubular member 102 coupled to a tubular coupling 104.
  • the tubular coupling 104 is coupled to a tubular coupling 106.
  • the tubular coupling 106 is coupled to a second expandable tubular member 108.
  • the tubular couplings, 104 and 106 provide a tubular coupling assembly for coupling the first and second expandable tubular members, 102 and 108, together that may include, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection.
  • the first and second expandable tubular members 12 have a plastic yield point YP-i, and the tubular couplings, 104 and 106, have a plastic yield point YP 2 .
  • the expandable tubular assembly 100 is positioned within a preexisting structure such as, for example, a wellbore 110 that traverses a subterranean formation 112.
  • an expansion device 114 may then be positioned within the second expandable tubular member 108.
  • the expansion device 114 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services,
  • the expansion device 114 is positioned within the second expandable tubular member 108 before, during, or after the placement of the expandable tubular assembly 100 within the preexisting structure 110.
  • the expansion device 114 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 108 to form a bell-shaped section.
  • the expansion device 114 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 108, the tubular couplings, 104 and 106, and at least a portion of the first expandable tubular member 102.
  • At least a portion of at least a portion of at least one of the first and second expandable tubular members, 102 and 108, are radially expanded into intimate contact with the interior surface of the preexisting structure 110.
  • the plastic yield point YP T is less than the plastic yield point YP 2 .
  • the amount of power and/or energy required to radially expand each unit length of the first and second expandable tubular members, 102 and 108 is less than the amount of power and/or energy required to radially expand each unit length of the tubular couplings, 104 and 106.
  • the first expandable tubular member 12 and/or the second expandable tubular member 14 have a ductility D PE and a yield strength YS PE prior to radial expansion and plastic deformation, and a ductility D AE and a yield strength YS AE after radial expansion and plastic deformation.
  • D PE is greater than D AE
  • YS AE is greater than YS PE .
  • the amount of power and/or energy required to radially expand each unit length of the first and/or second expandable tubular members, 12 and 14, is reduced. Furthermore, because the YS AE is greater than YS PE , the collapse strength of the first expandable tubular member 12 and/or the second expandable tubular member 14 is increased after the radial expansion and plastic deformation process.
  • an exemplary embodiment of an expandable tubular assembly 200 includes a first expandable tubular member 202 coupled to a second expandable tubular member 204 that defines radial openings 204a, 204b, 204c, and 204d.
  • the ends of the first and second expandable tubular members, 202 and 204 are coupled using, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection.
  • one or more of the radial openings, 204a, 204b, 204c, and 204d have circular, oval, square, and/or irregular cross sections and/or include portions that extend to and interrupt either end of the second expandable tubular member 204.
  • the expandable tubular assembly 200 is positioned within a preexisting structure such as, for example, a wellbore
  • an expansion device 210 may then be positioned within the second expandable tubular member 204.
  • the expansion device 210 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services,
  • the expansion device 210 is positioned within the second expandable tubular member 204 before, during, or after the placement of the expandable tubular assembly 200 within the preexisting structure 206.
  • the expansion device 210 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 204 to form a bell-shaped section.
  • the expansion device 20 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 204 and at least a portion of the first expandable tubular member 202.
  • the second expandable tubular member 204 had an anisotropy ratio AR greater than 1 , and the radial expansion and plastic deformation of the second expandable tubular member did not result in any of the openings, 204a, 204b, 204c, and 204d, splitting or otherwise fracturing the remaining portions of the second expandable tubular member. This was an unexpected result.
  • one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 are processed using a method 300 in which a tubular member in an initial state is thermo-mechanically processed in step 302.
  • the thermo-mechanical processing 302 includes one or more heat treating and/or mechanical forming processes. As a result, of the thermo- mechanical processing 302, the tubular member is transformed to an intermediate state. The tubular member is then further thermo-mechanically processed in step 304.
  • the thermo-mechanical processing 304 includes one or more heat treating and/or mechanical forming processes. As a result, of the thermo-mechanical processing 304, the tubular member is transformed to a final state.
  • the tubular member has a ductility D PE and a yield strength YS PE prior to the final thermo-mechanical processing in step 304, and a ductility D AE and a yield strength YS AE after final thermo-mechanical processing.
  • D PE is greater than D AE
  • YS AE is greater than YS PE .
  • one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 have the following characteristics:
  • the strain hardening exponent for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 0.12.
  • the expandability coefficient for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 0.12.
  • a tubular member having a higher expandability coefficient requires less power and/or energy to radially expand and plastically deform each unit length than a tubular member having a lower expandability coefficient.
  • a tubular member having a higher expandability coefficient requires less power and/or energy per unit length to radially expand and plastically deform than a tubular member having a lower expandability coefficient.
  • one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 are steel alloys having one of the following compositions:
  • a sample of an expandable tubular member composed of Alloy A exhibited a yield point before radial expansion and plastic deformation YP BE , a yield point after radial expansion and plastic deformation of about 16 % YP AE ie % .
  • YP AE24% > YP A E I 6 % YP BE -
  • the ductility of the sample of the expandable tubular member composed of Alloy A also exhibited a higher ductility prior to radial expansion and plastic deformation than after radial expansion and plastic deformation.
  • a sample of an expandable tubular member composed of Alloy B exhibited a yield point before radial expansion and plastic deformation YP BE , a yield point after radial expansion and plastic deformation of about 16 % YP AE ⁇ 6% , and a yield point after radial expansion and plastic deformation of about 24 % YP AE2 %.
  • the ductility of the sample of the expandable tubular member composed of Alloy B also exhibited a higher ductility prior to radial expansion and plastic deformation than after radial expansion and plastic deformation. These were unexpected results.
  • a sample of an expandable tubular member composed of Alloy B exhibited the following tensile characteristics before and after radial expansion and plastic deformation:
  • samples of expandable tubulars composed of Alloys A, B, C, and D exhibited the following tensile characteristics prior to radial expansion and plastic deformation:
  • one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 have a strain hardening exponent greater than 0.12, and a yield ratio is less than 0.85.
  • the carbon equivalent value C e for tubular members having a carbon content less than or equal to 0.12% (by weight), for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is less than 0.21.
  • the carbon equivalent value C e for tubular members having greater than 0.12% carbon content (by weight), for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is less than 0.36.
  • a first tubular member 2210 includes an internally threaded connection 2212 at an end portion 2214.
  • the end portion 2214 of the first tubular member 2210 abuts one side of the internal flange 2218 of the tubular sleeve 2216, and the internal diameter of the internal flange 2218 of the tubular sleeve 2216 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 2212 of the end portion 2214 of the first tubular member
  • An externally threaded connection 2224 of an end portion 2226 of a second tubular member 2228 having an annular recess 2230 is then positioned within the tubular sleeve
  • the internal flange 2214 of the first tubular member 2210.
  • the internal flange 2214 of the first tubular member 2210.
  • tubular sleeve 2216 mates with and is received within the annular recess 2230 of the end portion 2226 of the second tubular member 2228.
  • the tubular sleeve 2216 is coupled to and surrounds the external surfaces of the first and second tubular members,
  • the internally threaded connection 2212 of the end portion 2214 of the first tubular member 2210 is a box connection
  • the externally threaded connection 2224 of the end portion 2226 of the second tubular member 2228 is a pin connection.
  • the internal diameter of the tubular sleeve 2216 is at least approximately .020" greater than the outside diameters of the first and second tubular members, 2210 and 2228. In this manner, during the threaded coupling of the first and second tubular members, 2210 and 2228, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • tubular sleeve 2216 may be positioned within another structure 2232 such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device 2234 within and/or through the interiors of the first and second tubular members.
  • a conventional expansion device 2234 within and/or through the interiors of the first and second tubular members.
  • tubular sleeve 2216 facilitates the insertion and movement of the first and second tubular members within and through the structure 2232, and the movement of the expansion device 2234 through the interiors of the first and second tubular members,
  • 2210 and 2228 may be, for example, from top to bottom or from bottom to top.
  • tubular sleeve 2216 is also radially expanded and plastically deformed. As a result, the tubular sleeve 2216 may be maintained in circumferential tension and the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, may be maintained in circumferential compression.
  • Sleeve 2216 increases the axial compression loading of the connection between tubular members 2210 and 2228 before and after expansion by the expansion device 2234.
  • Sleeve 2216 may, for example, be secured to tubular members 2210 and
  • first and second tubular members are first and second tubular members
  • 2210 and 2228 are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global
  • tubular sleeve 2216 The use of the tubular sleeve 2216 during (a) the coupling of the first tubular member 2210 to the second tubular member 2228, (b) the placement of the first and second tubular members in the structure 2232, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits.
  • the tubular sleeve 2216 protects the exterior surfaces of the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, during handling and insertion of the tubular members within the structure 2232. In this manner, damage to the exterior surfaces of the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, is avoided that could otherwise result in stress concentrations that could cause a catastrophic failure during subsequent radial expansion operations.
  • tubular sleeve 2216 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 2228 to the first tubular member 2210. In this manner, misalignment that could result in damage to the threaded connections, 2212 and 2224, of the first and second tubular members, 2210 and 2228, may be avoided.
  • the tubular sleeve 2216 provides an indication of to what degree the first and second tubular members are threadably coupled.
  • tubular sleeve 2216 can be easily rotated, that would indicate that the first and second tubular members, 2210 and 2228, are not fully threadably coupled and in intimate contact with the internal flange 2218 of the tubular sleeve.
  • the tubular sleeve 2216 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228. In this manner, failure modes such as, for example, longitudinal cracks in the end portions, 2214 and 2226, of the first and second tubular members may be limited in severity or eliminated all together.
  • the tubular sleeve 2216 may provide a fluid tight metal-to-metal seal between interior surface of the tubular sleeve 2216 and the exterior surfaces of the end portions, 2214 and 2226, of the first and second tubular members. In this manner, fluidic materials are prevented from passing through the threaded connections, 2212 and 2224, of the first and second tubular members, 2210 and 2228, into the annulus between the first and second tubular members and the structure 2232.
  • the tubular sleeve 2216 may be maintained in circumferential tension and the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.
  • one or more portions of the first and second tubular members, 2210 and 2228, and the tubular sleeve 2216 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
  • a first tubular member 210 includes an internally threaded connection 2312 at an end portion 2314.
  • a first end of a tubular sleeve 2316 includes an internal flange 2318 and a tapered portion 2320.
  • a second end of the sleeve 2316 includes an internal flange 2321 and a tapered portion 2322.
  • An externally threaded connection 2324 of an end portion 2326 of a second tubular member 2328 having an annular recess 2330 is then positioned within the tubular sleeve 2316 and threadably coupled to the internally threaded connection 2312 of the end portion 2314 of the first tubular member 2310.
  • the internal flange 2318 of the sleeve 2316 mates with and is received within the annular recess 2330.
  • the first tubular member 2310 includes a recess 2331.
  • the sleeve 2316 is coupled to and surrounds the external surfaces of the first and second tubular members
  • the internally threaded connection 2312 of the end portion 2314 of the first tubular member 2310 is a box connection
  • the externally threaded connection 2324 of the end portion 2326 of the second tubular member 2328 is a pin connection.
  • the internal diameter of the tubular sleeve 2316 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2310 and 2328. In this manner, during the threaded coupling of the first and second tubular members 2310 and 2328, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2310 and 2328, and the tubular sleeve 2316 may then be positioned within another structure 2332 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2334 through and/or within the interiors of the first and second tubular members.
  • the tapered portions 2320 and 2322, of the tubular sleeve 2316 facilitates the insertion and movement of the first and second tubular members within and through the structure 2332, and the displacement of the expansion device 2334 through the interiors of the first and second tubular members 2310 and 2328, may be from top to bottom or from bottom to top.
  • the tubular sleeve 2316 is also radially expanded and plastically deformed.
  • the tubular sleeve 2316 may be maintained in circumferential tension and the end portions 2314 and 2326, of the first and second tubular members 2310 and 2328, may be maintained in circumferential compression.
  • Sleeve 2316 increases the axial tension loading of the connection between tubular members 2310 and 2328 before and after expansion by the expansion device 2334.
  • Sleeve 2316 may be secured to tubular members 2310 and 2328 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2310 and 2328, and the tubular sleeve 2316 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • 2410 includes an internally threaded connection 2412 at an end portion 2414.
  • a first end of a tubular sleeve 2416 includes an internal flange 2418 and a tapered portion 2420.
  • a second end of the sleeve 2416 includes an internal flange 2421 and a tapered portion 2422.
  • the first tubular member 2410 includes a recess
  • the internal flange 2421 mates with and is received within the annular recess 2431.
  • the sleeve 2416 is coupled to and surrounds the external surfaces of the first and second tubular members 2410 and 2428.
  • the internally threaded connection 2412 of the end portion 2414 of the first tubular member 2410 is a box connection
  • the externally threaded connection 2424 of the end portion 2426 of the second tubular member 2428 is a pin connection.
  • the internal diameter of the tubular sleeve 2416 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2410 and 2428. In this manner, during the threaded coupling of the first and second tubular members 2410 and 2428, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2410 and 2428, and the tubular sleeve 2416 may then be positioned within another structure 2432 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2434 through and/or within the interiors of the first and second tubular members.
  • the tapered portions 2420 and 2422, of the tubular sleeve 2416 facilitate the insertion and movement of the first and second tubular members within and through the structure 2432, and the displacement of the expansion device 2434 through the interiors of the first and second tubular members, 2410 and 2428, may be from top to bottom or from bottom to top.
  • the tubular sleeve 2416 is also radially expanded and plastically deformed.
  • the tubular sleeve 2416 may be maintained in circumferential tension and the end portions, 2414 and 2426, of the first and second tubular members, 2410 and 2428, may be maintained in circumferential compression.
  • the sleeve 2416 increases the axial compression and tension loading of the connection between tubular members 2410 and 2428 before and after expansion by expansion device 2424.
  • Sleeve 2416 may be secured to tubular members 2410 and 2428 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2410 and 2428, and the tubular sleeve 2416 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • a 2510 includes an internally threaded connection 2512 at an end portion 2514.
  • a first end of a tubular sleeve 2516 includes an internal flange 2518 and a relief 2520.
  • a second end of the sleeve 2516 includes an internal flange 2521 and a relief 2522.
  • An externally threaded connection 2524 of an end portion 2526 of a second tubular member 2528 having an annular recess 2530 is then positioned within the tubular sleeve 2516 and threadably coupled to the internally threaded connection 2512 of the end portion 2514 of the first tubular member 2510.
  • the internal flange 2518 of the sleeve 2516 mates with and is received within the annular recess 2530.
  • the first tubular member 2510 includes a recess 2531.
  • the internal flange 2521 mates with and is received within the annular recess 2531.
  • the sleeve 2516 is coupled to and surrounds the external surfaces of the first and second tubular members 2510 and 2528.
  • the internally threaded connection 2512 of the end portion 2514 of the first tubular member 2510 is a box connection
  • the externally threaded connection 2524 of the end portion 2526 of the second tubular member 2528 is a pin connection.
  • the internal diameter of the tubular sleeve 2516 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2510 and 2528. In this manner, during the threaded coupling of the first and second tubular members 2510 and 2528, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2510 and 2528, and the tubular sleeve 2516 may then be positioned within another structure 2532 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2534 through and/or within the interiors of the first and second tubular members.
  • the reliefs 2520 and 2522 are each filled with a sacrificial material 2540 including a tapered surface 2542 and 2544, respectively.
  • the material 2540 may be a metal or a synthetic, and is provided to facilitate the insertion and movement of the first and second tubular members 2510 and 2528, through the structure
  • the displacement of the expansion device 2534 through the interiors of the first and second tubular members 2510 and 2528, may, for example, be from top to bottom or from bottom to top.
  • the tubular sleeve 2516 is also radially expanded and plastically deformed.
  • the tubular sleeve 2516 may be maintained in circumferential tension and the end portions 2514 and 2526, of the first and second tubular members, 2510 and 2528, may be maintained in circumferential compression.
  • sacrificial material 2540 provided on sleeve 2516, avoids stress risers on the sleeve 2516 and the tubular member 2510.
  • the tapered surfaces 2542 and 2544 are intended to wear or even become damaged, thus incurring such wear or damage which would otherwise be borne by sleeve 2516.
  • Sleeve 2516 may be secured to tubular members 2510 and 2528 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2510 and 2528, and the tubular sleeve 2516 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • 2610 includes an internally threaded connection 2612 at an end portion 2614.
  • a first end of a tubular sleeve 2616 includes an internal flange 2618 and a tapered portion 2620.
  • a second end of the sleeve 2616 includes an internal flange 2621 and a tapered portion 2622.
  • the first tubular member 2610 includes a recess 2631.
  • the sleeve 2616 is coupled to and surrounds the external surfaces of the first and second tubular members
  • the internally threaded connection 2612 of the end portion 2614 of the first tubular member 2610 is a box connection
  • the externally threaded connection 2624 of the end portion 2626 of the second tubular member 2628 is a pin connection.
  • the internal diameter of the tubular sleeve 2616 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2610 and 2628. In this manner, during the threaded coupling of the first and second tubular members 2610 and 2628, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2610 and 2628, and the tubular sleeve 2616 may then be positioned within another structure 2632 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2634 through and/or within the interiors of the first and second tubular members.
  • the tapered portions 2620 and 2622, of the tubular sleeve 2616 facilitates the insertion and movement of the first and second tubular members within and through the structure 2632, and the displacement of the expansion device 2634 through the interiors of the first and second tubular members 2610 and 2628, may, for example, be from top to bottom or from bottom to top.
  • tubular sleeve 2616 is also radially expanded and plastically deformed.
  • the tubular sleeve 2616 may be maintained in circumferential tension and the end portions 2614 and 2626, of the first and second tubular members 2610 and 2628, may be maintained in circumferential compression.
  • Sleeve 2616 is covered by a thin walled cylinder of sacrificial material 2640.
  • Spaces 2623 and 2624, adjacent tapered portions 2620 and 2622, respectively, are also filled with an excess of the sacrificial material 2640.
  • the material may be a metal or a synthetic, and is provided to facilitate the insertion and movement of the first and second tubular members 2610 and 2628, through the structure 2632.
  • sacrificial material 2640 provided on sleeve 2616, avoids stress risers on the sleeve 2616 and the tubular member 2610.
  • the excess of the sacrificial material 2640 adjacent tapered portions 2620 and 2622 are intended to wear or even become damaged, thus incurring such wear or damage which would otherwise be borne by sleeve 2616.
  • Sleeve 2616 may be secured to tubular members 2610 and 2628 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2610 and 2628, and the tubular sleeve 2616 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
  • FIG. 2710 includes an internally threaded connection 2712 at an end portion 2714.
  • a first end of a tubular sleeve 2716 includes an internal flange 2718 and a tapered portion 2720.
  • a second end of the sleeve 2716 includes an internal flange 2721 and a tapered portion 2722.
  • An externally threaded connection 2724 of an end portion 2726 of a second tubular member 2728 having an annular recess 2730 is then positioned within the tubular sleeve 2716 and threadably coupled to the internally threaded connection 2712 of the end portion 2714 of the first tubular member 2710.
  • the internal flange 2718 of the sleeve 2716 mates with and is received within the annular recess 2730.
  • the first tubular member 2710 includes a recess 2731.
  • the internal flange 2731 includes a recess 2731.
  • the sleeve 2716 is coupled to and surrounds the external surfaces of the first and second tubular members
  • the internally threaded connection 2712 of the end portion 2714 of the first tubular member 2710 is a box connection
  • the externally threaded connection 2724 of the end portion 2726 of the second tubular member 2728 is a pin connection.
  • the internal diameter of the tubular sleeve 2716 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2710 and 2728. In this manner, during the threaded coupling of the first and second tubular members 2710 and 2728, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2710 and 2728, and the tubular sleeve 2716 may then be positioned within another structure 2732 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2734 through and/or within the interiors of the first and second tubular members.
  • the tapered portions 2720 and 2722, of the tubular sleeve 2716 facilitates the insertion and movement of the first and second tubular members within and through the structure 2732, and the displacement of the expansion device 2734 through the interiors of the first and second tubular members 2710 and 2728, may be from top to bottom or from bottom to top.
  • the tubular sleeve 2716 is also radially expanded and plastically deformed.
  • the tubular sleeve 2716 may be maintained in circumferential tension and the end portions 2714 and 2726, of the first and second tubular members 2710 and 2728, may be maintained in circumferential compression.
  • Sleeve 2716 has a variable thickness due to one or more reduced thickness portions 2790 and/or increased thickness portions 2792.
  • Varying the thickness of sleeve 2716 provides the ability to control or induce stresses at selected positions along the length of sleeve 2716 and the end portions 2724 and 2726.
  • Sleeve 2716 may be secured to tubular members 2710 and 2728 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2710 and 2728, and the tubular sleeve 2716 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
  • a first tubular member 2740 which may be coiled onto the grooves 2739 formed in sleeve 2716, thus varying the thickness along the length of sleeve 2716.
  • 2910 includes an internally threaded connection 2912 and an internal annular recess 2914 at an end portion 2916.
  • a first end of a tubular sleeve 2918 includes an internal flange 2920, and a second end of the sleeve 2916 mates with and receives the end portion 2916 of the first tubular member 2910.
  • An externally threaded connection 2922 of an end portion 2924 of a second tubular member 2926 having an annular recess 2928 is then positioned within the tubular sleeve 2918 and threadably coupled to the internally threaded connection 2912 of the end portion 2916 of the first tubular member 2910.
  • the internal flange 2920 of the sleeve 2918 mates with and is received within the annular recess 2928.
  • a sealing element 2930 is received within the internal annular recess 2914 of the end portion 2916 of the first tubular member 2910.
  • the internally threaded connection 2912 of the end portion 2916 of the first tubular member 2910 is a box connection
  • the externally threaded connection 2922 of the end portion 2924 of the second tubular member 2926 is a pin connection.
  • the internal diameter of the tubular sleeve 2918 is at least approximately .020" greater than the outside diameters of the first tubular member 2910. In this manner, during the threaded coupling of the first and second tubular members 2910 and 2926, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the tubular sleeve 2918 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members. [00267] During the radial expansion and plastic deformation of the first and second tubular members 2910 and 2926, the tubular sleeve 2918 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2918 may be maintained in circumferential tension and the end portions 2916 and 2924, of the first and second tubular members 2910 and 2926, respectively, may be maintained in circumferential compression.
  • the sealing element 2930 seals the interface between the first and second tubular members.
  • a metal to metal seal is formed between at least one of: the first and second tubular members 2910 and 2926, the first tubular member and the tubular sleeve 2918, and/or the second tubular member and the tubular sleeve.
  • the metal to metal seal is both fluid tight and gas tight.
  • 2930 have one or more of the material properties of one or more of the tubular members 12,
  • 3010 includes internally threaded connections 3012a and 3012b, spaced apart by a cylindrical internal surface 3014, at an end portion 3016. Externally threaded connections
  • a sealing element 3026 is received within an annulus defined between the internal cylindrical surface 3014 of the first tubular member 3010 and the external cylindrical surface 3020 of the second tubular member 3024.
  • the sealing element 3026 is an elastomeric and/or metallic sealing element.
  • the first and second tubular members 3010 and 3024 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the sealing element 3026 seals the interface between the first and second tubular members.
  • a metal to metal seal is formed between at least one of: the first and second tubular members 3010 and 3024, the first tubular member and the sealing element 3026, and/or the second tubular member and the sealing element.
  • the metal to metal seal is both fluid tight and gas tight.
  • the sealing element 3026 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 3010 and 3024, a metal to metal seal is formed between the first and second tubular members.
  • one or more portions of the first and second tubular members, 3010 and 3024, the sealing element 3026 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
  • a first tubular member Referring to Fig. 30b, in an exemplary embodiment, a first tubular member
  • 3030 includes internally threaded connections 3032a and 3032b, spaced apart by an undulating approximately cylindrical internal surface 3034, at an end portion 3036.
  • Externally threaded connections 3038a and 3038b, spaced apart by a cylindrical external surface 3040, of an end portion 3042 of a second tubular member 3044 are threadably coupled to the internally threaded connections, 3032a and 3032b, respectively, of the end portion 3036 of the first tubular member 3030.
  • a sealing element 3046 is received within an annulus defined between the undulating approximately cylindrical internal surface 3034 of the first tubular member 3030 and the external cylindrical surface 3040 of the second tubular member 3044.
  • the sealing element 3046 is an elastomeric and/or metallic sealing element.
  • the first and second tubular members 3030 and 3044 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the sealing element 3046 seals the interface between the first and second tubular members.
  • a metal to metal seal is formed between at least one of: the first and second tubular members 3030 and 3044, the first tubular member and the sealing element 3046, and/or the second tubular member and the sealing element.
  • the metal to metal seal is both fluid tight and gas tight.
  • the sealing element 3046 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 3030 and 3044, a metal to metal seal is formed between the first and second tubular members.
  • one or more portions of the first and second tubular members, 3030 and 3044, the sealing element 3046 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
  • 3050 includes internally threaded connections 3052a and 3052b, spaced apart by a cylindrical internal surface 3054 including one or more square grooves 3056, at an end portion 3058.
  • Externally threaded connections 3060a and 3060b, spaced apart by a cylindrical external surface 3062 including one or more square grooves 3064, of an end portion 3066 of a second tubular member 3068 are threadably coupled to the internally threaded connections, 3052a and 3052b, respectively, of the end portion 3058 of the first tubular member 3050.
  • a sealing element 3070 is received within an annulus defined between the cylindrical internal surface 3054 of the first tubular member 3050 and the external cylindrical surface 3062 of the second tubular member 3068.
  • the sealing element 3070 is an elastomeric and/or metallic sealing element.
  • the first and second tubular members 3050 and 3068 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the sealing element 3070 seals the interface between the first and second tubular members.
  • a metal to metal seal is formed between at least one of: the first and second tubular members, the first tubular member and the sealing element 3070, and/or the second tubular member and the sealing element.
  • the metal to metal seal is both fluid tight and gas tight.
  • the sealing element 3070 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 950 and 968, a metal to metal seal is formed between the first and second tubular members.
  • one or more portions of the first and second tubular members, 3050 and 3068, the sealing element 3070 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
  • 3110 includes internally threaded connections, 3112a and 3112b, spaced apart by a non- threaded internal surface 3114, at an end portion 3116.
  • Externally threaded connections, 3118a and 3118b, spaced apart by a non-threaded external surface 3120, of an end portion 3122 of a second tubular member 3124 are threadably coupled to the internally threaded connections, 3112a and 3112b, respectively, of the end portion 3122 of the first tubular member 3124.
  • First, second, and/or third tubular sleeves, 3126, 3128, and 3130 are coupled the external surface of the first tubular member 3110 in opposing relation to the threaded connection formed by the internal and external threads, 3112a and 3118a, the interface between the non-threaded surfaces, 3114 and 3120, and the threaded connection formed by the internal and external threads, 3112b and 3118b, respectively.
  • first and second tubular members 3110 and 3124, and the tubular sleeves 3126, 3128, and/or 3130 may then be positioned within another structure 3132 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 3134 through and/or within the interiors of the first and second tubular members.
  • tubular sleeves 3126, 3128 and/or 3130 are also radially expanded and plastically deformed.
  • the tubular sleeves 3126, 3128, and/or 3130 are maintained in circumferential tension and the end portions 3116 and 3122, of the first and second tubular members 3110 and 3124, may be maintained in circumferential compression.
  • the sleeves 3126, 3128, and/or 3130 may, for example, be secured to the first tubular member 3110 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 3110 and 3124, and the sleeves, 3126, 3128, and 3130 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102,
  • 3210 includes an internally threaded connection 3212 at an end portion 3214.
  • An externally threaded connection 3216 of an end portion 3218 of a second tubular member 3220 are threadably coupled to the internally threaded connection 3212 of the end portion 3214 of the first tubular member 3210.
  • the internally threaded connection 3212 of the end portion 3214 of the first tubular member 3210 is a box connection
  • the externally threaded connection 3216 of the end portion 3218 of the second tubular member 3220 is a pin connection.
  • a tubular sleeve 3222 including internal flanges 3224 and 3226 is positioned proximate and surrounding the end portion 3214 of the first tubular member 3210. As illustrated in Fig. 32b, the tubular sleeve 3222 is then forced into engagement with the external surface of the end portion 3214 of the first tubular member 3210 in a conventional manner. As a result, the end portions, 3214 and 3218, of the first and second tubular members, 3210 and 3220, are upset in an undulating fashion.
  • 3222 may then be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the tubular sleeve 3222 is also radially expanded and plastically deformed.
  • the tubular sleeve 3222 is maintained in circumferential tension and the end portions 3214 and 3218, of the first and second tubular members 3210 and 3220, may be maintained in circumferential compression.
  • one or more portions of the first and second tubular members, 3210 and 3220, and the sleeve 3222 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • 3310 includes an internally threaded connection 3312 and an annular projection 3314 at an end portion 3316.
  • the end portion 3316 of the first tubular member 3310 abuts one side of the internal flange 3320 of the tubular sleeve 3318 and the annular projection 3314 of the end portion of the first tubular member mates with and is received within the annular recess 3324 of the internal flange of the tubular sleeve, and the internal diameter of the internal flange 3320 of the tubular sleeve 3318 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310.
  • the internal flange 3332 of the tubular sleeve 3318 mates with and is received within the annular recess 3332 of the end portion 3328 of the second tubular member 3330.
  • the tubular sleeve 3318 is coupled to and surrounds the external surfaces of the first and second tubular members, 3310 and 3328.
  • the internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310 is a box connection
  • the externally threaded connection 3326 of the end portion 3328 of the second tubular member 3330 is a pin connection.
  • the internal diameter of the tubular sleeve 3318 is at least approximately .020" greater than the outside diameters of the first and second tubular members, 3310 and 3330. In this manner, during the threaded coupling of the first and second tubular members, 3310 and 3330, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • tubular sleeve 3318 may be positioned within another structure 3334 such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device 3336 within and/or through the interiors of the first and second tubular members.
  • a conventional expansion device 3336 within and/or through the interiors of the first and second tubular members.
  • tubular sleeve 3318 facilitates the insertion and movement of the first and second tubular members within and through the structure 3334, and the movement of the expansion device 3336 through the interiors of the first and second tubular members,
  • 3310 and 3330 may, for example, be from top to bottom or from bottom to top.
  • tubular sleeve 3318 is also radially expanded and plastically deformed. As a result, the tubular sleeve 3318 may be maintained in circumferential tension and the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, may be maintained in circumferential compression.
  • Sleeve 3316 increases the axial compression loading of the connection between tubular members 3310 and 3330 before and after expansion by the expansion device 3336.
  • Sleeve 3316 may be secured to tubular members 3310 and 3330, for example, by a heat shrink fit.
  • first and second tubular members are identical to each other.
  • 3310 and 3330 are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global
  • tubular sleeve 3318 during (a) the coupling of the first tubular member 3310 to the second tubular member 3330, (b) the placement of the first and second tubular members in the structure 3334, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits.
  • the tubular sleeve 3318 protects the exterior surfaces of the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, during handling and insertion of the tubular members within the structure 3334. In this manner, damage to the exterior surfaces of the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, is avoided that could otherwise result in stress concentrations that could cause a catastrophic failure during subsequent radial expansion operations.
  • tubular sleeve 3318 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 3330 to the first tubular member 3310. In this manner, misalignment that could result in damage to the threaded connections, 3312 and 3326, of the first and second tubular members, 3310 and 3330, may be avoided.
  • the tubular sleeve 3318 provides an indication of to what degree the first and second tubular members are threadably coupled.
  • tubular sleeve 3318 can be easily rotated, that would indicate that the first and second tubular members, 3310 and 3330, are not fully threadably coupled and in intimate contact with the internal flange 3320 of the tubular sleeve. Furthermore, the tubular sleeve 3318 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330. In this manner, failure modes such as, for example, longitudinal cracks in the end portions, 3316 and 3328, of the first and second tubular members may be limited in severity or eliminated all together.
  • the tubular sleeve 3318 may provide a fluid tight metal-to-metal seal between interior surface of the tubular sleeve 3318 and the exterior surfaces of the end portions, 3316 and 3328, of the first and second tubular members. In this manner, fluidic materials are prevented from passing through the threaded connections, 3312 and 3326, of the first and second tubular members, 3310 and 3330, into the annulus between the first and second tubular members and the structure 3334. Furthermore, because, following the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330, the tubular sleeve 3318 may be maintained in circumferential tension and the end portions,
  • first and second tubular members, 3310 and 3330 may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.
  • one or more portions of the first and second tubular members, 3310 and 3330, and the sleeve 3318 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • a first tubular member 3410 includes an internally threaded connection 1312 and one or more external grooves 3414 at an end portion 3416.
  • the end portion 3416 of the first tubular member 3410 abuts one side of the internal flange 3420 of the tubular sleeve 3418, and the internal diameter of the internal flange 3420 of the tubular sleeve 3416 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 3412 of the end portion 3416 of the first tubular member 3410.
  • tubular sleeve 3418 is coupled to and surrounds the external surfaces of the first and second tubular members, 3410 and 3432.
  • first and second tubular members 3418 may be positioned within another structure such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device within and/or through the interiors of the first and second tubular members.
  • the tapered portions, 3422 and 3424, of the tubular sleeve 3418 facilitate the insertion and movement of the first and second tubular members within and through the structure, and the movement of the expansion device through the interiors of the first and second tubular members, 3410 and 3432, may be from top to bottom or from bottom to top.
  • tubular sleeve 3418 is also radially expanded and plastically deformed. As a result, the tubular sleeve 3418 may be maintained in circumferential tension and the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, may be maintained in circumferential compression.
  • Sleeve 3416 increases the axial compression loading of the connection between tubular members 3410 and 3432 before and after expansion by the expansion device.
  • the sleeve 3418 may be secured to tubular members 3410 and 3432, for example, by a heat shrink fit.
  • the grooves 3414 and/or 3434 and/or the openings 3426 provide stress concentrations that in turn apply added stress forces to the mating threads of the threaded connections, 3412 and 3428.
  • the mating threads of the threaded connections, 3412 and 3428 are maintained in metal to metal contact thereby providing a fluid and gas tight connection.
  • the orientations of the grooves 3414 and/or 3434 and the openings 3426 are orthogonal to one another.
  • the grooves 3414 and/or 3434 are helical grooves.
  • first and second tubular members are first and second tubular members
  • 3410 and 3432 are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global
  • tubular sleeve 3418 The use of the tubular sleeve 3418 during (a) the coupling of the first tubular member 3410 to the second tubular member 3432, (b) the placement of the first and second tubular members in the structure, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits.
  • the tubular sleeve 3418 protects the exterior surfaces of the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, during handling and insertion of the tubular members within the structure.
  • tubular sleeve 3418 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 3432 to the first tubular member 3410. In this manner, misalignment that could result in damage to the threaded connections, 3412 and 3428, of the first and second tubular members, 3410 and 3432, may be avoided.
  • the tubular sleeve 3416 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the tubular sleeve 3418 can be easily rotated, that would indicate that the first and second tubular members, 3410 and 3432, are not fully threadably coupled and in intimate contact with the internal flange 3420 of the tubular sleeve. Furthermore, the tubular sleeve 3418 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 3410 and
  • 3418 may provide a fluid and gas tight metal-to-metal seal between interior surface of the tubular sleeve 3418 and the exterior surfaces of the end portions, 3416 and 3430, of the first and second tubular members. In this manner, fluidic materials are prevented from passing through the threaded connections, 3412 and 3430, of the first and second tubular members,
  • tubular sleeve 3418 may be maintained in circumferential tension and the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.
  • the first and second tubular members described above with reference to Figs. 1 to 34c are radially expanded and plastically deformed using the expansion device in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following:
  • the present application is related to the following: (1) U.S. patent application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, (2) U.S. patent application serial no.
  • an exemplary embodiment of an expandable tubular member 3500 includes a first tubular region 3502 and a second tubular portion 3504.
  • the material properties of the first and second tubular regions, 3502 and 3504, are different.
  • the yield points of the first and second tubular regions, 3502 and 3504, are different.
  • the yield point of the first tubular region 3502 is less than the yield point of the second tubular region 3504.
  • one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 incorporate the tubular member 3500.
  • the yield point within the first and second tubular regions, 3502a and 3502b, of the expandable tubular member 3502 vary as a function of the radial position within the expandable tubular member.
  • the yield point increases as a function of the radial position within the expandable tubular member 3502.
  • the relationship between the yield point and the radial position within the expandable tubular member 3502 is a linear relationship.
  • the relationship between the yield point and the radial position within the expandable tubular member 3502 is a non-linear relationship.
  • the yield point increases at different rates within the first and second tubular regions, 3502a and 3502b, as a function of the radial position within the expandable tubular member 3502.
  • the functional relationship, and value, of the yield points within the first and second tubular regions, 3502a and 3502b, of the expandable tubular member 3502 are modified by the radial expansion and plastic deformation of the expandable tubular member.
  • one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502, prior to a radial expansion and plastic deformation include a microstructure that is a combination of a hard phase, such as martensite, a soft phase, such as ferrite, and a transitionary phase, such as retained austentite.
  • a hard phase such as martensite
  • a soft phase such as ferrite
  • a transitionary phase such as retained austentite.
  • the hard phase provides high strength
  • the soft phase provides ductility
  • the transitionary phase transitions to a hard phase, such as martensite, during a radial expansion and plastic deformation.
  • the yield point of the tubular member increases as a result of the radial expansion and plastic deformation.
  • the tubular member is ductile, prior to the radial expansion and plastic deformation, thereby facilitating the radial expansion and plastic deformation.
  • the composition of a dual-phase expandable tubular member includes (weight percentages): about 0.1% C, 1.2% Mn, and 0.3% Si.
  • an expandable tubular member 3602a is provided that is a steel alloy having following material composition (by weight percentage): 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01 %Mo, 0.01% Nb, and 0.01% Ti.
  • the expandable tubular member 3602a provided in step 3602 has a yield strength of 45 ksi, and a tensile strength of 69 ksi.
  • the expandable tubular member 3602a includes a microstructure that includes martensite, peariite, and V, Ni, and/or Ti carbides.
  • the expandable tubular member 3602a is then heated at a temperature of 790 °C for about 10 minutes in step 3604.
  • the expandable tubular member 3602a is then quenched in water in step 3606.
  • the expandable tubular member 3602a includes a microstructure that includes new ferrite, grain peariite, martensite, and ferrite.
  • the expandable tubular member 3602a has a yield strength of 67 ksi, and a tensile strength of 95 ksi.
  • the expandable tubular member 3602a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above.
  • the yield strength of the expandable tubular member is about 95 ksi.
  • an expandable tubular member 3702a is provided that is a steel alloy having following material composition (by weight percentage): 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,
  • the expandable tubular member 3702a provided in step 3702 has a yield strength of 60 ksi, and a tensile strength of 80 ksi.
  • the expandable tubular member 3702a includes a microstructure that includes peariite and peariite striation.
  • the expandable tubular member 3702a is then heated at a temperature of 790 °C for about 10 minutes in step 3704.
  • the expandable tubular member 3702a is then quenched in water in step 3706.
  • the expandable tubular member 3702a includes a microstructure that includes ferrite, martensite, and bainite.
  • the expandable tubular member 3702a has a yield strength of 82 ksi, and a tensile strength of 130 ksi.
  • the expandable tubular member 3702a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above.
  • the yield strength of the expandable tubular member is about 130 ksi.
  • an expandable tubular member 3802a is provided that is a steel alloy having following material composition (by weight percentage): 0.08% C, 0.82% Mn, 0.006% P, 0.003% S,
  • the expandable tubular member 3802a provided in step 3802 has a yield strength of 56 ksi, and a tensile strength of 75 ksi.
  • the expandable tubular member 3802a includes a microstructure that includes grain peariite, widmanstatten martensite and carbides of V, Ni, and/or Ti.
  • the expandable tubular member 3802a is then heated at a temperature of 790 °C for about 10 minutes in step 3804.
  • the expandable tubular member 3802a is then quenched in water in step 3806.
  • the expandable tubular member 3802a includes a microstructure that includes bainite, peariite, and new ferrite.
  • the expandable tubular member 3802a has a yield strength of 60 ksi, and a tensile strength of 97 ksi.
  • the expandable tubular member 3802a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above.
  • the yield strength of the expandable tubular member is about 97 ksi.
  • teachings of the present disclosure are combined with one or more of the teachings disclosed in FR 2 841 626, filed on 6/28/2002, and published on 1/2/2004, the disclosure of which is incorporated herein by reference.
  • 3900 includes an adjustable expansion device 3902 and a hydroforming expansion device
  • the adjustable expansion device 3902 includes one or more elements of conventional adjustable expansion devices and/or one or more elements of the adjustable expansion devices disclosed in one or more of the related applications referenced above and/or one or more elements of the conventional commercially available adjustable expansion devices available from Baker Hughes,
  • the hydroforming expansion device 3904 includes one or more elements of conventional hydroforming expansion devices and/or one or more elements of the hydroforming expansion devices disclosed in one or more of the related applications referenced above and/or one or more elements of the conventional commercially available hydroforming devices available from Baker Hughes, Weatherford
  • adjustable expansion device 3902 and the hydroforming expansion device 3904 may be combined in a single device and/or include one or more elements of each other.
  • the expansion system is positioned within an expandable tubular assembly that includes first and second tubular members, 3908 and
  • the hydroforming expansion device 3904 may then be operated to radially expand and plastically deform a portion of the second tubular member 3910.
  • the hydroforming expansion device 3904 may then be disengaged from the second tubular member 3910.
  • the adjustable expansion device 3902 may then be positioned within the radially expanded portion of the second tubular member 3910 and the size the adjustable expansion device increased. [00349] In an exemplary embodiment, as illustrated in Fig. 39f, the adjustable expansion device 3902 may then be operated to radially expand and plastically deform one or more portions of the first and second tubular members, 3908 and 3910.
  • an exemplary embodiment of an expansion system 4000 includes a hydroforming expansion device 4002 that is coupled to a support member 4004.
  • the hydroforming expansion device 4002 includes one or more elements of conventional hydroforming expansion devices and/or one or more elements of the hydroforming expansion devices disclosed in one or more of the related applications referenced above and/or one or more elements of the conventional commercially available hydroforming devices available from Baker Hughes, Weatherford
  • the expansion system is positioned within an expandable tubular assembly that includes first and second tubular members, 4006 and
  • the hydroforming expansion device 4002 may then be repeatedly operated to radially expand and plastically deform one or more portions of the first and second tubular members, 4008 and 4010.
  • an exemplary embodiment of an expansion system 4100 includes an adjustable expansion device 4102 and a hydroforming expansion device 4104 that are both coupled to a tubular support member 4106.
  • the adjustable expansion device 4102 includes one or more elements of conventional adjustable expansion devices and/or one or more elements of the adjustable expansion devices disclosed in one or more of the related applications referenced above and/or one or more elements of the conventional commercially available adjustable expansion devices available from Baker Hughes,
  • the hydroforming expansion device 4104 includes one or more elements of conventional hydroforming expansion devices and/or one or more elements of the hydroforming expansion devices disclosed in one or more of the related applications referenced above and/or one or more elements of the conventional commercially available hydroforming devices available from Baker Hughes, Weatherford International, Schlumberger, and/or Enventure Global Technology L.L.C. and/or one or more elements of the hydroforming expansion devices disclosed in U.S. Patent No. 5,901 ,594, the disclosure of which is incorporated herein by reference.
  • the adjustable expansion device 4102 and the hydroforming expansion device 4104 may be combined in a single device and/or include one or more elements of each other. [00356] In an exemplary embodiment, during the operation of the expansion system
  • the expansion system is positioned within an expandable tubular assembly that includes first and second tubular members, 4108 and 4110, that are coupled end to end and positioned and supported within a preexisting structure such as, for example, a wellbore 4112 that traverses a subterranean formation 4114.
  • a shoe 4116 having a valveable passage 4118 is coupled to the lower portion of the second tubular member 4110.
  • the first and second tubular members, 4108 and 4110 include one or more of the characteristics of the expandable tubular members described in the present application.
  • the hydroforming expansion device 4104 may then be operated to radially expand and plastically deform a portion of the second tubular member 4110.
  • the hydroforming expansion device 4104 may then be disengaged from the second tubular member 4110.
  • the adjustable expansion device 4102 may then be positioned within the radially expanded portion of the second tubular member 4110 and the size the adjustable expansion device increased.
  • the valveable passage 4118 of the shoe 4116 may then be closed, for example, by placing a ball 4120 within the passage in a conventional manner.
  • the adjustable expansion device 4102 may then be operated to radially expand and plastically deform one or more portions of the first and second tubular members, 4108 and 4110, above the shoe 4116.
  • an exemplary embodiment of an expansion system 4200 includes a hydroforming expansion device 4202 that is coupled to a tubular support member 4204.
  • An expandable tubular member 4206 is coupled to and supported by the hydroforming expansion device 4202.
  • the hydroforming expansion device 4202 includes one or more elements of conventional hydroforming expansion devices and/or one or more elements of the hydroforming expansion devices disclosed in one or more of the related applications referenced above and/or one or more elements of the conventional commercially available hydroforming devices available from Baker Hughes, Weatherford
  • the expandable tubular member 4206 includes one or more of the characteristics of the expandable tubular members described in the present application.
  • the expansion system is positioned within an expandable tubular assembly that includes first and second tubular members, 4208 and
  • the second tubular member 4210 includes one or more radial passages 4212.
  • the expandable tubular member 4206 is positioned in opposing relation to the radial passages 4212 of the second tubular member
  • the hydroforming expansion device 4202 may then be operated to radially expand and plastically deform the expandable tubular member 4206 into contact with the interior surface of the second tubular member 4210 thereby covering and sealing off the radial passages 4212 of the second tubular member.
  • the hydroforming expansion device 4202 may then be disengaged from the expandable tubular member 4206.
  • the expansion system 4200 may then be removed from the wellbore 4212.
  • an exemplary embodiment of a hydroforming expansion system 4300 includes an expansion element 4302 that is provided substantially as disclosed in U.S. Patent No. 5,901 ,594, the disclosure of which is incorporated herein by reference.
  • a flow line 4304 is coupled to the inlet of the expansion element 4302 and the outlet of conventional 2-way/2-position flow control valve 4306.
  • a flow line 4308 is coupled to an inlet of the flow control valve 4306 and an outlet of a conventional accumulator 4310, and a flow line 4312 is coupled to another inlet of the flow control valve and a fluid reservoir
  • a flow line 4316 is coupled to the flow line 4308 and an the inlet of a conventional pressure relief valve 4318, and a flow line 4320 is coupled to the outlet of the pressure relief valve and the fluid reservoir 4314.
  • a flow line 4322 is coupled to the inlet of the accumulator 4310 and the outlet of a conventional check valve 4324.
  • a flow line 4326 is coupled to the inlet of the check valve 4324 and the outlet of a conventional pump 4328.
  • a flow line 4330 is coupled to the flow line 4326 and the inlet of a conventional pressure relief valve 4332.
  • a flow line 4334 is coupled to the outlet of the pressure relief valve 4332 and the fluid reservoir 4314, and a flow line 4336 is coupled to the inlet of the pump 4328 and the fluid reservoir.
  • a controller 4338 is operably coupled to the flow control valve 4306 and the pump 4328 for controlling the operation of the flow control valve and the pump.
  • the controller 4338 is a programmable general purpose controller.
  • Conventional pressure sensors, 4340, 4342 and 4344 are operably coupled to the expansion element 4302, the accumulator 4310, and the flow line 4326, respectively, and the controller 4338.
  • a conventional user interface 4346 is operably coupled to the controller
  • the system implements a method of operation 4400 in which, in step 4402, the user may select expansion of an expandable tubular member. If the user selects expansion in step 4402, then the controller 4338 determines if the operating pressure of the accumulator 4310, as sensed by the pressure sensor 4342, is greater than or equal to a predetermined value in step 4404.
  • step 4404 If the operating pressure of the accumulator 4310, as sensed by the pressure sensor 4342, is not greater than or equal to the predetermined value in step 4404, then the controller 4338 operates the pump 4328 to increase the operating pressure of the accumulator in step 4406. The controller 4338 then determines if the operating pressure of the accumulator 4310, as sensed by the pressure sensor 4342, is greater than or equal to a predetermined value in step 4408. If the operating pressure of the accumulator 4310, as sensed by the pressure sensor 4342, in step 4408, is not greater than or equal to the predetermined value, then the controller 4338 continues to operate the pump 4328 to increase the operating pressure of the accumulator in step 4406.
  • the controller 4338 operates the flow control valve 4306 to pressurize the expansion element 4302 in step 4410 by positioning the flow control valve to couple the flow lines 4304 and 4308 to one another. If the expansion operation has been completed in step 4412, then the controller 4338 operates the flow control valve 4306 to de-pressurize the expansion element 4302 in step 4414 by positioning the flow control valve to couple the flow lines 4304 and 4312 to one another.
  • one or more of the hydroforming expansion devices 4002, 4104, and 4202 incorporate one or more elements of the hydroforming expansion system 4300 and/or the operational steps of the method 4400.
  • FIG. 45a an exemplary embodiment of a liner hanger system
  • 4500 includes a tubular support member 4502 that defines a passage 4502a and includes an externally threaded connection 4502b at an end.
  • An internally threaded connection
  • 4504a of an end of an outer tubular mandrel 4504 that defines a passage 4504b and includes an external flange 4504c, an internal annular recess 4504d, an external annular recess 4504e, an external annular recess 4504f, an external flange 4504g, an external annular recess 4504h, an internal flange 4504i, an external flange 4504j, and a plurality of circumferentially spaced apart longitudinally aligned teeth 4504k at another end, is coupled to and receives the externally threaded connection 4502b of the end of the tubular support member 4502.
  • An end of a tubular liner hanger 4506 that abuts and mates with an end face of the external flange 4504c of the outer tubular mandrel 4504 receives and mates with the outer tubular mandrel, and includes internal teeth 4506a, a plurality of circumferentially spaced apart longitudinally aligned internal teeth 4506b, an internal flange 4506c, and an external threaded connection 4506d at another end.
  • at least a portion of the tubular liner hanger 4506 includes one or more of the characteristics of the expandable tubular members described in the present application.
  • An internal threaded connection 4508a of an end of a tubular liner 4508 receives and is coupled to the external threaded connection 4506d of the tubular liner hanger 4506.
  • Spaced apart elastomeric sealing elements, 4510, 4512, and 4514, are coupled to the exterior surface of the end of the tubular liner hanger 4506
  • An external flange 4516a of an end of an inner tubular mandrel 4516 that defines a longitudinal passage 4516b having a throat 4516ba and a radial passage 4516c and includes a sealing member 4516d mounted upon the external flange for sealingly engaging the inner annular recess 4504d of the outer tubular mandrel 4504, an external flange 4516e at another end that includes a plurality of circumferentially spaced apart teeth
  • a conventional rupture disc 4518 is received within and coupled to the radial passage 4516c of the inner tubular mandrel 4516.
  • a conventional packer cup 4520 is mounted within and coupled to the external annular recess 4504e of the outer tubular mandrel 4504 for sealingly engaging the interior surface of the tubular liner hanger 4506.
  • a locking assembly 4522 is mounted upon and coupled to the outer tubular mandrel 4504 proximate the external flange 4504g in opposing relation to the internal teeth 4506a of the tubular liner hanger 4506 for controliably engaging and locking the position of the tubular liner hanger relative to the outer tubular mandrel 4504.
  • the locking assembly 4522 may be a conventional locking device for locking the position of a tubular member relative to another member.
  • the locking assembly 4522 may include one or more elements of the locking assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no.
  • An adjustable expansion device assembly 4524 is mounted upon and coupled to the outer tubular mandrel 4504 between the locking assembly 4522 and the external flange 4504j for controliably radially expanding and plastically deforming the tubular liner hanger 4506.
  • the adjustable expansion device assembly 4524 may be a conventional adjustable expansion device assembly for radially expanding and plastically deforming tubular members that may include one or more elements of conventional adjustable expansion cones, mandrels, rotary expansion devices, hydroforming expansion devices and/or one or more elements of the one or more of the commercially available adjustable expansion devices of Enventure Global Technology LLC, Baker Hughes, Weatherford International, and/or Schlumberger and/or one or more elements of the adjustable expansion devices disclosed in one or more of the published patent applications and/or issued patents of Enventure Global Technology LLC, Baker Hughes, Weatherford International, Shell Oil Co. and/or Schlumberger.
  • the adjustable expansion device assembly 4524 may include one or more elements of the adjustable expansion device assemblies disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no.
  • a conventional SSR plug set 4526 is mounted within and coupled to the internal flange 4506c of the tubular liner hanger 4506.
  • the system during operation of the system 4500, as illustrated in Fig. 45a, the system is positioned within a wellbore 4528 that traverses a subterranean formation 4530 and includes a preexisting wellbore casing 4532 coupled to and positioned within the wellbore.
  • the system 4500 is positioned such that the tubular liner hanger 4506 overlaps with the casing 4532.
  • a ball 4534 is then positioned in the throat passage 4516ba by injecting fluidic materials 4536 into the system 4500 through the passages 4502a, 4504b, and 4516b, of the tubular support member 4502, outer tubular mandrel 4504, and inner tubular mandrel 4516, respectively.
  • the continued injection of the fluidic materials 4536 into the system 4500 pressurizes the passage 4516b of the inner tubular mandrel 4516 such that the rupture disc 4518 is ruptured thereby permitting the fluidic materials to pass through the radial passage 4516c of the inner tubular mandrel.
  • the interior of the tubular liner hanger 4506 is pressurized.
  • the continued injection of the fluidic materials 4536 into the interior of the tubular liner hanger 4506 radially expands and plastically deforms at least a portion of the tubular liner hanger.
  • the continued injection of the fluidic materials 4536 into the interior of the tubular liner hanger 4506 radially expands and plastically deforms a portion of the tubular liner hanger positioned in opposition to the adjustable expansion device assembly 4524.
  • the continued injection of the fluidic materials 4536 into the interior of the tubular liner hanger 4506 radially expands and plastically deforms a portion of the tubular liner hanger positioned in opposition to the adjustable expansion device assembly 4524 into engagement with the wellbore casing 4532.
  • the size of the adjustable expansion device assembly 4524 is then increased within the radially expanded portion of the tubular liner hanger 4506, and the locking assembly 4522 is operated to unlock the tubular liner hanger from engagement with the locking assembly.
  • the locking assembly 4522 and the adjustable expansion device assembly 4524 are operated using the operating pressure provided by the continued injection of the fluidic materials 4536 into the system 4500.
  • the adjustment of the adjustable expansion device assembly 4524 to a larger size radially expands and plastically deforms at least a portion of the tubular liner hanger 4506.
  • the adjustable expansion device assembly 4524 is displaced in a longitudinal direction relative to the tubular liner hanger 4506 thereby radially expanding and plastically deforming the tubular liner hanger.
  • the tubular liner hanger 4506 is radially expanded and plastically deformed into engagement with the casing 4532.
  • the adjustable expansion device assembly 4524 is displaced in a longitudinal direction relative to the tubular liner hanger 4506 due to the operating pressure within the tubular liner hanger generated by the continued injection of the fluidic materials 4536.
  • the adjustable expansion device assembly 4524 is displaced in a longitudinal direction relative to the tubular liner hanger 4506 due to the operating pressure within the tubular liner hanger below the packer cup 4520 generated by the continued injection of the fluidic materials 4536. In this manner, the adjustable expansion device assembly 4524 is pulled through the tubular liner hanger 4506 by the operation of the packer cup 4520.
  • the adjustable expansion device assembly 4524 is displaced in a longitudinal direction relative to the tubular liner hanger 4506 thereby radially expanding and plastically deforming the tubular liner hanger until the internal flange 4504i of the outer tubular mandrel 4504 engages the external flange 4516a of the end of the inner tubular mandrel 4516.
  • the 4504 due to the engagement of the internal flange 4504i of the outer tubular mandrel 4504 with the external flange 4516a of the end of the inner tubular mandrel 4516, the inner tubular mandrel and the
  • SSR plug set 4526 may be removed from the wellbore 4528.
  • a hardenable fluidic sealing material such as, for example, cement
  • a hardenable fluidic sealing material such as, for example, cement
  • the size of the adjustable expansion device 4524 is increased prior to, during, or after the hydroforming expansion of the tubular liner hanger 4506 caused by the injection of the fluidic materials 4536 into the interior of the tubular liner hanger.
  • At least a portion of the tubular liner hanger 4506 includes a plurality of nested expandable tubular members bonded together by, for example, amorphous bonding.
  • at least a portion of the tubular liner hanger 4506 is fabricated for materials particularly suited for subsequent drilling out operations such as, for example, aluminum and/or copper based materials and alloys.
  • the portion of the tubular liner hanger 4506 positioned below the adjustable expansion device 4524 is radially expanded and plastically deformed by displacing the adjustable expansion device downwardly.
  • At least a portion of the tubular liner hanger 4506 is fabricated for materials particularly suited for subsequent drilling out operations such as, for example, aluminum and/or copper based materials and alloys.
  • the portion of the tubular liner hanger 4506 fabricated for materials particularly suited for subsequent drilling out operations is not hydroformed by the injection of the fluidic materials 4536.
  • At least a portion of the tubular liner hanger 4506 is hydroformed by the injection of the fluidic materials 4536, the remaining portion of the tubular liner hanger above the initial position of the adjustable expansion device 4524 is then radially expanded and plastically deformed by displacing the adjustable expansion device upwardly, and the portion of the tubular liner hanger below the initial position of the adjustable expansion device is radially expanded by then displacing the adjustable expansion device downwardly.
  • the portion of the tubular liner hanger 4506 that is radially expanded and plastically deformed is radially expanded and plastically deformed solely by hydroforming caused by the injection of the fluidic materials 4536.
  • the portion of the tubular liner hanger 4506 that is radially expanded and plastically deformed is radially expanded and plastically deformed solely by the adjustment of the adjustable expansion device 4524 to an increased size and the subsequent displacement of the adjustable expansion device relative to the tubular liner hanger.
  • an exemplary embodiment of a system 4600 for radially expanding a tubular member includes a tubular support member 4602 that defines a passage 4602a.
  • 4604a is coupled to an end of the tubular support member 4602, and another end of the safety sub 4604 is coupled to an end of a tubular casing lock assembly 4606 that defines a passage 4606a.
  • the lock assembly 4606 may be a conventional locking device for locking the position of a tubular member relative to another member.
  • the lock assembly 4606 may include one or more elements of the locking assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
  • PCT/US03/18530 attorney docket number 25791.108.02, filed on 6/11/2003
  • PCT patent application serial number PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number
  • a end of a tubular support member 4608 that defines a passage 4608a and includes an outer annular recess 4608b is coupled to another end of the lock assembly
  • tubular support member 4606 and another end of the tubular support member 4608 is coupled to an end of a tubular support member 4610 that defines a passage 4610a, a radial passage 4610b, and includes an outer annular recess 4610c, an inner annular recess 461 Od, and circumferentially spaced apart teeth 461 Oe at another end.
  • an adjustable expansion device assembly 4612 is mounted upon and coupled to the outer annular recess 4610c of the tubular support member 4610.
  • the adjustable expansion device assembly 4612 may be a conventional adjustable expansion device assembly for radially expanding and plastically deforming tubular members that may include one or more elements of conventional adjustable expansion cones, mandrels, rotary expansion devices, hydroforming expansion devices and/or one or more elements of the one or more of the commercially available adjustable expansion devices of Enventure Global Technology LLC, Baker Hughes, Weatherford International, and/or Schlumberger and/or one or more elements of the adjustable expansion devices disclosed in one or more of the published patent applications and/or issued patents of Enventure Global Technology LLC, Baker Hughes, Weatherford International, Shell Oil
  • the adjustable expansion device assembly 4524 may include one or more elements of the adjustable expansion device assemblies disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
  • PCT/US03/18530 attorney docket number 25791.108.02, filed on 6/11/2003
  • PCT patent application serial number PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number
  • 4614aa and includes a plurality of circumferentially spaced apart teeth 4614b at an end that mate with and engage the teeth 461 Oe of the tubular support member 4610 for transmitting torsional loads therebetween and an external threaded connection 4614c is received within the inner annular recess 461 Od of the tubular support member.
  • an end of an expandable tubular member 4616 is coupled to the external threaded connection 4614c of the float shoe 4614 and another portion of the expandable tubular member is coupled to the lock assembly 4606.
  • at least a portion of the expandable tubular member 4616 includes one or more of the characteristics of the expandable tubular members described in the present application.
  • the portion of the expandable tubular member 4616 proximate and positioned in opposition to the adjustable expansion device assembly 4612 includes an outer expansion limiter sleeve 4618 for limiting the amount of radial expansion of the portion of the expandable tubular member proximate and positioned in opposition to the adjustable expansion device assembly.
  • at least a portion of the outer expansion limiter sleeve 4618 includes one or more of the characteristics of the expandable tubular members described in the present application.
  • a cup seal assembly 4620 is coupled to and positioned within the outer annular recess 4608b of the tubular support member 4608 for sealingly engaging the interior surface of the expandable tubular member 4616.
  • a rupture disc 4622 is positioned within and coupled to the radial passage 4610b of the tubular support member 4610.
  • the system is positioned within a wellbore 4624 that traverses a subterranean formation 4626 and includes a preexisting wellbore casing 4628 coupled to and positioned within the wellbore.
  • the system 4600 is positioned such that the expandable tubular member 4616 overlaps with the casing 4628.
  • a plug 4630 is then positioned in the throat passage 4614aa of the float shoe 4614 by injecting fluidic materials
  • the continued injection of the fluidic materials 4632 into the interior of the expandable tubular member 4616 radially expands and plastically deforms at least a portion of the expandable tubular member.
  • the continued injection of the fluidic materials 4632 into the interior of the expandable tubular member 4616 radially expands and plastically deforms a portion of the expandable tubular member positioned in opposition to the adjustable expansion device assembly 4612.
  • the size of the adjustable expansion device assembly 4612 is then increased within the radially expanded portion of the expandable tubular member 4616, and the lock assembly 4606 is operated to unlock the expandable tubular member from engagement with the lock assembly.
  • the lock assembly 4606 and the adjustable expansion device assembly 4612 are operated using the operating pressure provided by the continued injection of the fluidic materials 4632 into the system 4600.
  • the adjustment of the adjustable expansion device assembly 4612 to a larger size radially expands and plastically deforms at least a portion of the expandable tubular member 4616.
  • the adjustable expansion device assembly 4612 is displaced in a longitudinal direction relative to the expandable tubular member 4616 thereby radially expanding and plastically deforming the expandable tubular member.
  • the adjustable expansion device assembly 4612 is displaced in a longitudinal direction relative to the expandable tubular member 4616 due to the operating pressure within the expandable tubular member generated by the continued injection of the fluidic materials 4632.
  • a hardenable fluidic sealing material such as, for example, cement, may injected through the system 4600 before, during or after the radial expansion of the expandable tubular member
  • the size of the adjustable expansion device 4612 is increased prior to, during, or after the hydroforming expansion of the expandable tubular member 4616 caused by the injection of the fluidic materials 4632 into the interior of the expandable tubular member.
  • At least a portion of the expandable tubular member 4616 includes a plurality of nested expandable tubular members bonded together by, for example, amorphous bonding.
  • At least a portion of the expandable tubular member 4616 is fabricated for materials particularly suited for subsequent drilling out operations such as, for example, aluminum and/or copper based materials and alloys. [00419] In several alternative embodiments, during the operation of the system 4600, the portion of the expandable tubular member 4616 positioned below the adjustable expansion device 4612 is radially expanded and plastically deformed by displacing the adjustable expansion device downwardly.
  • At least a portion of the expandable tubular member 4616 is fabricated for materials particularly suited for subsequent drilling out operations such as, for example, aluminum and/or copper based materials and alloys.
  • the portion of the expandable tubular member 4616 fabricated for materials particularly suited for subsequent drilling out operations is not hydroformed by the injection of the fluidic materials 4632.
  • At least a portion of the expandable tubular member 4616 is hydroformed by the injection of the fluidic materials 4632, the remaining portion of the expandable tubular member above the initial position of the adjustable expansion device 4612 is then radially expanded and plastically deformed by displacing the adjustable expansion device upwardly, and the portion of the expandable tubular member below the initial position of the adjustable expansion device is radially expanded by then displacing the adjustable expansion device downwardly.
  • the portion of the expandable tubular member 4616 that is radially expanded and plastically deformed is radially expanded and plastically deformed solely by hydroforming caused by the injection of the fluidic materials 4632.
  • the portion of the expandable tubular member 4616 that is radially expanded and plastically deformed is radially expanded and plastically deformed solely by the adjustment of the adjustable expansion device 4612 to an increased size and the subsequent displacement of the adjustable expansion device relative to the expandable tubular member.
  • expandable tubular members fabricated from tellurium copper, leaded naval brass, phosphorous bronze, and aluminum- silicon bronze were successfully hydroformed and thereby radially expanded and plastically deformed by up to about 30% radial expansion, all of which were unexpected results.
  • the diamond shaped slots 4618a are deformed such that further radial expansion of the expansion limiter sleeve requires increased force.
  • the expansion limiter sleeve 4618 may be manufactured with slots whose cross sectional areas are decreased by the radial expansion and plastic deformation of the expansion limited sleeve thereby increasing the amount of force required to further radially expand the expansion limiter sleeve. In this manner, the extent to which the expandable tubular member 4616 may be radially expanded is limited. In several alternative embodiments, at least a portion of the expandable tubular member 4616 includes slots whose cross sectional areas are decreased by the radial expansion and plastic deformation of the expandable tubular member thereby increasing the amount of force required to further radially expand the expandable tubular member.
  • the bands 4618b are deformed such that the further radial expansion of the expansion limiter sleeve requires added force.
  • the expansion limiter sleeve 4618 may be manufactured with a circumferential bands whose orientation becomes more and more aligned with a direction that is orthogonal to the longitudinal axis of the sectional areas as a result of the radial expansion and plastic deformation of the bands thereby increasing the amount of force required to further radially expand the expansion limiter sleeve. In this manner, the extent to which the expandable tubular member 4616 may be radially expanded is limited.
  • At least a portion of the expandable tubular member 4616 includes circumferential bands whose orientation becomes more and more aligned with a direction that is orthogonal to the longitudinal axis of the sectional areas as a result of the radial expansion and plastic deformation of the bands thereby increasing the amount of force required to further radially expand the expandable tubular member.
  • the expansion limiter sleeve 4618 provides a restraining force that limits the extent to which the expandable tubular member 4616 may be radially expanded and plastically deformed. Furthermore, in several exemplary embodiments, the design of the expansion limiter sleeve 4618 provides a variable restraining force that limits the extent to which the expandable tubular member 4616 may be radially expanded and plastically deformed. In several exemplary embodiments, the variable restraining force of the expansion limiter sleeve 4618 increases in proportion to the degree to which the expandable tubular member 4616 has been radially expanded. [00428] Referring to Fig.
  • an exemplary embodiment of a system 4700 for radially expanding a tubular member includes a tubular support member 4702 that defines a passage 4702a.
  • An end of a conventional tubular safety sub 4704 that defines a passage 4704a is coupled to an end of the tubular support member 4702, and another end of the safety sub 4704 is coupled to an end of a tubular ball gripper assembly 4706 that defines a passage 4706a.
  • the ball gripper assembly 4706 may be a conventional device for limiting movement of tubular member relative to another member that employs, for example, one or more separate discrete ball-like elements to controliably engage and limit relative movement of the tubular member in one or more directions.
  • the ball gripper assembly 4706 may include one or more elements of the ball grabber assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no.
  • An end of a tubular casing lock assembly 4708 that defines a passage 4708a is coupled to the other end of the ball gripper assembly 4706.
  • the casing lock assembly 4708 may be a conventional device for limiting movement of a tubular member relative to another member.
  • the casing lock assembly 4708 may include one or more elements of the casing lock assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no.
  • tubular tension actuator assembly 4710 that defines a passage 4710a and one or more external mounting holes 4710b and includes an internal annular recess 4710c at one end is coupled to the other end of the casing lock assembly 4708.
  • the tubular tension actuator assembly 4710 may be a conventional device for displacing a member relative to another member.
  • the tubular tension actuator assembly 4710 may include one or more elements of the tension actuator assemblies disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number
  • PCT/US03/14153 attorney docket number 25791.104.02, filed on 11/13/2003
  • PCT patent application serial number PCT/US03/18530 attorney docket number 25791.108.02, filed on 6/11/2003
  • PCT patent application serial number PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT patent application serial number PCT/US04/07711 attorney docket number 25791.253.02, filed on
  • PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number
  • a primary solid tubular expansion cone 4712 that includes a tapered external surface 4712a at one end 4712b is coupled to the other end of the tubular tension actuator assembly 4710.
  • An expandable tubular casing 4714 that defines one or more mounting holes 4714a at one end receives and mates with the safety sub 4704, ball gripper assembly
  • the end of the tubular casing 4714 receives and mates with the non-tapered end and a portion of the tapered end
  • the end of the tubular casing 4714 that receives and mates with the portion of the tapered end 4712b of the tubular expansion cone 4712 is flared.
  • the outside diameter of the flared tapered end of the tubular casing 4714 is less than or equal to the maximum outside diameter of the tapered end 4712b of the tubular expansion cone 4712.
  • An end of a mounting pin 4716 is received within and coupled to the mounting hole 4710b of the tension actuator assembly
  • the expandable tubular casing 4714 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j.
  • the mounting pin 4716 permits torque to be transmitted between the expandable tubular casing 4714 and the tension actuator assembly
  • An expandable tubular sleeve 4720 that includes a first end 4720a including an external annular recess 4720aa, an intermediate portion 4720b, and a second end 4720c having an internal threaded connection 4720d mates with and receives the secondary tubular expansion cone 4718.
  • the expandable tubular sleeve 4720 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j.
  • the wall thickness of the first end 4720a of the tubular sleeve 4720 is greater than the wall thickness of the second end 4720c of the tubular sleeve, and the wall thickness of the intermediate portion 4720b of the tubular sleeve is tapered.
  • the outside diameter of the sealing member 4722 is less than or equal to the maximum outside diameter of the tapered end 4712b of the tubular expansion cone 4712.
  • a float shoe 4724 that defines a passage 4724a having a throat 4724aa and a passage 4724b and includes an external annular recess 4724c at one end that is received within and mates with the internal annular recess 4718d of the end of the secondary tubular expansion cone 4718, a plurality of circumferentially spaced apart shoulders 4724d at another end, a plurality of circumferentially spaced apart teeth 4724e for engaging the circumferentially spaced apart teeth 4718e of the secondary tubular expansion cone 4718, and a conventional float element 4724f is received within, mates with, and is coupled to the internal threaded connection 4720d of the end of the expandable tubular sleeve 4720.
  • the outside diameter of the spaced apart shoulders 4724d of the float shoe 4724 are greater than the outside diameter of the maximum outside diameter of the tapered end 4712b of the tubular expansion cone 4712.
  • the interaction of the circumferentially spaced apart teeth 4724e of the float shoe 4724 with the circumferentially spaced apart teeth 4718e of the secondary tubular expansion cone 4718 permits torque loads to be transmitted there between.
  • the circumferentially spaced apart shoulders 4724d further define circumferentially spaced apart axial flow passages there between.
  • the system is positioned within a wellbore 4726 that traverses a subterranean formation 4728.
  • a hardenable fluidic sealing material 4730 such as, for example, cement may then be injected into the system 4700 through the passages 4702a,
  • the fluidic material 4730 may then be conveyed past the float element 4724f of the float shoe 4724 and through the passage
  • a conventional plug 4734 is then positioned within the throat 4724aa of the passage 4724a of the float shoe 4724 by injecting fluidic material 4736 into the system
  • 4706a, 4708a, 4710a, and 4718a may be pressurized by the continued injection of the fluidic material 4736.
  • the passages 4702a, 4704a, 4706a, 4708a, 4710a, and 4718a may be pressurized by the continued injection of the fluidic material 4736 into the system.
  • the casing lock assembly 4708 is operated to engage the expandable tubular casing
  • the tension actuator assembly 4710 is operated to displace the primary tubular expansion cone 4712, secondary tubular expansion cone 4718, expandable tubular sleeve
  • the end of the expandable tubular casing 4714 is radially expanded and plastically deformed by the tapered external surface 4712a of the primary tubular expansion cone 4712. Furthermore, as a result, the radially expanded and plastically deformed end of the tubular casing 4714 receives and mates with the expandable tubular sleeve 4720 and the sealing member 4722. Furthermore, as a result, the mounting pin 4716 is sheared.
  • the of the expandable tubular casing 4714 is radially expanded and plastically deformed by the tapered external surface 4712a of the primary tubular expansion cone 4712 until the end of the expandable tubular casing impacts the end face of the shoulders 4724d of the float shoe
  • the passages 4702a, 4704a, 4706a, 4708a, 4710a, and 4718a may continue to be pressurized by the continued injection of the fluidic material 4736 into the system.
  • the casing lock assembly 4708 and the tension actuator assembly 4710 may continue to be operated in the manner described above with reference to Fig. 47c.
  • the primary tubular expansion cone 4712 is further displaced upwardly in the longitudinal direction 4738 relative to the expandable tubular casing 4714, and the secondary tubular expansion cone 4718 is displaced upwardly relative to the expandable tubular sleeve 4720, and the sealing member 4722 in the longitudinal direction 4738.
  • the further upward displacement of the expandable tubular sleeve 4720, the sealing member 4722, and the float shoe 4724, during the continued operation of the tension actuator assembly 4710 is prevented due to the interaction between the end of the expandable tubular casing 4714 and the end face of the shoulders 4724d of the float shoe 4724.
  • the end of the expandable tubular casing 4714 is further radially expanded and plastically deformed by the tapered external surface 4712a of the primary tubular expansion cone 4712, and portions, 4720a and 4720b, of the expandable tubular sleeve 4720 are radially expanded and plastically deformed by the tapered external surface 4718c of the secondary tubular expansion cone 4718 within the expandable tubular casing.
  • the sealing member 4722 engages and fluidicly seals the interface between the expandable tubular casing 4714 and the expandable tubular sleeve 4720.
  • a metal to metal, fluid tight seal is formed between the interior surface of the expandable tubular casing and the exterior surface of the expandable tubular sleeve.
  • the casing lock assembly 4708 releases the expandable tubular casing 4714.
  • the tension actuator assembly 4710 may be operated to radially expand and plastically deform the expandable tubular sleeve 4720 by operating the tension actuator assembly in a first stroke to radially expand and plastically deform a portion of the expandable tubular sleeve 4720.
  • the casing lock assembly 4708 is operated to release the expandable tubular casing 4714, such as, for example, by reducing the operating pressure of the fluidic material 4736.
  • the tension actuator assembly 4710 is then re-set to an initial position by displacing the tubular support member 4702, the tubular safety sub 4704, the ball gripper assembly 4706, the casing lock assembly, and the portion of the tension actuator assembly rigidly coupled to the end of the casing lock assembly upwardly relative to the expandable tubular casing 4714.
  • the operating pressure of the fluidic material 4736 is increased, and the tension actuator assembly is then operated in a second stroke to radially expand and plastically deform a further portion of the expandable tubular sleeve 4720. In several exemplary embodiments, this process may be repeated as often as required in order to radially expand and plastically deform the desired portions of the expandable tubular sleeve 4720.
  • the ball gripper assembly 4706 is also operated to limit displacement of the expandable tubular casing 4714 in one or more longitudinal directions by, for example, adjusting the operating pressure of the fluidic material 4736.
  • the maximum outside diameter of the system is the maximum outside diameter of the system
  • the system 4700 includes the ball gripper assembly 4706 and/or the casing lock assembly 4708.
  • the casing lock assembly 4708 is omitted from the system 4700.
  • the system 4700 relies only upon the ball gripper assembly 4706 to limit displacement of the expandable tubular casing 4714.
  • the operation of the ball gripper assembly 4706 and/or the casing lock assembly 4708 may be replaced with, or enhanced by, the use of conventional hydraulic or mechanical slips.
  • the expandable tubular sleeve 4720 is fabricated from materials particularly suited to being removed using a drilling device such as, for example, aluminum or brass.
  • the float shoe 4724 may include a sliding sleeve valve for controlling the flow of fluidic materials through the float shoe.
  • the secondary tubular expansion cone 4718 includes a conventional stinger attached thereto for manipulating and thereby controlling the operation of the sliding sleeve valve.
  • an exemplary embodiment of a system 4800 for radially expanding a tubular member includes a tubular support member 4802 that defines a passage 4802a.
  • 4804a is coupled to an end of the tubular support member 4802, and another end of the safety sub 4804 is coupled to an end of a tubular ball gripper assembly 4806 that defines a passage 4806a.
  • the ball gripper assembly 4806 may be a conventional device for limiting movement of tubular member relative to another member that employs, for example, one or more separate discrete ball-like elements to controliably engage and limit relative movement of the tubular member in one or more directions.
  • the ball gripper assembly 4806 may include one or more elements of the ball gripper assemblies disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
  • PCT/US03/18530 attorney docket number 25791.108.02, filed on 6/11/2003
  • PCT patent application serial number PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number
  • an end of a tubular casing lock assembly 4808 that defines a passage 4808a is coupled to the other end of the ball gripper assembly 4806.
  • the casing lock assembly 4808 may be a conventional device for limiting movement of a tubular member relative to another member.
  • the casing lock assembly 4808 may include one or more elements of the casing lock assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
  • PCT/US03/18530 attorney docket number 25791.108.02, filed on 6/11/2003
  • PCT patent application serial number PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number
  • tubular tension actuator assembly 4810a is coupled to the other end of the casing lock assembly 4808.
  • the tubular tension actuator assembly 4810 may be a conventional device for displacing a member relative to another member.
  • the tubular tension actuator assembly 4810 may include one or more elements of the tension actuator assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
  • PCT/US03/18530 attorney docket number 25791.108.02, filed on 6/11/2003
  • PCT patent application serial number PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number
  • An end of a tubular support member 4812 that defines a passage 4812a and includes an external annular recess 4812b is coupled to the other end of the tubular tension actuator assembly 4810.
  • a sealing cup assembly 4814 is positioned within and coupled to the external annular recess 4812b of the 4812.
  • the sealing cup assembly 4814 may include one or more conventional sealing cup assemblies and/or one or more of the elements of one or more of the sealing cup assemblies disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3)
  • PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT patent application serial number PCT/US04/07711 attorney docket number 25791.253.02, filed on 3/11/2004
  • PCT/US2004/009434 attorney docket number 25791.260.02, filed on 3/26/2004
  • PCT patent application serial number PCT/US2004/010317, attorney docket number
  • an end of an expansion device assembly 4816 that defines a passage 4816a and a mounting hole 4816aa and includes an adjustable expansion device 4816b at one end, an external annular recess 4816c, a tapered external expansion surface 4816d, an internal annular recess 4816e, and a plurality of circumferentially spaced apart teeth 4816f at another end is coupled to the other end of the tubular support member 4812.
  • the adjustable expansion device 4816b may be a conventional adjustable expansion device that may include a tapered outer expansion surface whose shape, size, and/or position is adjustable, a rotary expansion device, one or more of the elements of the conventional commercially available expansion devices of Baker Hughes,
  • the adjustable expansion device 4816b includes one or more elements of one or more of the adjustable expansion devices disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
  • PCT/US03/18530 attorney docket number 25791.108.02, filed on 6/11/2003
  • PCT patent application serial number PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number
  • An end of a mounting pin 4818 is received within and coupled to the mounting hole 4816aa of the expansion device assembly 4816, and another of the mounting pin is received within a mounting hole 4820a defined within an expandable tubular casing 4820 that receives the tubular support member 4802, the tubular safety sub 4804, the tubular ball gripper assembly 4806, the tubular casing lock assembly 4808, the tubular tension actuator assembly 4810, the tubular support member 4812, the sealing cup assembly 4814, and the end of the expansion device assembly 4816.
  • the expandable tubular casing 4820 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j. In an exemplary embodiment, during the operation of the system
  • the mounting pin 4818 permits torque to be transmitted between the expandable tubular casing 4820 and the expansion device assembly 4816.
  • the torque pin 4818 is fabricated from a drillable material such as, for example, brass or aluminum.
  • the sealing cup assembly 4814 sealingly engages the internal diameter of the expandable tubular casing 4820 during the operation of the system 4800.
  • An expandable tubular sleeve 4822 that includes a first end 4822a including an external annular recess 4822aa, an intermediate portion 4822b, and a second end 4822c having an internal threaded connection 4822d mates with and is received within the external annular recess 4816c of the expansion device assembly 4816.
  • the wall thickness of the first end 4822a of the expandable tubular sleeve 4822 is greater than the wall thickness of the second end 4822c of the expandable tubular sleeve, and the wall thickness of the intermediate portion 4822b of the expandable tubular sleeve is tapered.
  • the intermediate portion 4822b of the expandable tubular sleeve 4822 mates with and receives the external tapered surface 4816d of the expansion device assembly 4816.
  • the expandable tubular sleeve 4822 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j.
  • a sealing member 4824 is received within and coupled to the external annular recess 4822aa of the first end 4822a of the expandable tubular sleeve 4822.
  • the outside diameter of the intermediate portion 4822b and the second end 4822c of the tubular sleeve 4822 are both less than or equal to the maximum outside diameter of the expandable tubular casing 4822.
  • the outside diameter of the sealing member 4824 is less than or equal to the maximum outside diameter of the expandable tubular casing 4820.
  • a float shoe 4826 that defines a passage 4826a having a throat 4826aa and a passage 4826b and includes an external annular recess 4826c at one end that is received within and mates with the internal annular recess 4816e of the end of the expansion device assembly 4816, a plurality of circumferentially spaced apart shoulders 4826d at another end, a plurality of circumferentially spaced apart teeth 4826e for engaging the circumferentially spaced apart teeth 4816f of the end of the expansion device assembly 4816, and a conventional float element 4826f is received within, mates with, and is coupled to the internal threaded connection 4822d of the end of the expandable tubular sleeve 4822.
  • the outside diameter of the spaced apart shoulders 4826d of the float shoe 4826 are greater than the outside diameters of both the expandable tubular casing
  • the circumferentially spaced apart shoulders 4826d further define circumferentially spaced apart axial flow passages there between.
  • the system is positioned within a wellbore 4828 that traverses a subterranean formation 4830.
  • a hardenable fluidic sealing material 4832 such as, for example, cement may then be injected into the system 4800 through the passages 4802a,
  • the fluidic material 4832 may then be conveyed past the float element 4826f of the float shoe 4826 and through the passage
  • a conventional plug 4836 is then positioned within the throat 4826aa of the passage 4826a of the float shoe 4826 by injecting fluidic material 4838 into the system
  • 4806a, 4808a, 4810a, 4812a, and 4816a may be pressurized by the continued injection of the fluidic material 4838.
  • the passages 4802a, 4804a, 4806a, 4808a, 4810a, 4812a and 4816a may be pressurized by the continued injection of the fluidic material 4838 into the system.
  • the casing lock assembly 4808 is operated to engage the expandable tubular casing 4820 and the outside diameter of the adjustable expansion device 4816b of the expansion device assembly 4816 is increased.
  • the adjustable expansion device 4816b of the expansion device assembly 4816 includes one or more external expansion surfaces 4816ba for engaging and radially expanding and plastically deforming the expandable tubular casing 4820.
  • the passages 4802a, 4804a, 4806a, 4808a, 4810a, 4812a and 4816a may continue to be pressurized by the continued injection of the fluidic material 4838 into the system.
  • the casing lock assembly 4808 continues to be operated to engage the expandable tubular casing 4820 and the tension actuator assembly 4810 is operated to displace the expansion device assembly 4816, expandable tubular sleeve 4822, sealing member 4824, and float shoe 4826 upwardly in a longitudinal direction 4840 relative to the expandable tubular casing 4820.
  • the end of the expandable tubular casing 4820 is radially expanded and plastically deformed by the external expansion surfaces 4816ba of the adjustable expansion device 4816b of the expansion device assembly 4816.
  • the radially expanded and plastically deformed end of the tubular casing 4820 receives and mates with the expandable tubular sleeve 4822 and the sealing member 4824. Furthermore, as a result, the mounting pin 4818 is sheared.
  • the end of the expandable tubular casing 4820 is radially expanded and plastically deformed by the external expansion surfaces 4816ba of the adjustable expansion device 4816b of the expansion device assembly 4816 until the end of the expandable tubular casing impacts the end face of the shoulders 4826d of the float shoe 4826.
  • the passages 4802a, 4804a, 4806a, 4808a, 4810a, 4812a, and 4816a may continue to be pressurized by the continued injection of the fluidic material 4838 into the system.
  • the casing lock assembly 4808 and the tension actuator assembly 4810 may continue to be operated in the manner described above with reference to Fig. 48d.
  • the adjustable expansion device 4816b of the expansion device assembly 4816 is further displaced upwardly in the longitudinal direction 4840 relative to the expandable tubular casing 4820, and the tapered external expansion surface 4816d of the expansion device assembly is displaced upwardly relative to the expandable tubular sleeve
  • the sealing member 4824 engages and fluidicly seals the interface between the expandable tubular casing 4820 and the expandable tubular sleeve 4822.
  • a metal to metal, fluid tight seal is formed between the interior surface of the expandable tubular casing and the exterior surface of the expandable tubular sleeve.
  • the casing lock assembly 4808 releases the expandable tubular casing 4820.
  • the annulus within the expandable tubular casing 4820 below and proximate to the sealing cup assembly 4814 is pressurized by the injection of the fluidic material 4838 into the system 4800 thereby applying an upward axial force to the tubular support member 4812.
  • the adjustable expansion device 4816b of the expansion device assembly 4816 is pulled through the expandable tubular casing 4820.
  • the expandable tubular casing 4820 is further radially expanded and plastically deformed by the external expansion surfaces 4816ba of the adjustable expansion device 4816b of the expansion device assembly 4816.
  • the tension actuator assembly 4810 may be operated to radially expand and plastically deform the expandable tubular sleeve 4822 by operating the tension actuator assembly in a first stroke to radially expand and plastically deform a portion of the expandable tubular sleeve 4822.
  • the casing lock assembly 4808 is operated to release the expandable tubular casing 4820, such as, for example, by reducing the operating pressure of the fluidic material 4838.
  • the tension actuator assembly 4810 is then re-set to an initial position by displacing the tubular support member 4802, the tubular safety sub 4804, the ball gripper assembly 4806, the casing lock assembly 4808, and the portion of the tension actuator assembly rigidly coupled to the end of the casing lock assembly upwardly relative to the expandable tubular casing 4820.
  • the operating pressure of the fluidic material 4838 is increased, and the tension actuator assembly 4810 is then operated in a second stroke to radially expand and plastically deform a further portion of the expandable tubular sleeve 4822. In several exemplary embodiments, this process may be repeated as often as required in order to radially expand and plastically deform the desired portions of the expandable tubular sleeve 4822.
  • the ball gripper assembly 4806 is also operated to limit displacement of the expandable tubular casing 4820 in one or more longitudinal directions by, for example, adjusting the operating pressure of the fluidic material 4838.
  • the maximum outside diameter of the system is the maximum outside diameter of the system
  • the system 4800 includes the ball gripper assembly 4806 and/or the casing lock assembly 4808.
  • the casing lock assembly 4808 is omitted from the system 4800. As a result, the system 4800 relies only upon the ball gripper assembly 4806 to limit displacement of the expandable tubular casing 4820. [00468] In several exemplary embodiments of the system 4800, the operation of the ball gripper assembly 4806 and/or the casing lock assembly 4808 may be replaced with, or enhanced by, the use of conventional hydraulic or mechanical slips. [00469] In several exemplary embodiments of the system 4800, the expandable tubular sleeve 4822 is fabricated from materials particularly suited to being removed using a drilling device such as, for example, aluminum or brass.
  • the float shoe 4826 may include a sliding sleeve valve for controlling the flow of fluidic materials through the float shoe.
  • the end of the expansion device assembly 4816 includes a conventional stinger attached thereto for manipulating and thereby controlling the operation of the sliding sleeve valve.
  • the sealing cup assembly 4814 may be positioned above or below the casing lock assembly 4808.
  • an exemplary embodiment of a system 4900 for radially expanding a tubular member includes a tubular support member 4902 that defines a passage 4902a.
  • 4904a is coupled to an end of the tubular support member 4902, and another end of the safety sub 4904 is coupled to an end of a tubular ball gripper assembly 4906 that defines a passage 4906a.
  • the ball gripper assembly 4906 may be a conventional device for limiting movement of tubular member relative to another member that employs, for example, one or more separate discrete ball-like elements to controliably engage and limit relative movement of the tubular member in one or more directions.
  • the ball gripper assembly 4906 may include one or more elements of the ball gripper assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
  • PCT/US03/18530 attorney docket number 25791.108.02, filed on 6/11/2003
  • PCT patent application serial number PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number
  • an end of a tubular casing lock assembly 4908 that defines a passage 4908a is coupled to the other end of the ball gripper assembly 4908.
  • the casing lock assembly 4908 may be a conventional device for limiting movement of a tubular member relative to another member.
  • the casing lock assembly 4908 may include one or more elements of the casing lock assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
  • PCT/US03/18530 attorney docket number 25791.108.02, filed on 6/11/2003
  • PCT patent application serial number PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number
  • tubular tension actuator assembly 4910a is coupled to the other end of the casing lock assembly 4908.
  • the tubular tension actuator assembly 4910 may be a conventional device for displacing a member relative to another member.
  • the tubular tension actuator assembly 4910 may include one or more elements of the tension actuator assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
  • PCT/US03/18530 attorney docket number 25791.108.02, filed on 6/11/2003
  • PCT patent application serial number PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number
  • An end of a tubular support member 4912 that defines a passage 4912a and includes an external annular recess 4912b is coupled to the other end of the tubular tension actuator assembly 4910.
  • a sealing cup assembly 4914 is positioned within and coupled to the external annular recess 4912b of the tubular support member 4912.
  • the sealing cup assembly 4914 may include one or more conventional sealing cup assemblies and/or one or more of the elements of one or more of the sealing cup assemblies disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on
  • PCT/US03/18530 attorney docket number 25791.108.02, filed on 6/11/2003
  • PCT patent application serial number PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number
  • an end of an expansion device assembly 4916 that defines a passage 4916a and a mounting hole 4916aa and includes an adjustable expansion device 4916b at one end, an external annular recess 4916c, a tapered external expansion surface 4916d, an internal annular recess 4916e, and a plurality of circumferentially spaced apart teeth 4916f at another end is coupled to the other end of the tubular support member 4912.
  • the adjustable expansion device 4916b may be a conventional adjustable expansion device that may include a tapered outer expansion surface whose shape, size, and/or position is adjustable, a rotary expansion device, one or more of the elements of the conventional commercially available expansion devices of Baker Hughes,
  • the adjustable expansion device 4916b includes one or more elements of one or more of the adjustable expansion devices disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
  • PCT/US03/18530 attorney docket number 25791.108.02, filed on 6/11/2003
  • PCT patent application serial number PCT/US03/29858 attorney docket number 25791.112.02
  • PCT patent application serial number PCT/US03/29460 attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003
  • PCT/US2004/010317 attorney docket number 25791.270.02, filed on 4/2/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number 25791.272.02, filed on 4/7/2004
  • PCT patent application serial number PCT/US2004/010712, attorney docket number 25791.272.02, filed on 4/7/2004
  • An end of a mounting pin 4918 is received within and coupled to the mounting hole 4916aa of the expansion device assembly 4916, and another of the mounting pin is received within a mounting hole 4920a defined within an expandable tubular casing 4920 that receives the tubular support member 4902, the tubular safety sub 4904, the tubular ball gripper assembly 4906, the tubular casing lock assembly 4908, the tubular tension actuator assembly 4910, the tubular support member 4912, the sealing cup assembly 4914, and the end of the expansion device assembly 4916.
  • the expandable tubular casing 4920 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j. In an exemplary embodiment, during the operation of the system
  • the mounting pin 4918 permits torque to be transmitted between the expandable tubular casing 4920 and the expansion device assembly 4816.
  • the torque pin 4918 is fabricated from a drillable material such as, for example, brass or aluminum.
  • the sealing cup assembly 4914 sealingly engages the internal diameter of the expandable tubular casing 4920 during the operation of the system 4900.
  • tubular slotted sleeve 4921 that receives the end of the expansion device assembly 4916, including the adjustable expansion device 4916b, is coupled to an end of the expandable tubular casing 4920 and the other end of the tubular slotted sleeve includes a tapered end face 4921a.
  • the tubular slotted sleeve 4921 includes one or more perforations that may, for example, includes slots, circular holes, or other perforations.
  • An expandable tubular sleeve 4922 that includes a first end 4922a including a tapered external annular recess 4922aa that mates with the tapered end face 4921a of the tubular slotted sleeve 4921 , an external annular recess 4922ab spaced apart from the tapered external annular recess, an intermediate portion 4922b, and a second end 4922c having an internal threaded connection 4922d mates with and is received within the external annular recess 4916c of the expansion device assembly 4916.
  • the wall thickness of the first end 4922a of the expandable tubular sleeve 4922 is greater than the wall thickness of the second end 4922c of the expandable tubular sleeve, and the wall thickness of the intermediate portion 4922b of the expandable tubular sleeve is tapered.
  • the intermediate portion 4922b of the expandable tubular sleeve 4922 mates with and receives the external tapered surface 4916d of the expansion device assembly 4916.
  • the expandable tubular sleeve 4922 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j.
  • a sealing member 4924 is received within and coupled to the external annular recess 4922ab of the first end 4922a of the expandable tubular sleeve 4922.
  • the outside diameters of the intermediate portion 4922b and the second end 4922c of the tubular sleeve 4922 are both less than or equal to the maximum outside diameter of the expandable tubular casing 4920.
  • the outside diameter of the sealing member 4924 is less than or equal to the maximum outside diameter of the expandable tubular casing 4920.
  • a float shoe 4926 that defines a passage 4926a having a throat 4926aa and a passage 4926b and includes an external annular recess 4926c at one end that is received within and mates with the internal annular recess 4916e of the end of the expansion device assembly 4916, a plurality of circumferentially spaced apart shoulders 4926d at another end, a plurality of circumferentially spaced apart teeth 4926e for engaging the circumferentially spaced apart teeth 4916f of the end of the expansion device assembly 4916, and a conventional float element 4926f is received within, mates with, and is coupled to the internal threaded connection 4922d of the end of the expandable tubular sleeve 4922.
  • the outside diameter of the spaced apart shoulders 4926d of the float shoe 4926 are greater than the outside diameters of both the expandable tubular casing
  • the circumferentially spaced apart shoulders 4926d further define circumferentially spaced apart axial flow passages there between.
  • the system is positioned within a wellbore 4928 that traverses a subterranean formation 4930. In an exemplary embodiment, during operation of the system
  • the tubular slotted sleeve 4921 prevents debris within the wellbore 4928 from damaging the adjustable expansion device 4916b of the expansion device assembly 4916.
  • a hardenable fluidic sealing material 4932 such as, for example, cement may then be injected into the system 4900 through the passages 4902a, 4904a, 4906a, 4908a, 4910a,
  • the fluidic material 4932 may then be conveyed past the float element 4926f of the float shoe 4926 and through the passage 4926b into an annulus 4934 between the system 4900 and the interior surface of the wellbore 4928.
  • a conventional plug 4936 is then positioned within the throat 4926aa of the passage 4926a of the float shoe 4926 by injecting fluidic material 4938 into the system
  • 4906a, 4908a, 4910a, 4912a, and 4916a may be pressurized by the continued injection of the fluidic material 4938.
  • the passages 4902a, 4904a, 4906a, 4908a, 4910a, 4912a and 4916a may be pressurized by the continued injection of the fluidic material 4938 into the system.
  • the casing lock assembly 4908 is operated to engage the expandable tubular casing 4920 and the outside diameter of the adjustable expansion device 4916b of the expansion device assembly 4916 is increased.
  • the portion of the tubular slotted sleeve 4921 that receives the adjustable expansion device 4916b is radially expanded and plastically deformed.
  • the adjustable expansion device 4916b of the expansion device assembly 4916 includes one or more external expansion surfaces
  • the passages 4902a, 4904a, 4906a, 4908a, 4910a, 4912a and 4916a may continue to be pressurized by the continued injection of the fluidic material 4938 into the system.
  • the casing lock assembly 4908 continues to be operated to engage the expandable tubular casing 4920 and the tension actuator assembly 4910 is operated to displace the expansion device assembly 4916, expandable tubular sleeve 4922, sealing member 4924, and float shoe 4926 upwardly in a longitudinal direction 4940 relative to the expandable tubular casing 4920 and the tubular slotted sleeve 4921.
  • tubular slotted sleeve 4921 and the end of the expandable tubular casing 4920 are radially expanded and plastically deformed by the external expansion surfaces 4816ba of the adjustable expansion device 4816b of the expansion device assembly 4816. Furthermore, as a result, the tubular slotted sleeve 4921 engages the tapered end face of the shoulders
  • the radially expanded and plastically deformed end of the tubular casing 4920 receives and mates with the expandable tubular sleeve 4922 and the sealing member 4924. Furthermore, as a result, the mounting pin 4918 is sheared.
  • the end of the expandable tubular casing 4920 is radially expanded and plastically deformed by the external expansion surfaces 4916ba of the adjustable expansion device 4916b of the expansion device assembly 4916 until the end of the expandable tubular casing impacts the end faces of the shoulders 4926d of the float shoe 4926.
  • the passages 4902a, 4904a, 4906a, 4908a, 4910a, 4912a, and 4916a may continue to be pressurized by the continued injection of the fluidic material 4938 into the system.
  • the casing lock assembly 4908 and the tension actuator assembly 4910 may continue to be operated in the manner described above with reference to Fig. 49d.
  • the adjustable expansion device 4916b of the expansion device assembly 4916 is further displaced upwardly in the longitudinal direction 4940 relative to the expandable tubular casing 4920, and the tapered external expansion surface 4916d of the expansion device assembly is displaced upwardly relative to the expandable tubular sleeve
  • the sealing member 4924 engages and fluidicly seals the interface between the expandable tubular casing 4920 and the expandable tubular sleeve 4922.
  • a metal to metal, fluid tight seal is formed between the interior surface of the expandable tubular casing and the exterior surface of the expandable tubular sleeve.
  • the casing lock assembly 4908 releases the expandable tubular casing 4920.
  • the annulus within the expandable tubular casing 4920 below and proximate to the sealing cup assembly 4914 is pressurized by the injection of the fluidic material 4938 into the system 4900 thereby applying an upward axial force to the tubular support member 4912.
  • the adjustable expansion device 4916b of the expansion device assembly 4916 is pulled through the expandable tubular casing 4920.
  • the expandable tubular casing 4920 is further radially expanded and plastically deformed by the external expansion surfaces 4916ba of the adjustable expansion device 4916b of the expansion device assembly 4916.
  • the tension actuator assembly 4910 may be operated to radially expand and plastically deform the expandable tubular sleeve 4922 by operating the tension actuator assembly in a first stroke to radially expand and plastically deform a portion of the expandable tubular sleeve 4922.
  • the casing lock assembly 4908 is operated to release the expandable tubular casing 4920, such as, for example, by reducing the operating pressure of the fluidic material 4938.
  • the tension actuator assembly 4910 is then re-set to an initial position by displacing the tubular support member 4902, the tubular safety sub
  • the operating pressure of the fluidic material 4938 is increased, and the tension actuator assembly 4910 is then operated in a second stroke to radially expand and plastically deform a further portion of the expandable tubular sleeve 4922. In several exemplary embodiments, this process may be repeated as often as required in order to radially expand and plastically deform the desired portions of the expandable tubular sleeve 4922.
  • the ball gripper assembly 4906 is also operated to limit displacement of the expandable tubular casing 4920 in one or more longitudinal directions by, for example, adjusting the operating pressure of the fluidic material 4938.
  • the maximum outside diameter of the system is the maximum outside diameter of the system
  • the system 4900 includes the ball gripper assembly 4906 and/or the casing lock assembly 4908.
  • the casing lock assembly 4908 is omitted from the system 4900.
  • the system 4900 relies only upon the ball gripper assembly 4906 to limit displacement of the expandable tubular casing 4920.
  • the operation of the ball gripper assembly 4906 and/or the casing lock assembly 4908 may be replaced with, or enhanced by, the use of conventional hydraulic or mechanical slips.
  • the expandable tubular sleeve 4922 is fabricated from materials particularly suited to being removed using a drilling device such as, for example, aluminum or brass.
  • the float shoe 4926 may include a sliding sleeve valve for controlling the flow of fluidic materials through the float shoe.
  • the end of the expansion device assembly 4916 includes a conventional stinger attached thereto for manipulating and thereby controlling the operation of the sliding sleeve valve.
  • the sealing cup assembly 4914 may be positioned above or below the casing lock assembly 4908.
  • an exemplary embodiment of a system 5000 for radially expanding a tubular member includes a tubular support member
  • 5002 that defines a passage 5002a, one or more radial openings 5002b, and one or more mounting holes 5002c, and includes an internal annular recess 5002d, an internal annular recess 5002e, and an internal annular recess 5002f.
  • 5004 that defines a passage 5004a, a mounting hole 5004b, a radial passage 5004c, a radial passage 5004d, a radial passage 5004e, and mounting hole 5004f, and includes an external annular recess 5004g, an external annular recess 5004h, an external annular recess 5004i including external circumferentially spaced apart splines 5004j, an external threaded connection 5004k, an external threaded connection 5004I, an external flange
  • a tapered external flange 5004n including circumferentially spaced apart T-shaped slots 5004o, and an external flange 5004p at another end including circumferentially spaced apart teeth 5004q, is received within and mates with the internal annular recess 5002d of the tubular support member 5002.
  • 5004n of the tubular support member 5004 includes a plurality of faceted surfaces 5004na.
  • Locking dogs 5006 that include internal spaced-apart flanges, 5006a and
  • a tubular locking dog retainer sleeve 5008 that includes external spaced-apart flanges, 5008a and 5008b, positioned in opposition to the spaced-apart flanges, 5006a and 5006b, respectively, of the locking dogs 5006 receives and mates with an end of the tubular support member 5004.
  • the tubular member 5010 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j.
  • An end of an expansion sleeve 5012 that includes an internal threaded connection 5012a at one end is coupled to the other end of the expandable tubular member 5010.
  • the expansion sleeve 5012 is fabricated from aluminum and/or brass and/or alloys of one or both and/or includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j.
  • a rupture disk 5016 is positioned within and coupled to the mounting hole 5004b of the tubular support member 5004.
  • 5018a and includes an external flange 5018b and an internal flange 5018c, including circumferentially spaced apart internal splines 5018d that mate with the external splines
  • a mounting pin 5020 is received within and coupled to the mounting hole 5002c of the tubular support member 5002 and the mounting hole 5018a of the sleeve 5018 for transmitting torque loads there between.
  • An upper tubular sealing cup retainer 5022 that includes an internal threaded connection 5022a that is coupled to the external threaded connection 5004k of the tubular support member 5004 and an angled end face 5022b and an external tapered flange 5022c at another end that engages the interior surface of the expandable tubular member 5010 is positioned proximate an end face of the external splines 5004j of the tubular support member 5004.
  • a float shoe 5024 defines a passage 5024a having a throat 5024aa and a passage 5024b and includes an external annular recess 5024c, circumferentially spaced apart teeth 5024d for engaging the circumferentially spaced apart teeth 5004q of the tubular support member 5004, an external threaded connection 5024e coupled to the internal threaded connection 5012a of the end of the expansion sleeve 5012, and a conventional float element 5024f.
  • a lower tubular sealing cup retainer 5026 that defines a plurality of circumferentially spaced apart internal longitudinal passages 5026a includes an internal threaded connection 5026b that is coupled to the external threaded connection 5004I of the tubular support member 5004.
  • a lower tubular cup seal support 5028 that receives, mates with, and is coupled to the tubular support member 5004 is positioned proximate the lower tubular sealing cup retainer 5026.
  • a lower cup seal 5030 that receives, mates with, and is coupled to the tubular support member 5004 and sealingly engages the interior surface of the expandable tubular member 5010 is positioned proximate the lower tubular sealing cup retainer 5026.
  • a lower cup seal support 5032 receives, mates with, and is coupled to the tubular support member 5004 and receives, mates with, and supports the lower cup seal 5030.
  • a lower back-up cup seal 5034 that receives, mates with, and is coupled to the tubular support member 5004 and sealingly engages the interior surface of the expandable tubular member 5010 receives and mates with the lower cup seal 5030 and the lower cup seal support 5032.
  • a lower tubular cup seal support 5036 that receives, mates with, and is coupled to the tubular support member 5004 is positioned proximate to, mates with, and supports, the lower back-up cup seal 5034.
  • An upper tubular cup seal support 5038 that receives, mates with, and is coupled to the tubular support member 5004 is positioned proximate the lower tubular cup seal support 5036.
  • An upper cup seal 5040 that receives, mates with, and is coupled to the tubular support member 5004 and sealingly engages the interior surface of the expandable tubular member 5010 is positioned proximate the upper tubular cup seal support 5038.
  • An upper cup seal support 5042 receives, mates with, and is coupled to the tubular support member 5004 and receives, mates with, and supports the upper cup seal 5040.
  • An upper back-up cup seal 5044 that receives, mates with, and is coupled to the tubular support member 5004 and sealingly engages the interior surface of the expandable tubular member 5010 receives and mates with the upper cup seal 5040 and the upper cup seal support 5042.
  • a tubular expansion cone retainer 5046 that defines circumferentially spaced apart internal passages 5046a that are fluidicly coupled to the circumferentially spaced apart internal longitudinal passages 5026a of the lower tubular sealing cup retainer 5026 and circumferentially spaced apart internal longitudinal passages 5046a and circumferentially spaced apart radially directed T-shaped grooves 5046b, and includes a tapered shoulder 5046c at one end and an internal annular recess 5046d that mates with and receives the external flange 5004m of the tubular support member 5004.
  • a rupture disc 5048 is positioned within and coupled to the mounting hole 5004f of the tubular support member
  • Circumferentially spaced apart expansion cone segments 5050 include T- shaped mounting elements 5050a that are slidably received within and mate with corresponding T-shaped grooves 5046b of the tubular expansion cone retainer 5046 and T- shaped mounting elements 5050b that are slidably received within and mate with corresponding T-shaped slots 5004o of the tubular support member 5004.
  • each expansion cone segment 5050 is mounted upon a corresponding faceted surface 5004na of the tapered flange 5004n of the tubular support member 5004.
  • the expansion cone segments 5050 define a substantially contiguous outer expansion surface when displaced to a final radial outward position.
  • the tubular support member 5004, the tubular expansion cone retainer 5046, and the expansion cone segments 5050 together provide an adjustable expansion device 5052.
  • the adjustable expansion device 5052 which provides expansion surfaces whose radial extent are adjustable, includes one or more elements of the adjustable expansion devices disclosed in
  • the system is positioned within a wellbore 5054 that traverses a subterranean formation 5056.
  • a hardenable fluidic sealing material 5058 such as, for example, cement may then be injected into the system 5000 through the passages
  • the fluidic material 5058 may then be conveyed past the float element 5024f of the float shoe 5024 and through the passage 5024b into an annulus 5060 between the system 5000 and the interior surface of the wellbore 5054.
  • the fluidic material 5058 may then be conveyed past the float element 5024f of the float shoe 5024 and through the passage 5024b into an annulus 5060 between the system 5000 and the interior surface of the wellbore 5054.
  • a conventional plug 5062 is then positioned within the throat 5024aa of the passage 5024a of the float shoe 5024 by injecting fluidic material 5064 into the system
  • the passages 5002a and 5002b may be pressurized by the continued injection of the fluidic material 5064 into the system.
  • the rupture disc 5048 is burst thereby permitting the pressurized fluidic material 5064 to be conveyed through the radial passage 5004f of the tubular support member 5004 and into the annulus defined between the tubular support member 5004 and the tubular expansion cone retainer 5046.
  • the expansion cone segments 5050 are displaced in a longitudinal direction 5066.
  • the expansion cone segments 5050 are slidably mounted for movement on the T-shaped slots 5004o of the tapered external flange
  • the expansion cone segments 5050 are also displaced outwardly in a radial direction and thereby engage and radially expand and plastically deform the expansion sleeve 5012.
  • the outward radial displacement of the expansion cone segments 5050 also radially expands and plastically deforms the expandable tubular member 5010. In this manner, the size of the adjustable expansion device 5052 is increased.
  • the passages 5002a and 5002b may continue to be pressurized by the continued injection of the fluidic material 5064 into the system.
  • the pressurized fluidic material 5064 conveyed through the radial passage 5004f of the tubular support member 5004 and into the annulus defined between the tubular support member 5004 and the tubular expansion cone retainer 5046 pressurizes an annulus defined by the tubular support member 5004 and the expandable tubular member 5010 below the lower cup seal
  • tubular support member 5004 As a result, the tubular support member 5004, the tubular sleeve 5014, and the locking dog retainer sleeve 5008 are displaced in the direction 5068 relative to the tubular support member 5002 and the locking dogs 5006 thereby releasing the flanges, 5006a and
  • the passages 5002a and 5002b may continue to be pressurized by the continued injection of the fluidic material 5064 into the system.
  • the pressurized fluidic material 5064 conveyed through the radial passage 5004f of the tubular support member 5004 and into the annulus defined between the tubular support member 5004 and the tubular expansion cone retainer 5046 continues to pressurize the annulus defined by the tubular support member 5004 and the expandable tubular member 5010 below the lower cup seal 5030.
  • the pressurized fluidic material 5064 within the annulus defined by the tubular support member 5004 and the expandable tubular member 5010 below the lower cup seal 5030 continues to apply a longitudinal force to the tubular support member
  • the tubular support member 5004 and the adjustable expansion device 5052 are displaced in the direction 5068 relative to the expandable tubular member 5010 thereby radially expanding and plastically deforming the expandable tubular member.
  • the expandable tubular member 5010 may be released from engagement with the locking dogs 5006.
  • the plug 5062 may be released from engagement with the throat
  • the operating pressure of the injected fluidic material 5064 may be increased sufficiently to burst the rupture disk 5016 thereby permitting the fluidic material to be conveyed through the passage 5004b into the annulus defined between the tubular support member 5004 and the emergency release tubular sleeve 5014.
  • the emergency release tubular sleeve 5014 is displaced in a direction 5070 relative to the tubular support member 5004.
  • the locking dog retainer sleeve 5008 is displaced in the direction 5070 relative to the locking dogs 5006 thereby releasing the flanges, 5006a and 5006b, of the locking dogs 5006 from engagement with the flanges, 5008a and 5008b, of the locking dog retainer sleeve 5008.
  • the spring arms, 5006d and 5006e, of the locking dogs 5006 displace the locking dogs radially inward and out of locking engagement with the expandable tubular member 5010. In this manner, the expandable tubular member 5010 may be controliably released from engagement with the locking dogs 5006.
  • the tubular support member 5002 includes one or more elements of a conventional safety sub.
  • tubular support member 5002 the tubular support member 5004, the locking dogs 5006, and the locking dog retainer sleeve
  • 5008 provide a locking assembly for controliably locking the expandable tubular member
  • tubular support member 5002 tubular support member 5002
  • conventional casing locking tools may be substituted for, or used in addition to, the locking assembly.
  • the lower tubular cup seal support 5028, the lower cup seal 5030, the lower cup seal support 5032, the lower back-up cup seal 5034, the lower tubular cup seal support 5036, the upper tubular cup seal support 5038, the upper cup seal 5040, the upper cup seal support 5042, and the upper back-up cup seal 5044 provide a sealing assembly for sealing the interface between the tubular support member 5004 and the expandable tubular member 5010.
  • an annulus is defined between the tubular support member 5004 and the expandable tubular member 5010, below the sealing assembly, that may be pressurized thereby permitting the sealing assembly to apply a tensile upward force to the tubular support member 5004.
  • tubular support member 5004 may be pulled upwardly out of the expandable tubular member 5010.
  • adjustable expansion device 5052 may be pulled upwardly through the expandable tubular member 5010 to thereby radially expand and plastically deform the expandable tubular member.
  • the adjustable expansion device 5052 is used to expand a portion of the expandable tubular member 5010 and/or the expandable sleeve 5012, and another expansion device, which may be fixed or adjustable in size, may be used to radially expand and plastically deform the remaining portions of the expandable tubular member and/or the expandable sleeve.
  • the expandable sleeve 5012 is fabricated from a drillable material such as, for example, aluminum or copper, and is coupled to the end of the expandable tubular member 5010 by, for example, amorphous bonding.
  • the amount of force required to radially expand the expandable sleeve 5012 is significantly less than the amount of force required to radially expand the expandable tubular member 5010.
  • any unexpanded portions of the expandable sleeve 5012 are removed by, for example, drilling.
  • the float element 5024f of the float shoe 5024 is fabricated from drillable materials such as, for example, aluminum, brass, composite materials, and/or concrete in order to facilitate its subsequent removal.
  • the float shoe 5024 includes a pressure balanced sliding sleeve valve, or other equivalent valve, to permit the control of the passage of fluidic materials through the passages of the float shoe, before or after the place of the plug 5062 within the throat

Abstract

A radial expansion system.

Description

RADIAL EXPANSION SYSTEM Cross Reference To Related Applications [001] This application claims the benefit of the filing dates of the following: (1 ) U.S. provisional patent application serial number 60/500435, attorney docket number 25791.304, filed on 9/05/2003, (2) U.S. provisional patent application serial number 60/585,370, attorney docket number 25791.299, filed on 7/2/2004; and (3) U.S. provisional patent application serial number 60/600679, attorney docket number 25791.194, filed on 8/11/2004, the disclosures of which are incorporated herein by reference.
[002] This application is a continuation-in-part of one or more of the following: (1 ) PCT application US02/04353, filed on 2/14/02, attorney docket no. 25791.50.02, which claims priority from U.S. provisional patent application serial no. 60/270,007, attorney docket no. 25791.50, filed on 2/20/2001 ; (2) PCT application US 03/00609, filed on 1/9/03, attorney docket no. 25791.71.02, which claims priority from U.S. provisional patent application serial no. 60/357,372 , attorney docket no. 25791.71 , filed on 2/15/02; (3) U.S. provisional patent application serial number 60/585,370, attorney docket number 25791.299, filed on 7/2/2004; and (4) U.S. provisional patent application serial number 60/600679, attorney docket number 25791.194, filed on 8/11/2004, the disclosures of which are incorporated herein by reference.
[003] This application is related to the following co-pending applications: (1 ) U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/ ,293, filed on 12/7/98, (2) U.S. patent application serial no. 09/510,913, attorney docket no. 25791.7.02, filed on 2/23/2000, which claims priority from provisional application 60/121 ,702, filed on 2/25/99, (3) U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, which claims priority from provisional application 60/119,611 , filed on 2/11/99, (4) U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (5) U.S. patent application serial no. 10/169,434, attorney docket no. 25791.10.04, filed on 7/1/02, which claims priority from provisional application 60/183,546, filed on 2/18/00, (6) U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (7) U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (8) U.S. patent number 6,575,240, which was filed as patent application serial no. 09/511,941, attorney docket no. 25791.16.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,907, filed on 2/26/99, (9)
U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (10) U.S. patent application serial no. 09/981 ,916, attorney docket no. 25791.18, filed on 10/18/01 as a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (11) U.S. patent number 6,604,763, which was filed as application serial no. 09/559,122, attorney docket no. 25791.23.02, filed on
4/26/2000, which claims priority from provisional application 60/131 ,106, filed on 4/26/99,
(12) U.S. patent application serial no. 10/030,593, attorney docket no. 25791.25.08, filed on
1/8/02, which claims priority from provisional application 60/146,203, filed on 7/29/99, (13)
U.S. provisional patent application serial no. 60/143,039, attorney docket no. 25791.26, filed on 7/9/99, (14) U.S. patent application serial no. 10/111 ,982, attorney docket no.
25791.27.08, filed on 4/30/02, which claims priority from provisional patent application serial no. 60/162,671, attorney docket no. 25791.27, filed on 11/1/1999, (15) U.S. provisional patent application serial no. 60/154,047, attorney docket no. 25791.29, filed on 9/16/1999,
(16) U.S. provisional patent application serial no. 60/438,828, attorney docket no. 25791.31 , filed on 1/9/03, (17) U.S. patent number 6,564,875, which was filed as application serial no.
09/679,907, attorney docket no. 25791.34.02, on 10/5/00, which claims priority from provisional patent application serial no. 60/159,082, attorney docket no. 25791.34, filed on
10/12/1999, (18) U.S. patent application serial no. 10/089,419, filed on 3/27/02, attorney docket no. 25791.36.03, which claims priority from provisional patent application serial no.
60/159,039, attorney docket no. 25791.36, filed on 10/12/1999, (19) U.S. patent application serial no. 09/679,906, filed on 10/5/00, attorney docket no. 25791.37.02, which claims priority from provisional patent application serial no. 60/159,033, attorney docket no.
25791.37, filed on 10/12/1999, (20) U.S. patent application serial no. 10/303,992, filed on
11/22/02, attorney docket no. 25791.38.07, which claims priority from provisional patent application serial no. 60/212,359, attorney docket no. 25791.38, filed on 6/19/2000, (21 ) U.S. provisional patent application serial no. 60/165,228, attorney docket no. 25791.39, filed on
11/12/1999, (22) U.S. provisional patent application serial no. 60/455,051 , attorney docket no. 25791.40, filed on 3/14/03, (23) PCT application US02/2477, filed on 6/26/02, attorney docket no. 25791.44.02, which claims priority from U.S. provisional patent application serial no. 60/303,711 , attorney docket no. 25791.44, filed on 7/6/01 , (24) U.S. patent application serial no. 10/311 ,412, filed on 12/12/02, attorney docket no. 25791.45.07, which claims priority from provisional patent application serial no. 60/221 ,443, attorney docket no.
25791.45, filed on 7/28/2000, (25) U.S. patent application serial no. 10/, filed on 12/18/02, attorney docket no. 25791.46.07, which claims priority from provisional patent application serial no. 60/221,645, attorney docket no. 25791.46, filed on 7/28/2000, (26) U.S. patent application serial no. 10/322,947, filed on 1/22/03, attorney docket no. 25791.47.03, which claims priority from provisional patent application serial no. 60/233,638, attorney docket no. 25791.47, filed on 9/18/2000, (27) U.S. patent application serial no. 10/406,648, filed on 3/31/03, attorney docket no. 25791.48.06, which claims priority from provisional patent application serial no. 60/237,334, attorney docket no. 25791.48, filed on 10/2/2000, (28) PCT application US02/04353, filed on 2/14/02, attorney docket no. 25791.50.02, which claims priority from U.S. provisional patent application serial no. 60/270,007, attorney docket no. 25791.50, filed on 2/20/2001 , (29) U.S. patent application serial no. 10/465,835, filed on 6/13/03, attorney docket no. 25791.51.06, which claims priority from provisional patent application serial no. 60/262,434, attorney docket no. 25791.51 , filed on 1/17/2001 , (30) U.S. patent application serial no. 10/465,831 , filed on 6/13/03, attorney docket no. 25791.52.06, which claims priority from U.S. provisional patent application serial no. 60/259,486, attorney docket no. 25791.52, filed on 1/3/2001 , (31) U.S. provisional patent application serial no. 60/452,303, filed on 3/5/03, attorney docket no. 25791.53, (32) U.S. patent number 6,470,966, which was filed as patent application serial number 09/850,093, filed on 5/7/01, attorney docket no. 25791.55, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (33) U.S. patent number 6,561 ,227, which was filed as patent application serial number 09/852,026 , filed on 5/9/01 , attorney docket no. 25791.56, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (34) U.S. patent application serial number 09/852,027, filed on 5/9/01 , attorney docket no. 25791.57, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (35) PCT Application US02/25608, attorney docket no. 25791.58.02, filed on 8/13/02, which claims priority from provisional application 60/318,021 , filed on 9/7/01 , attorney docket no. 25791.58, (36) PCT Application US02/24399, attorney docket no. 25791.59.02, filed on 8/1/02, which claims priority from U.S. provisional patent application serial no. 60/313,453, attorney docket no. 25791.59, filed on 8/20/2001 , (37) PCT Application US02/29856, attorney docket no. 25791.60.02, filed on 9/19/02, which claims priority from U.S. provisional patent application serial no. 60/326,886, attorney docket no. 25791.60, filed on 10/3/2001 , (38) PCT Application US02/20256, attorney docket no. 25791.61.02, filed on 6/26/02, which claims priority from U.S. provisional patent application serial no. 60/303,740, attorney docket no.
25791.61 , filed on 7/6/2001 , (39) U.S. patent application serial no. 09/962,469, filed on
9/25/01, attorney docket no. 25791.62, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (40) U.S. patent application serial no. 09/962,470, filed on 9/25/01, attorney docket no. 25791.63, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on
3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99,
(41) U.S. patent application serial no. 09/962,471 , filed on 9/25/01 , attorney docket no.
25791.64, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application
60/124,042, filed on 3/11/99, (42) U.S. patent application serial no. 09/962,467, filed on
9/25/01, attorney docket no. 25791.65, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (43) U.S. patent application serial no. 09/962,468, filed on 9/25/01, attorney docket no. 25791.66, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on
3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99,
(44) PCT application US 02/25727, filed on 8/14/02, attorney docket no. 25791.67.03, which claims priority from U.S. provisional patent application serial no. 60/317,985, attorney docket no. 25791.67, filed on 9/6/2001 , and U.S. provisional patent application serial no.
60/318,386, attorney docket no. 25791.67.02, filed on 9/10/2001, (45) PCT application US
02/39425, filed on 12/10/02, attorney docket no. 25791.68.02, which claims priority from
U.S. provisional patent application serial no. 60/343,674 , attorney docket no. 25791.68, filed on 12/27/2001 , (46) U.S. utility patent application serial no. 09/969,922, attorney docket no. 25791.69, filed on 10/3/2001 , which is a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (47) U.S. utility patent application serial no.
10/516,467, attorney docket no. 25791.70, filed on 12/10/01 , which is a continuation application of U.S. utility patent application serial no. 09/969,922, attorney docket no.
25791.69, filed on 10/3/2001 , which is a continuation-in-part application of U.S. patent no.
6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (48) PCT application US 03/00609, filed on 1/9/03, attorney docket no. 25791.71.02, which claims priority from U.S. provisional patent application serial no. 60/357,372 , attorney docket no. 25791.71 , filed on 2/15/02, (49) U.S. patent application serial no. 10/074,703, attorney docket no. 25791.74, filed on 2/12/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (50) U.S. patent application serial no. 10/074,244, attorney docket no. 25791.75, filed on 2/12/02, which is a divisional of
U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (51) U.S. patent application serial no. 10/076,660, attorney docket no. 25791.76, filed on 2/15/02, which is a divisional of U.S. patent number
6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121 ,841 , filed on 2/26/99, (52) U.S. patent application serial no. 10/076,661 , attorney docket no. 25791.77, filed on 2/15/02, which is a divisional of U.S. patent number
6,568,471, which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121,841, filed on 2/26/99, (53) U.S. patent application serial no. 10/076,659, attorney docket no. 25791.78, filed on 2/15/02, which is a divisional of U.S. patent number
6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121 ,841 , filed on 2/26/99, (54) U.S. patent application serial no. 10/078,928, attorney docket no. 25791.79, filed on 2/20/02, which is a divisional of U.S. patent number
6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121 ,841, filed on 2/26/99, (55) U.S. patent application serial no. 10/078,922, attorney docket no. 25791.80, filed on 2/20/02, which is a divisional of U.S. patent number
6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121 ,841 , filed on 2/26/99, (56) U.S. patent application serial no. 10/078,921 , attorney docket no. 25791.81 , filed on 2/20/02, which is a divisional of U.S. patent number
6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121,841 , filed on 2/26/99, (57) U.S. patent application serial no. 10/261 ,928, attorney docket no. 25791.82, filed on 10/1/02, which is a divisional of U.S. patent number
6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no.
25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (58) U.S. patent application serial no. 10/079,276 , attorney docket no.
25791.83, filed on 2/20/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on
2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99,
(59) U.S. patent application serial no. 10/262,009, attorney docket no. 25791.84, filed on
10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (60) U.S. patent application serial no. 10/092,481 , attorney docket no. 25791.85, filed on 3/7/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no.
09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (61) U.S. patent application serial no.
10/261 ,926, attorney docket no. 25791.86, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (62) PCT application US 02/36157, filed on 11/12/02, attorney docket no. 25791.87.02, which claims priority from U.S. provisional patent application serial no. 60/338,996, attorney docket no. 25791.87, filed on 11/12/01 , (63) PCT application US 02/36267, filed on 11/12/02, attorney docket no. 25791.88.02, which claims priority from U.S. provisional patent application serial no. 60/339,013, attorney docket no.
25791.88, filed on 11/12/01, (64) PCT application US 03/11765, filed on 4/16/03, attorney docket no. 25791.89.02, which claims priority from U.S. provisional patent application serial no. 60/383,917, attorney docket no. 25791.89, filed on 5/29/02, (65) PCT application US
03/15020, filed on 5/12/03, attorney docket no. 25791.90.02, which claims priority from U.S. provisional patent application serial no. 60/391 ,703, attorney docket no. 25791.90, filed on
6/26/02, (66) PCT application US 02/39418, filed on 12/10/02, attorney docket no.
25791.92.02, which claims priority from U.S. provisional patent application serial no.
60/346,309, attorney docket no. 25791.92, filed on 1/7/02, (67) PCT application US
03/06544, filed on 3/4/03, attorney docket no. 25791.93.02, which claims priority from U.S. provisional patent application serial no. 60/372,048, attorney docket no. 25791.93, filed on
4/12/02, (68) U.S. patent application serial no. 10/331 ,718, attorney docket no. 25791.94, filed on 12/30/02, which is a divisional U.S. patent application serial no. 09/679,906, filed on
10/5/00, attorney docket no. 25791.37.02, which claims priority from provisional patent application serial no. 60/159,033, attorney docket no. 25791.37, filed on 10/12/1999, (69)
PCT application US 03/04837, filed on 2/29/03, attorney docket no. 25791.95.02, which claims priority from U.S. provisional patent application serial no. 60/363,829, attorney docket no. 25791.95, filed on 3/13/02, (70) U.S. patent application serial no. 10/261 ,927, attorney docket no. 25791.97, filed on 10/1/02, which is a divisional of U.S. patent number
6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (71) U.S. patent application serial no. 10/262,008, attorney docket no.
25791.98, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on
6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (72)
U.S. patent application serial no. 10/261 ,925, attorney docket no. 25791.99, filed on
10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (73) U.S. patent application serial no. 10/199,524, attorney docket no. 25791.100, filed on 7/19/02, which is a continuation of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (74) PCT application US
03/10144, filed on 3/28/03, attorney docket no. 25791.101.02, which claims priority from
U.S. provisional patent application serial no. 60/372,632, attorney docket no. 25791.101 , filed on 4/15/02, (75) U.S. provisional patent application serial no. 60/412,542, attorney docket no. 25791.102, filed on 9/20/02, (76) PCT application US 03/14153, filed on 5/6/03, attorney docket no. 25791.104.02, which claims priority from U.S. provisional patent application serial no. 60/380,147, attorney docket no. 25791.104, filed on 5/6/02, (77) PCT application US 03/19993, filed on 6/24/03, attorney docket no. 25791.106.02, which claims priority from U.S. provisional patent application serial no. 60/397,284, attorney docket no.
25791.106, filed on 7/19/02, (78) PCT application US 03/13787, filed on 5/5/03, attorney docket no. 25791.107.02, which claims priority from U.S. provisional patent application serial no. 60/387,486 , attorney docket no. 25791.107, filed on 6/10/02, (79) PCT application
US 03/18530, filed on 6/11/03, attorney docket no. 25791.108.02, which claims priority from
U.S. provisional patent application serial no. 60/387,961 , attorney docket no. 25791.108, filed on 6/12/02, (80) PCT application US 03/20694, filed on 7/1/03, attorney docket no.
25791.110.02, which claims priority from U.S. provisional patent application serial no.
60/398,061 , attorney docket no. 25791.110, filed on 7/24/02, (81) PCT application US
03/20870, filed on 7/2/03, attorney docket no. 25791.111.02, which claims priority from U.S. provisional patent application serial no. 60/399,240, attorney docket no. 25791.111 , filed on
7/29/02, (82) U.S. provisional patent application serial no. 60/412,487, attorney docket no.
25791.112, filed on 9/20/02, (83) U.S. provisional patent application serial no. 60/412,488, attorney docket no. 25791.114, filed on 9/20/02, (84) U.S. patent application serial no.
10/280,356, attorney docket no. 25791.115, filed on 10/25/02, which is a continuation of
U.S. patent number 6,470,966, which was filed as patent application serial number
09/850,093, filed on 5/7/01 , attorney docket no. 25791.55, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (85) U.S. provisional patent application serial no.
60/412,177, attorney docket no. 25791.117, filed on 9/20/02, (86) U.S. provisional patent application serial no. 60/412,653, attorney docket no. 25791.118, filed on 9/20/02, (87) U.S. provisional patent application serial no. 60/405,610, attorney docket no. 25791.119, filed on
8/23/02, (88) U.S. provisional patent application serial no. 60/405,394, attorney docket no.
25791.120, filed on 8/23/02, (89) U.S. provisional patent application serial no. 60/412,544, attorney docket no. 25791.121 , filed on 9/20/02, (90) PCT application US 03/24779, filed on
8/8/03, attorney docket no. 25791.125.02, which claims priority from U.S. provisional patent application serial no. 60/407,442, attorney docket no. 25791.125, filed on 8/30/02, (91) U.S. provisional patent application serial no. 60/423,363, attorney docket no. 25791.126, filed on
12/10/02, (92) U.S. provisional patent application serial no. 60/412,196, attorney docket no.
25791.127, filed on 9/20/02, (93) U.S. provisional patent application serial no. 60/412,187, attorney docket no. 25791.128, filed on 9/20/02, (94) U.S. provisional patent application serial no. 60/412,371 , attorney docket no. 25791.129, filed on 9/20/02, (95) U.S. patent application serial no. 10/382,325, attorney docket no. 25791.145, filed on 3/5/03, which is a continuation of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (96) U.S. patent application serial no. 10/624,842, attorney docket no. 25791.151, filed on 7/22/03, which is a divisional of
U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02, filed on
2/10/2000, which claims priority from provisional application 60/119,611, filed on 2/11/99,
(97) U.S. provisional patent application serial no. 60/431 ,184, attorney docket no.
25791.157, filed on 12/5/02, (98) U.S. provisional patent application serial no. 60/448,526, attorney docket no. 25791.185, filed on 2/18/03, (99) U.S. provisional patent application serial no. 60/461 ,539, attorney docket no. 25791.186, filed on 4/9/03, (100) U.S. provisional patent application serial no. 60/462,750, attorney docket no. 25791.193, filed on 4/14/03,
(101) U.S. provisional patent application serial no. 60/436,106, attorney docket no.
25791.200, filed on 12/23/02, (102) U.S. provisional patent application serial no. 60/442,942, attorney docket no. 25791.213, filed on 1/27/03, (103) U.S. provisional patent application serial no. 60/442,938, attorney docket no. 25791.225, filed on 1/27/03, (104) U.S. provisional patent application serial no. 60/418,687, attorney docket no. 25791.228, filed on 4/18/03,
(105) U.S. provisional patent application serial no. 60/454,896, attorney docket no.
25791.236, filed on 3/14/03, (106) U.S. provisional patent application serial no. 60/450,504, attorney docket no. 25791.238, filed on 2/26/03, (107) U.S. provisional patent application serial no. 60/451 ,152, attorney docket no. 25791.239, filed on 3/9/03, (108) U.S. provisional patent application serial no. 60/455,124, attorney docket no. 25791.241 , filed on 3/17/03,
(109) U.S. provisional patent application serial no. 60/453,678, attorney docket no.
25791.253, filed on 3/11/03, (110) U.S. patent application serial no. 10/421 ,682, attorney docket no. 25791.256, filed on 4/23/03, which is a continuation of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (111) U.S. provisional patent application serial no. 60/457,965, attorney docket no. 25791.260, filed on 3/27/03,
(112) U.S. provisional patent application serial no. 60/455,718, attorney docket no.
25791.262, filed on 3/18/03, (113) U.S. patent number 6,550,821 , which was filed as patent application serial no. 09/811 ,734, filed on 3/19/01 , (114) U.S. patent application serial no.
10/436,467, attorney docket no. 25791.268, filed on 5/12/03, which is a continuation of U.S. patent number 6,604,763, which was filed as application serial no. 09/559,122, attorney docket no. 25791.23.02, filed on 4/26/2000, which claims priority from provisional application
60/131 ,106, filed on 4/26/99, (115) U.S. provisional patent application serial no. 60/459,776, attorney docket no. 25791.270, filed on 4/2/03, (116) U.S. provisional patent application serial no. 60/461 ,094, attorney docket no. 25791.272, filed on 4/8/03, (117) U.S. provisional patent application serial no. 60/461 ,038, attorney docket no. 25791.273, filed on 4/7/03,
(118) U.S. provisional patent application serial no. 60/463,586, attorney docket no.
25791.277, filed on 4/17/03, (119) U.S. provisional patent application serial no. 60/472,240, attorney docket no. 25791.286, filed on 5/20/03, (120) U.S. patent application serial no.
10/619,285, attorney docket no. 25791.292, filed on 7/14/03, which is a continuation-in-part of U.S. utility patent application serial no. 09/969,922, attorney docket no. 25791.69, filed on
10/3/2001 , which is a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number
25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (121) U.S. utility patent application serial no. 10/418,688, attorney docket no. 25791.257, which was filed on 4/18/03, as a division of U.S. utility patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (122) PCT patent application serial no. PCT/US04/06246, attorney docket no. 25791.238.02, filed on
2/26/2004, (123) PCT patent application serial number PCT/US04/08170, attorney docket number 25791.40.02, filed on 3/15/04, (124) PCT patent application serial number
PCT/US04/08171 , attorney docket number 25791.236.02, filed on 3/15/04, (125) PCT patent application serial number PCT/US04/08073, attorney docket number 25791.262.02, filed on
3/18/04, (126) PCT patent application serial number PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (127) PCT patent application serial number
PCT/US2004/009434, attorney docket number 25791.260.02, filed on 3/26/2004, (128) PCT patent application serial number PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (129) PCT patent application serial number PCT/US2004/010712, attorney docket number 25791.272.02, filed on 4/6/2004, (130) PCT patent application serial number PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, (131 ) PCT patent application serial number PCT/2004/011973, attorney docket number 25791.277.02, filed on 4/15/2004, (132) U.S. provisional patent application serial number 60/495,056, attorney docket number 25791.301 , filed on 8/14/2003, (133) U.S. provisional patent application serial number 60/585,370, attorney docket number 25791.299, filed on 7/2/2004, and (134) U.S. provisional patent application serial number 60/600679, attorney docket number 25791.194, filed on 8/11/2004, the disclosures of which are incorporated herein by reference. Background of the Invention [004] This invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration. Summary Of The Invention [005] According to one aspect of the present invention, a method of forming a tubular liner within a preexisting structure is provided that includes positioning a tubular assembly within the preexisting structure; and radially expanding and plastically deforming the tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
[006] According to another aspect of the present invention, an expandable tubular member is provided that includes a steel alloy including: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr.
[007] According to another aspect of the present invention, an expandable tubular member is provided that includes a steel alloy including: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr.
[008] According to another aspect of the present invention, an expandable tubular member is provided that includes a steel alloy including: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr.
[009] According to another aspect of the present invention, an expandable tubular member is provided that includes a steel alloy including: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr.
[0010] According to another aspect of the present invention, an expandable tubular member is provided, wherein the yield point of the expandable tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 65.9 ksi after the radial expansion and plastic deformation.
[0011] According to another aspect of the present invention, an expandable tubular member is provided, wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 40 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
[0012] According to another aspect of the present invention, an expandable tubular member is provided, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.48.
[0013] According to another aspect of the present invention, an expandable tubular member is provided, wherein the yield point of the expandable tubular member is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation.
[0014] According to another aspect of the present invention, an expandable tubular member is provided, wherein the yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 28 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
[0015] According to another aspect of the present invention, an expandable tubular member is provided, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.04.
[0016] According to another aspect of the present invention, an expandable tubular member is provided, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.92.
[0017] According to another aspect of the present invention, an expandable tubular member is provided, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.34.
[0018] According to another aspect of the present invention, an expandable tubular member is provided, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
[0019] According to another aspect of the present invention, an expandable tubular member is provided, wherein the yield point of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
[0020] According to another aspect of the present invention, an expandable tubular member is provided, wherein the expandability coefficient of the expandable tubular member, prior to the radial expansion and plastic deformation, is greater than 0.12. [0021] According to another aspect of the present invention, an expandable tubular member is provided, wherein the expandability coefficient of the expandable tubular member is greater than the expandability coefficient of another portion of the expandable tubular member.
[0022] According to another aspect of the present invention, an expandable tubular member is provided, wherein the tubular member has a higher ductility and a lower yield point prior to a radial expansion and plastic deformation than after the radial expansion and plastic deformation.
[0023] According to another aspect of the present invention, a method of radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member is provided that includes radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member.
[0024] According to another aspect of the present invention, a system for radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member is provided that includes means for radially expanding the tubular assembly within a preexisting structure; and means for using less power to radially expand each unit length of the first tubular member than required to radially expand each unit length of the second tubular member.
[0025] According to another aspect of the present invention, a method of manufacturing a tubular member is provided that includes processing a tubular member until the tubular member is characterized by one or more intermediate characteristics; positioning the tubular member within a preexisting structure; and processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics.
[0026] According to another aspect of the present invention, an apparatus is provided that includes an expandable tubular assembly; and an expansion device coupled to the expandable tubular assembly; wherein a predetermined portion of the expandable tubular assembly has a lower yield point than another portion of the expandable tubular assembly.
[0027] According to another aspect of the present invention, an expandable tubular member is provided, wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 5.8 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
[0028] According to another aspect of the present invention, a method of determining the expandability of a selected tubular member is provided that includes determining an anisotropy value for the selected tubular member, determining a strain hardening value for the selected tubular member; and multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member.
[0029] According to another aspect of the present invention, a method of radially expanding and plastically deforming tubular members is provided that includes selecting a tubular member; determining an anisotropy value for the selected tubular member; determining a strain hardening value for the selected tubular member; multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member; and if the anisotropy value is greater than 0.12, then radially expanding and plastically deforming the selected tubular member.
[0030] According to another aspect of the present invention, a radially expandable tubular member apparatus is provided that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.
[0031] According to another aspect of the present invention, a radially expandable tubular member apparatus is provided that includes: a first tubular member; a second tubular member engaged with the first tubular member forming a joint; a sleeve overlapping and coupling the first and second tubular members at the joint; the sleeve having opposite tapered ends and a flange engaged in a recess formed in an adjacent tubular member; and one of the tapered ends being a surface formed on the flange; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.
[0032] According to another aspect of the present invention, a method of joining radially expandable tubular members is provided that includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
[0033] According to another aspect of the present invention, a method of joining radially expandable tubular members is provided that includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint, wherein the flange is engaged in a recess formed in an adjacent one of the tubular members; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
[0034] According to another aspect of the present invention, an expandable tubular assembly is provided that includes a first tubular member; a second tubular member coupled to the first tubular member; a first threaded connection for coupling a portion of the first and second tubular members; a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members; a tubular sleeve coupled to and receiving end portions of the first and second tubular members; and a sealing element positioned between the first and second spaced apart threaded connections for sealing an interface between the first and second tubular member; wherein the sealing element is positioned within an annulus defined between the first and second tubular members; and wherein, prior to a radial expansion and plastic deformation of the assembly, a predetermined portion of the assembly has a lower yield point than another portion of the apparatus.
[0035] According to another aspect of the present invention, a method of joining radially expandable tubular members is provided that includes: providing a first tubular member; providing a second tubular member; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members; threadably coupling the first and second tubular members at a first location; threadably coupling the first and second tubular members at a second location spaced apart from the first location; sealing an interface between the first and second tubular members between the first and second locations using a compressible sealing element, wherein the first tubular member, second tubular member, sleeve, and the sealing element define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
[0036] According to another aspect of the present invention, an expandable tubular member is provided, wherein the carbon content of the tubular member is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.21. [0037] According to another aspect of the present invention, an expandable tubular member is provided, wherein the carbon content of the tubular member is greater than 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.36. [0038] According to another aspect of the present invention, a method of selecting tubular members for radial expansion and plastic deformation is provided that includes selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is less than or equal to 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.21 , then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
[0039] According to another aspect of the present invention, a method of selecting tubular members for radial expansion and plastic deformation is provided that includes selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is greater than 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.36, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
[0040] According to another aspect of the present invention, an expandable tubular member is provided that includes a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body. [0041] According to another aspect of the present invention, a method of manufacturing an expandable tubular member has been provided that includes: providing a tubular member; heat treating the tubular member; and quenching the tubular member; wherein following the quenching, the tubular member comprises a microstructure comprising a hard phase structure and a soft phase structure.
[0042] According to another aspect of the present invention, a method of radially expanding a tubular assembly is provided that includes radially expanding and plastically deforming a lower portion of the tubular assembly by pressurizing the interior of the lower portion of the tubular assembly; and then, radially expanding and plastically deforming the remaining portion of the tubular assembly by contacting the interior of the tubular assembly with an expansion device.
[0043] According to another aspect of the present invention, a system for radially expanding a tubular assembly is provided that includes means for radially expanding and plastically deforming a lower portion of the tubular assembly by pressurizing the interior of the lower portion of the tubular assembly; and then, means for radially expanding and plastically deforming the remaining portion of the tubular assembly by contacting the interior of the tubular assembly with an expansion device. [0044] According to another aspect of the present invention, a method of repairing a tubular assembly is provided that includes positioning a tubular patch within the tubular assembly; and radially expanding and plastically deforming a tubular patch into engagement with the tubular assembly by pressurizing the interior of the tubular patch.
[0045] According to another aspect of the present invention, a system for repairing a tubular assembly is provided that includes means for positioning a tubular patch within the tubular assembly; and means for radially expanding and plastically deforming a tubular patch into engagement with the tubular assembly by pressurizing the interior of the tubular patch.
[0046] According to another aspect of the present invention, a method of radially expanding a tubular member is provided that includes accumulating a supply of pressurized fluid; and controliably injecting the pressurized fluid into the interior of the tubular member.
[0047] According to another aspect of the present invention, a system for radially expanding a tubular member is provided that includes means for accumulating a supply of pressurized fluid; and means for controliably injecting the pressurized fluid into the interior of the tubular member.
[0048] According to another aspect of the present invention, an apparatus for radially expanding a tubular member is provided that includes a fluid reservoir; a pump for pumping fluids out of the fluid reservoir; an accumulator for receiving and accumulating the fluids pumped from the reservoir; a flow control valve for controliably releasing the fluids accumulated within the reservoir; and an expansion element for engaging the interior of the tubular member to define a pressure chamber within the tubular member and receiving the released accumulated fluids into the pressure chamber.
[0049] According to another aspect of the present invention, an apparatus for radially expanding a tubular member is provided that includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device; and an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
[0050] According to another aspect of the present invention, an apparatus for radially expanding a tubular member is provided that includes: an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device; an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member; means for transmitting torque between the expandable tubular member and the tubular support member; means for sealing the interface between the expandable tubular member and the tubular support member; another tubular support member received within the tubular support member releasably coupled to the expandable tubular member; means for transmitting torque between the expandable tubular member and the other tubular support member; means for transmitting torque between the other tubular support member and the tubular support member; means for sealing the interface between the other tubular support member and the tubular support member; means for sealing the interface between the expandable tubular member and the tubular support member; means for sensing the operating pressure within the other tubular support member; means for pressurizing the interior of the other tubular support member; means for limiting axial displacement of the other tubular support member relative to the tubular support member; and a tubular liner coupled to an end of the expandable tubular member; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
[0051] According to another aspect of the present invention, a method for radially expanding a tubular member is provided that includes positioning a tubular member and an adjustable expansion device within a preexisting structure; radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; increasing the size of the adjustable expansion device; and radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member.
[0052] According to another aspect of the present invention, a system for radially expanding a tubular member is provided that includes means for positioning a tubular member and an adjustable expansion device within a preexisting structure; means for radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; means for increasing the size of the adjustable expansion device; and means for radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member.
[0053] According to another aspect of the present invention, a method of radially expanding and plastically deforming an expandable tubular member is provided that includes limiting the amount of radial expansion of the expandable tubular member.
[0054] According to another aspect of the present invention, an apparatus for radially expanding a tubular member is provided that includes an expandable tubular member; an expansion device coupled to the expandable tubular member for radially expanding and plastically deforming the expandable tubular member; and an tubular expansion limiter coupled to the expandable tubular member for limiting the degree to which the expandable tubular member may be radially expanded and plastically deformed. [0055] According to another aspect of the present invention, an apparatus for radially expanding a tubular member is provided that includes: an expandable tubular member; an expansion device coupled to the expandable tubular member for radially expanding and plastically deforming the expandable tubular member; an tubular expansion limiter coupled to the expandable tubular member for limiting the degree to which the expandable tubular member may be radially expanded and plastically deformed; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device and the expansion device; means for transmitting torque between the expandable tubular member and the tubular support member; means for sealing the interface between the expandable tubular member and the tubular support member; means for sensing the operating pressure within the tubular support member; and means for pressurizing the interior of the tubular support member; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
[0056] According to another aspect of the present invention, a method for radially expanding a tubular member is provided that includes positioning a tubular member and an adjustable expansion device within a preexisting structure; radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; limiting the extent to which the portion of the tubular member is radially expanded and plastically deformed by pressurizing the interior of the tubular member; increasing the size of the adjustable expansion device; and radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member.
[0057] According to another aspect of the present invention, a system for radially expanding a tubular member is provided that includes means for positioning a tubular member and an adjustable expansion device within a preexisting structure; means for radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; means for limiting the extent to which the portion of the tubular member is radially expanded and plastically deformed by pressurizing the interior of the tubular member; means for increasing the size of the adjustable expansion device; and means for radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member. [0058] According to another aspect of the present invention, an apparatus for radially expanding an expandable tubular member is provided that includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; a first expansion device coupled to the tubular support member; a second expansion device coupled to the tubular support member; and an expandable tubular sleeve coupled to the second expansion device. [0059] According to another aspect of the present invention, a method for radially expanding a tubular member is provided that includes positioning an expandable tubular member and an expandable tubular sleeve within a preexisting structure; radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve; and radially expanding and plastically deforming at least a portion of the expandable tubular sleeve.
[0060] According to another aspect of the present invention, a system for radially expanding a tubular member is provided that includes means for positioning an expandable tubular member and an expandable tubular sleeve within a preexisting structure; means for radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve; and means for radially expanding and plastically deforming at least a portion of the expandable tubular sleeve. [0061] According to another aspect of the present invention, an apparatus for radially expanding an expandable tubular member is provided that includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; an adjustable expansion device coupled to the tubular support member; a non-adjustable expansion device coupled to the tubular support member; and an expandable tubular sleeve coupled to the non-adjustable expansion device.
[0062] According to another aspect of the present invention, a method for radially expanding a tubular member is provided that include positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; increasing the size of the adjustable expansion device; radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve using the adjustable expansion device; and radially expanding and plastically deforming at least a portion of the expandable tubular sleeve. [0063] According to another aspect of the present invention, a system for radially expanding a tubular member is provided that includes means for positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; means for increasing the size of the adjustable expansion device; means for radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve using the adjustable expansion device; and means for radially expanding and plastically deforming at least a portion of the expandable tubular sleeve.
[0064] According to another aspect of the present invention, an apparatus for radially expanding an expandable tubular member has been provided that includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; and an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member.
[0065] According to another aspect of the present invention, a method for radially expanding a tubular member has been provided that includes positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; increasing the size of the adjustable expansion device to radially expand and plastically deform at least a portion of at least one of the expandable tubular member and the expandable tubular sleeve; and radially expanding and plastically deforming at least another portion of the expandable tubular member using the adjustable expansion device.
[0066] According to another aspect of the present invention, a system for radially expanding a tubular member has been provided that includes means for positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; means for increasing the size of the adjustable expansion device to radially expand and plastically deform at least a portion of at least one of the expandable tubular member and the expandable tubular sleeve; and means for radially expanding and plastically deforming at least another portion of the expandable tubular member using the adjustable expansion device. Brief Description of the Drawings
[0067] Fig. 1 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
[0068] Fig. 2 is a fragmentary cross sectional view of the expandable tubular member of Fig.
1 after positioning an expansion device within the expandable tubular member. [0069] Fig. 3 is a fragmentary cross sectional view of the expandable tubular member of Fig.
2 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.
[0070] Fig. 4 is a fragmentary cross sectional view of the expandable tubular member of Fig.
3 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
[0071] Fig. 5 is a graphical illustration of exemplary embodiments of the stress/strain curves for several portions of the expandable tubular member of Figs. 1-4.
[0072] Fig. 6 is a graphical illustration of the an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member of Figs. 1-4.
[0073] Fig. 7 is a fragmentary cross sectional illustration of an embodiment of a series of overlapping expandable tubular members.
[0074] Fig. 8 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
[0075] Fig. 9 is a fragmentary cross sectional view of the expandable tubular member of Fig.
8 after positioning an expansion device within the expandable tubular member.
[0076] Fig. 10 is a fragmentary cross sectional view of the expandable tubular member of
Fig. 9 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.
[0077] Fig. 11 is a fragmentary cross sectional view of the expandable tubular member of
Fig. 10 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
[0078] Fig. 12 is a graphical illustration of exemplary embodiments of the stress/strain curves for several portions of the expandable tubular member of Figs. 8-11.
[0079] Fig. 13 is a graphical illustration of an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member of Figs. 8-11.
[0080] Fig. 14 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
[0081] Fig. 15 is a fragmentary cross sectional view of the expandable tubular member of
Fig. 14 after positioning an expansion device within the expandable tubular member.
[0082] Fig. 16 is a fragmentary cross sectional view of the expandable tubular member of
Fig. 15 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.
[0083] Fig. 17 is a fragmentary cross sectional view of the expandable tubular member of
Fig. 16 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
[0084] Fig. 18 is a flow chart illustration of an exemplary embodiment of a method of processing an expandable tubular member.
[0085] Fig. 19 is a graphical illustration of the an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member during the operation of the method of Fig. 18.
[0086] Fig. 20 is a graphical illustration of stress/strain curves for an exemplary embodiment of an expandable tubular member.
[0087] Fig. 21 is a graphical illustration of stress/strain curves for an exemplary embodiment of an expandable tubular member.
[0088] Fig. 22 is a fragmentary cross-sectional view illustrating an embodiment of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, an embodiment of a tubular sleeve supported by the end portion of the first tubular member, and a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member and engaged by a flange of the sleeve. The sleeve includes the flange at one end for increasing axial compression loading.
[0089] Fig. 23 is a fragmentary cross-sectional view illustrating an embodiment of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
The sleeve includes flanges at opposite ends for increasing axial tension loading.
[0090] Fig. 24 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members. The sleeve includes flanges at opposite ends for increasing axial compression/tension loading.
[0091] Fig. 25 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members. The sleeve includes flanges at opposite ends having sacrificial material thereon.
[0092] Fig. 26 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members. The sleeve includes a thin walled cylinder of sacrificial material.
[0093] Fig. 27 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members. The sleeve includes a variable thickness along the length thereof.
[0094] Fig. 28 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members. The sleeve includes a member coiled onto grooves formed in the sleeve for varying the sleeve thickness.
[0095] Fig. 29 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.
[0096] Figs. 30a-30c are fragmentary cross-sectional illustrations of exemplary embodiments of expandable connections.
[0097] Fig. 31 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.
[0098] Figs. 32a and 32b are fragmentary cross-sectional illustrations of the formation of an exemplary embodiment of an expandable connection.
[0099] Fig. 33 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.
[00100] Figs. 34a, 34b and 34c are fragmentary cross-sectional illustrations of an exemplary embodiment of an expandable connection.
[00101] Fig. 35a is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable tubular member.
[00102] Fig. 35b is a graphical illustration of an exemplary embodiment of the variation in the yield point for the expandable tubular member of Fig. 35a.
[00103] Fig. 36a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
[00104] Fig. 36b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
[00105] Fig. 36c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing. [00106] Fig. 37a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
[00107] Fig. 37b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
[00108] Fig. 37c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
[00109] Fig. 38a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
[00110] Fig. 38b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
[00111] Fig. 38c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
[00112] Fig. 39a is a fragmentary cross sectional illustration of an exemplary embodiment of expandable tubular members positioned within a preexisting structure.
[00113] Fig. 39b is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 39a after placing an adjustable expansion device and a hydroforming expansion device within the expandable tubular members.
[00114] Fig. 39c is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 39b after operating the hydroforming expansion device to radially expand and plastically deform at least a portion of the expandable tubular members.
[00115] Fig. 39d is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 39c after operating the hydroforming expansion device to disengage from the expandable tubular members.
[00116] Fig. 39e is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 39d after positioning the adjustable expansion device within the radially expanded portion of the expandable tubular members and then adjusting the size of the adjustable expansion device.
[00117] Fig. 39f is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 39e after operating the adjustable expansion device to radially expand another portion of the expandable tubular members.
[00118] Fig. 40a is a fragmentary cross sectional illustration of an exemplary embodiment of expandable tubular members positioned within a preexisting structure.
[00119] Fig. 40b is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 40a after placing a hydroforming expansion device within a portion of the expandable tubular members. [00120] Fig. 40c is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 40b after operating the hydroforming expansion device to radially expand and plastically deform at least a portion of the expandable tubular members. [00121] Fig. 40d is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 40c after placing the hydroforming expansion device within another portion of the expandable tubular members.
[00122] Fig. 40e is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 40d after operating the hydroforming expansion device to radially expand and plastically deform at least another portion of the expandable tubular members. [00123] Fig. 40f is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 40e after placing the hydroforming expansion device within another portion of the expandable tubular members.
[00124] Fig. 40g is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 40f after operating the hydroforming expansion device to radially expand and plastically deform at least another portion of the expandable tubular members. [00125] Fig. 41a is a fragmentary cross sectional illustration of an exemplary embodiment of expandable tubular members positioned within a preexisting structure, wherein the bottom most tubular member includes a valveable passageway. [00126] Fig. 41b is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41a after placing a hydroforming expansion device within the lower most expandable tubular member.
[00127] Fig. 41c is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41b after operating the hydroforming expansion device to radially expand and plastically deform at least a portion of the lower most expandable tubular member. [00128] Fig. 41 d is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41c after disengaging hydroforming expansion device from the lower most expandable tubular member.
[00129] Fig. 41 e is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41 d after positioning the adjustable expansion device within the radially expanded and plastically deformed portion of the lower most expandable tubular member. [00130] Fig. 41f is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41 e after operating the adjustable expansion device to engage the radially expanded and plastically deformed portion of the lower most expandable tubular member. [00131] Fig. 41 g is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41f after operating the adjustable expansion device to radially expand and plastically deform at least another portion of the expandable tubular members. [00132] Fig. 41 h is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41g after machining away the lower most portion of the lower most expandable tubular member.
[00133] Fig. 42a is a fragmentary cross sectional illustration of an exemplary embodiment of tubular members positioned within a preexisting structure, wherein one of the tubular members includes one or more radial passages.
[00134] Fig. 42b is a fragmentary cross sectional illustration of the tubular members of
Fig. 42a after placing a hydroforming casing patch device within the tubular member having the radial passages.
[00135] Fig. 42c is a fragmentary cross sectional illustration of the tubular members of
Fig. 42b after operating the hydroforming expansion device to radially expand and plastically deform a tubular casing patch into engagement with the tubular member having the radial passages.
[00136] Fig. 41 d is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41c after disengaging the hydroforming expansion device from the tubular member having the radial passages.
[00137] Fig. 41e is a fragmentary cross sectional illustration of the expandable tubular members of Fig. 41 d after removing the hydroforming expansion device from the tubular member having the radial passages.
[00138] Fig. 43 is a schematic illustration of an exemplary embodiment of a hydroforming expansion device.
[00139] Figs. 44a-44b are flow chart illustrations of an exemplary method of operating the hydroforming expansion device of Fig. 43.
[00140] Fig. 45a is a fragmentary cross sectional illustration of an exemplary embodiment of a radial expansion system positioned within a cased section of a wellbore.
[00141] Fig. 45b is a fragmentary cross sectional illustration of the system of Fig. 45a following the placement of a ball within the throat passage of the system.
[00142] Fig. 45c is a fragmentary cross sectional illustration of the system of Fig. 45b during the injection of fluidic materials to burst the burst disc of the system.
[00143] Fig. 45d is a fragmentary cross sectional illustration of the system of Fig. 45c during the continued injection of fluidic materials to radially expand and plastically deform at least a portion of the tubular liner hanger.
[00144] Fig. 45e is a fragmentary cross sectional illustration of the system of Fig. 45d during the continued injection of fluidic materials to adjust the size of the adjustable expansion device assembly. [00145] Fig. 45f is a fragmentary cross sectional illustration of the system of Fig. 45e during the displacement of the adjustable expansion device assembly to radially expand another portion of the tubular liner hanger.
[00146] Fig. 45g is a fragmentary cross sectional illustration of the system of Fig. 45f following the removal of the system from the wellbore.
[00147] Fig. 46a is a fragmentary cross sectional illustration of an exemplary embodiment of a radial expansion system positioned within a cased section of a wellbore.
[00148] Fig. 46b is a fragmentary cross sectional illustration of the system of Fig. 46a following the placement of a plug within the throat passage of the system.
[00149] Fig. 46c is a fragmentary cross sectional illustration of the system of Fig. 46b during the injection of fluidic materials to burst the burst disc of the system.
[00150] Fig. 46d is a fragmentary cross sectional illustration of the system of Fig. 46c during the continued injection of fluidic materials to radially expand and plastically deform at least a portion of the tubular liner hanger.
[00151] Fig. 46e is a fragmentary cross sectional illustration of the system of Fig. 46d during the continued injection of fluidic materials to adjust the size of the adjustable expansion device assembly.
[00152] Fig. 46f is a fragmentary cross sectional illustration of the system of Fig. 46e during the displacement of the adjustable expansion device assembly to radially expand another portion of the tubular liner hanger.
[00153] Fig. 46g is a top view of a portion of an exemplary embodiment of an expansion limiter sleeve prior to the radial expansion and plastic deformation of the expansion limiter sleeve.
[00154] Fig. 46h is a top view of a portion of the expansion limiter sleeve of Fig. 46g after the radial expansion and plastic deformation of the expansion limiter sleeve.
[00155] Fig. 46i is a top view of a portion of an exemplary embodiment of an expansion limiter sleeve prior to the radial expansion and plastic deformation of the expansion limiter sleeve.
[00156] Fig. 46ia is a fragmentary cross sectional view of the expansion limiter sleeve of Fig. 46i.
[00157] Fig. 46j is a top view of a portion of the expansion limiter sleeve of Fig. 46i after the radial expansion and plastic deformation of the expansion limiter sleeve.
[00158] Fig. 47a is a fragmentary cross sectional illustration of an exemplary embodiment of a system for radially expanding and plastically deforming a tubular member during the injection of a hardenable fluidic sealing material into the system. [00159] Fig. 47b is a fragmentary cross sectional illustration of the system of Fig. 47a during the subsequent placement of a plug within the flow passages of the system to permit the passages of the system to be pressurized.
[00160] Fig. 47c is a fragmentary cross sectional illustration of the system of Fig. 47b during the subsequent pressurization of the flow passages of the system to operate and displace the expansion cone of the system to radially expand and plastically deform a portion of the expandable tubular casing.
[00161] Fig. 47d is a fragmentary cross sectional illustration of the system of Fig. 47c during the subsequent continued pressurization of the flow passages of the system to operate and displace the expansion cones of the system to radially expand and plastically deform further portions of the expandable tubular casing and a portion of the expandable tubular sleeve.
[00162] Fig. 47e is a fragmentary cross sectional illustration of the system of Fig. 47d during the subsequent pressurization of the flow passages of the system to operate and displace the expansion cone of the system to radially expand and plastically deform further portions of the expandable tubular casing.
[00163] Fig. 48a is a fragmentary cross sectional illustration of an exemplary embodiment of a system for radially expanding and plastically deforming a tubular member during the injection of a hardenable fluidic sealing material into the system.
[00164] Fig. 48b is a fragmentary cross sectional illustration of the system of Fig. 48a during the subsequent placement of a plug within the flow passages of the system to permit the passages of the system to be pressurized.
[00165] Fig. 48c is a fragmentary cross sectional illustration of the system of Fig. 48b during the subsequent pressurization of the flow passages of the system to operate and adjust the size of the adjustable expansion device of the system.
[00166] Fig. 48d is a fragmentary cross sectional illustration of the system of Fig. 48c during the subsequent pressurization of the flow passages of the system to operate and displace the expansion device of the system to radially expand and plastically deform a portion of the expandable tubular casing.
[00167] Fig. 48e is a fragmentary cross sectional illustration of the system of Fig. 48d during the subsequent continued pressurization of the flow passages of the system to operate and displace the expansion device of the system to radially expand and plastically deform further portions of the expandable tubular casing and a portion of the expandable tubular sleeve.
[00168] Fig. 48f is a fragmentary cross sectional illustration of the system of Fig. 48e during the subsequent pressurization of the flow passages of the system to operate and displace the expansion cone of the system to radially expand and plastically deform further portions of the expandable tubular casing.
[00169] Fig. 49a is a fragmentary cross sectional illustration of an exemplary embodiment of a system for radially expanding and plastically deforming a tubular member during the injection of a hardenable fluidic sealing material into the system.
[00170] Fig. 49b is a fragmentary cross sectional illustration of the system of Fig. 49a during the subsequent placement of a plug within the flow passages of the system to permit the passages of the system to be pressurized.
[00171] Fig. 49c is a fragmentary cross sectional illustration of the system of Fig. 49b during the subsequent pressurization of the flow passages of the system to operate and adjust the size of the adjustable expansion device of the system.
[00172] Fig. 49d is a fragmentary cross sectional illustration of the system of Fig. 49c during the subsequent pressurization of the flow passages of the system to operate and displace the expansion device of the system to radially expand and plastically deform a portion of the expandable tubular casing.
[00173] Fig. 49e is a fragmentary cross sectional illustration of the system of Fig. 49d during the subsequent continued pressurization of the flow passages of the system to operate and displace the expansion device of the system to radially expand and plastically deform further portions of the expandable tubular casing and a portion of the expandable tubular sleeve.
[00174] Fig. 49f is a fragmentary cross sectional illustration of the system of Fig. 49e during the subsequent pressurization of the flow passages of the system to operate and displace the expansion cone of the system to radially expand and plastically deform further portions of the expandable tubular casing.
[00175] Fig. 50a is a fragmentary cross sectional illustration of an exemplary embodiment of a system for radially expanding and plastically deforming a tubular member during the injection of a hardenable fluidic sealing material into the system.
[00176] Fig. 50b is a fragmentary cross sectional illustration of the system of Fig. 50a during the subsequent placement of a plug within the flow passages of the system to permit the passages of the system to be pressurized.
[00177] Fig. 50c is a fragmentary cross sectional illustration of the system of Fig. 50b during the subsequent pressurization of the flow passages of the system to operate and adjust the size of the adjustable expansion device of the system to radially expand and plastically deform a portion of the expandable sleeve.
[00178] Fig. 50d is a fragmentary cross sectional illustration of the system of Fig. 50c during the subsequent pressurization of the flow passages of the system to operate and displace the expansion device of the system to radially expand and plastically deform a portion of the expandable tubular casing and release the expandable tubular casing from engagement with the casing lock assembly.
[00179] Fig. 50e is a fragmentary cross sectional illustration of the system of Fig. 50d during the subsequent continued pressurization of the flow passages of the system to operate and displace the expansion device of the system to radially expand and plastically deform further portions of the expandable tubular casing.
[00180] Fig. 50f is a fragmentary cross sectional illustration of the system of Fig. 50b during an emergency release of the expandable tubular casing from engagement with the locking dogs of the casing lock assembly. Detailed Description of the Illustrative Embodiments
[00181] Referring initially to Fig. 1 , an exemplary embodiment of an expandable tubular assembly 10 includes a first expandable tubular member 12 coupled to a second expandable tubular member 14. In several exemplary embodiments, the ends of the first and second expandable tubular members, 12 and 14, are coupled using, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection. In an exemplary embodiment, the first expandable tubular member 12 has a plastic yield point YP-i, and the second expandable tubular member 14 has a plastic yield point YP . In an exemplary embodiment, the expandable tubular assembly 10 is positioned within a preexisting structure such as, for example, a wellbore 16 that traverses a subterranean formation 18.
[00182] As illustrated in Fig. 2, an expansion device 20 may then be positioned within the second expandable tubular member 14. In several exemplary embodiments, the expansion device 20 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services,
Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C. In several exemplary embodiments, the expansion device 20 is positioned within the second expandable tubular member 14 before, during, or after the placement of the expandable tubular assembly 10 within the preexisting structure 16.
[00183] As illustrated in Fig. 3, the expansion device 20 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member
14 to form a bell-shaped section.
[00184] As illustrated in Fig. 4, the expansion device 20 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 14 and at least a portion of the first expandable tubular member 12. [00185] In an exemplary embodiment, at least a portion of at least a portion of at least one of the first and second expandable tubular members, 12 and 14, are radially expanded into intimate contact with the interior surface of the preexisting structure 16. [00186] In an exemplary embodiment, as illustrated in Fig. 5, the plastic yield point YPi is greater than the plastic yield point YP2. In this manner, in an exemplary embodiment, the amount of power and/or energy required to radially expand the second expandable tubular member 14 is less than the amount of power and/or energy required to radially expand the first expandable tubular member 12.
[00187] In an exemplary embodiment, as illustrated in Fig. 6, the first expandable tubular member 12 and/or the second expandable tubular member 14 have a ductility DPE and a yield strength YSPE prior to radial expansion and plastic deformation, and a ductility DAE and a yield strength YSAE after radial expansion and plastic deformation. In an exemplary embodiment, DPE is greater than DAE. and YSAE is greater than YSPE. In this manner, the first expandable tubular member 12 and/or the second expandable tubular member 14 are transformed during the radial expansion and plastic deformation process. Furthermore, in this manner, in an exemplary embodiment, the amount of power and/or energy required to radially expand each unit length of the first and/or second expandable tubular members, 12 and 14, is reduced. Furthermore, because the YSAE is greater than YSPE, the collapse strength of the first expandable tubular member 12 and/or the second expandable tubular member 14 is increased after the radial expansion and plastic deformation process. [00188] In an exemplary embodiment, as illustrated in Fig. 7, following the completion of the radial expansion and plastic deformation of the expandable tubular assembly 10 described above with reference to Figs. 1-4, at least a portion of the second expandable tubular member 14 has an inside diameter that is greater than at least the inside diameter of the first expandable tubular member 12. In this manner a bell-shaped section is formed using at least a portion of the second expandable tubular member 14. Another expandable tubular assembly 22 that includes a first expandable tubular member 24 and a second expandable tubular member 26 may then be positioned in overlapping relation to the first expandable tubular assembly 10 and radially expanded and plastically deformed using the methods described above with reference to Figs. 1-4. Furthermore, following the completion of the radial expansion and plastic deformation of the expandable tubular assembly 20, in an exemplary embodiment, at least a portion of the second expandable tubular member 26 has an inside diameter that is greater than at least the inside diameter of the first expandable tubular member 24. In this manner a bell-shaped section is formed using at least a portion of the second expandable tubular member 26. Furthermore, in this manner, a mono- diameter tubular assembly is formed that defines an internal passage 28 having a substantially constant cross-sectional area and/or inside diameter. [00189] Referring to Fig. 8, an exemplary embodiment of an expandable tubular assembly
100 includes a first expandable tubular member 102 coupled to a tubular coupling 104. The tubular coupling 104 is coupled to a tubular coupling 106. The tubular coupling 106 is coupled to a second expandable tubular member 108. In several exemplary embodiments, the tubular couplings, 104 and 106, provide a tubular coupling assembly for coupling the first and second expandable tubular members, 102 and 108, together that may include, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection. In an exemplary embodiment, the first and second expandable tubular members 12 have a plastic yield point YP-i, and the tubular couplings, 104 and 106, have a plastic yield point YP2. In an exemplary embodiment, the expandable tubular assembly 100 is positioned within a preexisting structure such as, for example, a wellbore 110 that traverses a subterranean formation 112.
[00190] As illustrated in Fig. 9, an expansion device 114 may then be positioned within the second expandable tubular member 108. In several exemplary embodiments, the expansion device 114 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services,
Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C. In several exemplary embodiments, the expansion device 114 is positioned within the second expandable tubular member 108 before, during, or after the placement of the expandable tubular assembly 100 within the preexisting structure 110.
[00191] As illustrated in Fig. 10, the expansion device 114 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 108 to form a bell-shaped section.
[00192] As illustrated in Fig. 11 , the expansion device 114 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 108, the tubular couplings, 104 and 106, and at least a portion of the first expandable tubular member 102.
[00193] In an exemplary embodiment, at least a portion of at least a portion of at least one of the first and second expandable tubular members, 102 and 108, are radially expanded into intimate contact with the interior surface of the preexisting structure 110.
[00194] In an exemplary embodiment, as illustrated in Fig. 12, the plastic yield point YPT is less than the plastic yield point YP2. In this manner, in an exemplary embodiment, the amount of power and/or energy required to radially expand each unit length of the first and second expandable tubular members, 102 and 108, is less than the amount of power and/or energy required to radially expand each unit length of the tubular couplings, 104 and 106.
[00195] In an exemplary embodiment, as illustrated in Fig. 13, the first expandable tubular member 12 and/or the second expandable tubular member 14 have a ductility DPE and a yield strength YSPE prior to radial expansion and plastic deformation, and a ductility DAE and a yield strength YSAE after radial expansion and plastic deformation. In an exemplary embodiment, DPE is greater than DAE, and YSAE is greater than YSPE. In this manner, the first expandable tubular member 12 and/or the second expandable tubular member 14 are transformed during the radial expansion and plastic deformation process. Furthermore, in this manner, in an exemplary embodiment, the amount of power and/or energy required to radially expand each unit length of the first and/or second expandable tubular members, 12 and 14, is reduced. Furthermore, because the YSAEis greater than YSPE, the collapse strength of the first expandable tubular member 12 and/or the second expandable tubular member 14 is increased after the radial expansion and plastic deformation process.
[00196] Referring to Fig. 14, an exemplary embodiment of an expandable tubular assembly 200 includes a first expandable tubular member 202 coupled to a second expandable tubular member 204 that defines radial openings 204a, 204b, 204c, and 204d.
In several exemplary embodiments, the ends of the first and second expandable tubular members, 202 and 204, are coupled using, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection. In an exemplary embodiment, one or more of the radial openings, 204a, 204b, 204c, and 204d, have circular, oval, square, and/or irregular cross sections and/or include portions that extend to and interrupt either end of the second expandable tubular member 204. In an exemplary embodiment, the expandable tubular assembly 200 is positioned within a preexisting structure such as, for example, a wellbore
206 that traverses a subterranean formation 208.
[00197] As illustrated in Fig. 15, an expansion device 210 may then be positioned within the second expandable tubular member 204. In several exemplary embodiments, the expansion device 210 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services,
Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C. In several exemplary embodiments, the expansion device 210 is positioned within the second expandable tubular member 204 before, during, or after the placement of the expandable tubular assembly 200 within the preexisting structure 206.
[00198] As illustrated in Fig. 16, the expansion device 210 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 204 to form a bell-shaped section.
[00199] As illustrated in Fig. 16, the expansion device 20 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 204 and at least a portion of the first expandable tubular member 202.
[00200] In an exemplary embodiment, the anisotropy ratio AR for the first and second expandable tubular members is defined by the following equation: AR = In (WTf/WT0)/ln (Df/D0); where AR = anisotropy ratio; where WTf = final wall thickness of the expandable tubular member following the radial expansion and plastic deformation of the expandable tubular member; where WTj = initial wall thickness of the expandable tubular member prior to the radial expansion and plastic deformation of the expandable tubular member; where Df = final inside diameter of the expandable tubular member following the radial expansion and plastic deformation of the expandable tubular member; and where Dj = initial inside diameter of the expandable tubular member prior to the radial expansion and plastic deformation of the expandable tubular member. [00201] In an exemplary embodiment, the anisotropy ratio AR for the first and/or second expandable tubular members, 204 and 204, is greater than 1.
[00202] In an exemplary experimental embodiment, the second expandable tubular member 204 had an anisotropy ratio AR greater than 1 , and the radial expansion and plastic deformation of the second expandable tubular member did not result in any of the openings, 204a, 204b, 204c, and 204d, splitting or otherwise fracturing the remaining portions of the second expandable tubular member. This was an unexpected result. [00203] Referring to Fig. 18, in an exemplary embodiment, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 are processed using a method 300 in which a tubular member in an initial state is thermo-mechanically processed in step 302. In an exemplary embodiment, the thermo-mechanical processing 302 includes one or more heat treating and/or mechanical forming processes. As a result, of the thermo- mechanical processing 302, the tubular member is transformed to an intermediate state. The tubular member is then further thermo-mechanically processed in step 304. In an exemplary embodiment, the thermo-mechanical processing 304 includes one or more heat treating and/or mechanical forming processes. As a result, of the thermo-mechanical processing 304, the tubular member is transformed to a final state.
[00204] In an exemplary embodiment, as illustrated in Fig. 19, during the operation of the method 300, the tubular member has a ductility DPE and a yield strength YSPE prior to the final thermo-mechanical processing in step 304, and a ductility DAE and a yield strength YSAE after final thermo-mechanical processing. In an exemplary embodiment, DPE is greater than DAE, and YSAE is greater than YSPE. In this manner, the amount of energy and/or power required to transform the tubular member, using mechanical forming processes, during the final thermo-mechanical processing in step 304 is reduced. Furthermore, in this manner, because the YSAE is greater than YSPE, the collapse strength of the tubular member is increased after the final thermo-mechanical processing in step 304. [00205] In an exemplary embodiment, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, have the following characteristics:
Figure imgf000037_0001
[00206] In an exemplary embodiment, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, are characterized by an expandability coefficient f: i. f = r X n ii. where f = expandability coefficient; 1. r = anisotropy coefficient; and 2. n = strain hardening exponent. [00207] In an exemplary embodiment, the anisotropy coefficient for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 1. In an exemplary embodiment, the strain hardening exponent for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 0.12. In an exemplary embodiment, the expandability coefficient for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 0.12. [00208] In an exemplary embodiment, a tubular member having a higher expandability coefficient requires less power and/or energy to radially expand and plastically deform each unit length than a tubular member having a lower expandability coefficient. In an exemplary embodiment, a tubular member having a higher expandability coefficient requires less power and/or energy per unit length to radially expand and plastically deform than a tubular member having a lower expandability coefficient. [00209] In several exemplary experimental embodiments, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, are steel alloys having one of the following compositions:
Figure imgf000038_0001
[00210] In exemplary experimental embodiment, as illustrated in Fig. 20, a sample of an expandable tubular member composed of Alloy A exhibited a yield point before radial expansion and plastic deformation YPBE, a yield point after radial expansion and plastic deformation of about 16 % YPAEie%. and a yield point after radial expansion and plastic deformation of about 24 % YPAE24%- In an exemplary experimental embodiment, YPAE24% > YPAEI6% YPBE- Furthermore, in an exemplary experimental embodiment, the ductility of the sample of the expandable tubular member composed of Alloy A also exhibited a higher ductility prior to radial expansion and plastic deformation than after radial expansion and plastic deformation. These were unexpected results. [00211] In an exemplary experimental embodiment, a sample of an expandable tubular member composed of Alloy A exhibited the following tensile characteristics before and after radial expansion and plastic deformation:
Figure imgf000039_0001
[00212] In exemplary experimental embodiment, as illustrated in Fig. 21 , a sample of an expandable tubular member composed of Alloy B exhibited a yield point before radial expansion and plastic deformation YPBE, a yield point after radial expansion and plastic deformation of about 16 % YPAEι6%, and a yield point after radial expansion and plastic deformation of about 24 % YPAE2 %. In an exemplary embodiment, YPAE2 % > YPAEI6% > YPBE- Furthermore, in an exemplary experimental embodiment, the ductility of the sample of the expandable tubular member composed of Alloy B also exhibited a higher ductility prior to radial expansion and plastic deformation than after radial expansion and plastic deformation. These were unexpected results. [00213] In an exemplary experimental embodiment, a sample of an expandable tubular member composed of Alloy B exhibited the following tensile characteristics before and after radial expansion and plastic deformation:
Figure imgf000040_0001
[00214] In an exemplary experimental embodiment, samples of expandable tubulars composed of Alloys A, B, C, and D exhibited the following tensile characteristics prior to radial expansion and plastic deformation:
Figure imgf000041_0001
[00215] In an exemplary embodiment, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 have a strain hardening exponent greater than 0.12, and a yield ratio is less than 0.85. [00216] In an exemplary embodiment, the carbon equivalent Ce, for tubular members having a carbon content (by weight percentage) less than or equal to 0.12%, is given by the following expression: Cβ = C + Mn/6 + (Cr + Mo + V + Ti + Nb)/5 + (Ni + Cu)/15 where Ce = carbon equivalent value; a. C = carbon percentage by weight; b. Mn = manganese percentage by weight; c. Cr = chromium percentage by weight; d. Mo = molybdenum percentage by weight; e. V = vanadium percentage by weight; f. Ti = titanium percentage by weight; g. Nb = niobium percentage by weight; h. Ni = nickel percentage by weight; and i. Cu = copper percentage by weight. [00217] In an exemplary embodiment, the carbon equivalent value Ce,for tubular members having a carbon content less than or equal to 0.12% (by weight), for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is less than 0.21. [00218] In an exemplary embodiment, the carbon equivalent Ce, for tubular members having more than 0.12% carbon content (by weight), is given by the following expression: Cβ = C + Si/ 30 + (Mn + Cu + Cr)/20 + Ni/6Q + Mo/15 + V /10 + 5 *B where Ce = carbon equivalent value; a. C = carbon percentage by weight; b. Si = silicon percentage by weight; c. Mn = manganese percentage by weight; d. Cu copper percentage by weight; e. Cr chromium percentage by weight; f. Ni nickel percentage by weight; g- Mo molybdenum percentage by weight; h. V vanadium percentage by weight; and i. B boron percentage by weight.
[00219] In an exemplary embodiment, the carbon equivalent value Ce, for tubular members having greater than 0.12% carbon content (by weight), for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is less than 0.36.
[00220] Referring to Fig. 22 in an exemplary embodiment, a first tubular member 2210 includes an internally threaded connection 2212 at an end portion 2214. A first end of a tubular sleeve 2216 that includes an internal flange 2218 having a tapered portion 2220, and a second end that includes a tapered portion 2222, is then mounted upon and receives the end portion 2214 of the first tubular member 2210. In an exemplary embodiment, the end portion 2214 of the first tubular member 2210 abuts one side of the internal flange 2218 of the tubular sleeve 2216, and the internal diameter of the internal flange 2218 of the tubular sleeve 2216 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 2212 of the end portion 2214 of the first tubular member
2210. An externally threaded connection 2224 of an end portion 2226 of a second tubular member 2228 having an annular recess 2230 is then positioned within the tubular sleeve
2216 and threadably coupled to the internally threaded connection 2212 of the end portion
2214 of the first tubular member 2210. In an exemplary embodiment, the internal flange
2218 of the tubular sleeve 2216 mates with and is received within the annular recess 2230 of the end portion 2226 of the second tubular member 2228. Thus, the tubular sleeve 2216 is coupled to and surrounds the external surfaces of the first and second tubular members,
2210 and 2228.
[00221] The internally threaded connection 2212 of the end portion 2214 of the first tubular member 2210 is a box connection, and the externally threaded connection 2224 of the end portion 2226 of the second tubular member 2228 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2216 is at least approximately .020" greater than the outside diameters of the first and second tubular members, 2210 and 2228. In this manner, during the threaded coupling of the first and second tubular members, 2210 and 2228, fluidic materials within the first and second tubular members may be vented from the tubular members.
[00222] As illustrated in Fig. 22, the first and second tubular members, 2210 and
2228, and the tubular sleeve 2216 may be positioned within another structure 2232 such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device 2234 within and/or through the interiors of the first and second tubular members. The tapered portions,
2220 and 2222, of the tubular sleeve 2216 facilitate the insertion and movement of the first and second tubular members within and through the structure 2232, and the movement of the expansion device 2234 through the interiors of the first and second tubular members,
2210 and 2228, may be, for example, from top to bottom or from bottom to top.
[00223] During the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228, the tubular sleeve 2216 is also radially expanded and plastically deformed. As a result, the tubular sleeve 2216 may be maintained in circumferential tension and the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, may be maintained in circumferential compression.
[00224] Sleeve 2216 increases the axial compression loading of the connection between tubular members 2210 and 2228 before and after expansion by the expansion device 2234. Sleeve 2216 may, for example, be secured to tubular members 2210 and
2228 by a heat shrink fit.
[00225] In several alternative embodiments, the first and second tubular members,
2210 and 2228, are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global
Technology L.L.C.
[00226] The use of the tubular sleeve 2216 during (a) the coupling of the first tubular member 2210 to the second tubular member 2228, (b) the placement of the first and second tubular members in the structure 2232, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits. For example, the tubular sleeve 2216 protects the exterior surfaces of the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, during handling and insertion of the tubular members within the structure 2232. In this manner, damage to the exterior surfaces of the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, is avoided that could otherwise result in stress concentrations that could cause a catastrophic failure during subsequent radial expansion operations.
Furthermore, the tubular sleeve 2216 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 2228 to the first tubular member 2210. In this manner, misalignment that could result in damage to the threaded connections, 2212 and 2224, of the first and second tubular members, 2210 and 2228, may be avoided. In addition, during the relative rotation of the second tubular member with respect to the first tubular member, required during the threaded coupling of the first and second tubular members, the tubular sleeve 2216 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the tubular sleeve 2216 can be easily rotated, that would indicate that the first and second tubular members, 2210 and 2228, are not fully threadably coupled and in intimate contact with the internal flange 2218 of the tubular sleeve. Furthermore, the tubular sleeve 2216 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228. In this manner, failure modes such as, for example, longitudinal cracks in the end portions, 2214 and 2226, of the first and second tubular members may be limited in severity or eliminated all together. In addition, after completing the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228, the tubular sleeve 2216 may provide a fluid tight metal-to-metal seal between interior surface of the tubular sleeve 2216 and the exterior surfaces of the end portions, 2214 and 2226, of the first and second tubular members. In this manner, fluidic materials are prevented from passing through the threaded connections, 2212 and 2224, of the first and second tubular members, 2210 and 2228, into the annulus between the first and second tubular members and the structure 2232. Furthermore, because, following the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228, the tubular sleeve 2216 may be maintained in circumferential tension and the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.
[00227] In several exemplary embodiments, one or more portions of the first and second tubular members, 2210 and 2228, and the tubular sleeve 2216 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
[00228] Referring to Fig. 23, in an exemplary embodiment, a first tubular member 210 includes an internally threaded connection 2312 at an end portion 2314. A first end of a tubular sleeve 2316 includes an internal flange 2318 and a tapered portion 2320. A second end of the sleeve 2316 includes an internal flange 2321 and a tapered portion 2322. An externally threaded connection 2324 of an end portion 2326 of a second tubular member 2328 having an annular recess 2330, is then positioned within the tubular sleeve 2316 and threadably coupled to the internally threaded connection 2312 of the end portion 2314 of the first tubular member 2310. The internal flange 2318 of the sleeve 2316 mates with and is received within the annular recess 2330. [00229] The first tubular member 2310 includes a recess 2331. The internal flange
2321 mates with and is received within the annular recess 2331. Thus, the sleeve 2316 is coupled to and surrounds the external surfaces of the first and second tubular members
2310 and 2328.
[00230] The internally threaded connection 2312 of the end portion 2314 of the first tubular member 2310 is a box connection, and the externally threaded connection 2324 of the end portion 2326 of the second tubular member 2328 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2316 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2310 and 2328. In this manner, during the threaded coupling of the first and second tubular members 2310 and 2328, fluidic materials within the first and second tubular members may be vented from the tubular members.
[00231] As illustrated in Fig. 23, the first and second tubular members 2310 and 2328, and the tubular sleeve 2316 may then be positioned within another structure 2332 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2334 through and/or within the interiors of the first and second tubular members. The tapered portions 2320 and 2322, of the tubular sleeve 2316 facilitates the insertion and movement of the first and second tubular members within and through the structure 2332, and the displacement of the expansion device 2334 through the interiors of the first and second tubular members 2310 and 2328, may be from top to bottom or from bottom to top.
[00232] During the radial expansion and plastic deformation of the first and second tubular members 2310 and 2328, the tubular sleeve 2316 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2316 may be maintained in circumferential tension and the end portions 2314 and 2326, of the first and second tubular members 2310 and 2328, may be maintained in circumferential compression.
[00233] Sleeve 2316 increases the axial tension loading of the connection between tubular members 2310 and 2328 before and after expansion by the expansion device 2334.
Sleeve 2316 may be secured to tubular members 2310 and 2328 by a heat shrink fit.
[00234] In several exemplary embodiments, one or more portions of the first and second tubular members, 2310 and 2328, and the tubular sleeve 2316 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204.
[00235] Referring to Fig. 24, in an exemplary embodiment, a first tubular member
2410 includes an internally threaded connection 2412 at an end portion 2414. A first end of a tubular sleeve 2416 includes an internal flange 2418 and a tapered portion 2420. A second end of the sleeve 2416 includes an internal flange 2421 and a tapered portion 2422. An externally threaded connection 2424 of an end portion 2426 of a second tubular member
2428 having an annular recess 2430, is then positioned within the tubular sleeve 2416 and threadably coupled to the internally threaded connection 2412 of the end portion 2414 of the first tubular member 2410. The internal flange 2418 of the sleeve 2416 mates with and is received within the annular recess 2430. The first tubular member 2410 includes a recess
2431. The internal flange 2421 mates with and is received within the annular recess 2431.
Thus, the sleeve 2416 is coupled to and surrounds the external surfaces of the first and second tubular members 2410 and 2428.
[00236] The internally threaded connection 2412 of the end portion 2414 of the first tubular member 2410 is a box connection, and the externally threaded connection 2424 of the end portion 2426 of the second tubular member 2428 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2416 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2410 and 2428. In this manner, during the threaded coupling of the first and second tubular members 2410 and 2428, fluidic materials within the first and second tubular members may be vented from the tubular members.
[00237] As illustrated in Fig. 24, the first and second tubular members 2410 and 2428, and the tubular sleeve 2416 may then be positioned within another structure 2432 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2434 through and/or within the interiors of the first and second tubular members. The tapered portions 2420 and 2422, of the tubular sleeve 2416 facilitate the insertion and movement of the first and second tubular members within and through the structure 2432, and the displacement of the expansion device 2434 through the interiors of the first and second tubular members, 2410 and 2428, may be from top to bottom or from bottom to top.
[00238] During the radial expansion and plastic deformation of the first and second tubular members, 2410 and 2428, the tubular sleeve 2416 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2416 may be maintained in circumferential tension and the end portions, 2414 and 2426, of the first and second tubular members, 2410 and 2428, may be maintained in circumferential compression.
[00239] The sleeve 2416 increases the axial compression and tension loading of the connection between tubular members 2410 and 2428 before and after expansion by expansion device 2424. Sleeve 2416 may be secured to tubular members 2410 and 2428 by a heat shrink fit.
[00240] In several exemplary embodiments, one or more portions of the first and second tubular members, 2410 and 2428, and the tubular sleeve 2416 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204.
[00241] Referring to Fig. 25, in an exemplary embodiment, a first tubular member
2510 includes an internally threaded connection 2512 at an end portion 2514. A first end of a tubular sleeve 2516 includes an internal flange 2518 and a relief 2520. A second end of the sleeve 2516 includes an internal flange 2521 and a relief 2522. An externally threaded connection 2524 of an end portion 2526 of a second tubular member 2528 having an annular recess 2530, is then positioned within the tubular sleeve 2516 and threadably coupled to the internally threaded connection 2512 of the end portion 2514 of the first tubular member 2510. The internal flange 2518 of the sleeve 2516 mates with and is received within the annular recess 2530. The first tubular member 2510 includes a recess 2531. The internal flange 2521 mates with and is received within the annular recess 2531. Thus, the sleeve 2516 is coupled to and surrounds the external surfaces of the first and second tubular members 2510 and 2528.
[00242] The internally threaded connection 2512 of the end portion 2514 of the first tubular member 2510 is a box connection, and the externally threaded connection 2524 of the end portion 2526 of the second tubular member 2528 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2516 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2510 and 2528. In this manner, during the threaded coupling of the first and second tubular members 2510 and 2528, fluidic materials within the first and second tubular members may be vented from the tubular members.
[00243] As illustrated in Fig. 25, the first and second tubular members 2510 and 2528, and the tubular sleeve 2516 may then be positioned within another structure 2532 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2534 through and/or within the interiors of the first and second tubular members. The reliefs 2520 and 2522 are each filled with a sacrificial material 2540 including a tapered surface 2542 and 2544, respectively. The material 2540 may be a metal or a synthetic, and is provided to facilitate the insertion and movement of the first and second tubular members 2510 and 2528, through the structure
2532. The displacement of the expansion device 2534 through the interiors of the first and second tubular members 2510 and 2528, may, for example, be from top to bottom or from bottom to top.
[00244] During the radial expansion and plastic deformation of the first and second tubular members 2510 and 2528, the tubular sleeve 2516 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2516 may be maintained in circumferential tension and the end portions 2514 and 2526, of the first and second tubular members, 2510 and 2528, may be maintained in circumferential compression.
[00245] The addition of the sacrificial material 2540, provided on sleeve 2516, avoids stress risers on the sleeve 2516 and the tubular member 2510. The tapered surfaces 2542 and 2544 are intended to wear or even become damaged, thus incurring such wear or damage which would otherwise be borne by sleeve 2516. Sleeve 2516 may be secured to tubular members 2510 and 2528 by a heat shrink fit.
[00246] In several exemplary embodiments, one or more portions of the first and second tubular members, 2510 and 2528, and the tubular sleeve 2516 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204.
[00247] Referring to Fig. 26, in an exemplary embodiment, a first tubular member
2610 includes an internally threaded connection 2612 at an end portion 2614. A first end of a tubular sleeve 2616 includes an internal flange 2618 and a tapered portion 2620. A second end of the sleeve 2616 includes an internal flange 2621 and a tapered portion 2622.
An externally threaded connection 2624 of an end portion 2626 of a second tubular member
2628 having an annular recess 2630, is then positioned within the tubular sleeve 2616 and threadably coupled to the internally threaded connection 2612 of the end portion 2614 of the first tubular member 2610. The internal flange 2618 of the sleeve 2616 mates with and is received within the annular recess 2630.
[00248] The first tubular member 2610 includes a recess 2631. The internal flange
2621 mates with and is received within the annular recess 2631. Thus, the sleeve 2616 is coupled to and surrounds the external surfaces of the first and second tubular members
2610 and 2628.
[00249] The internally threaded connection 2612 of the end portion 2614 of the first tubular member 2610 is a box connection, and the externally threaded connection 2624 of the end portion 2626 of the second tubular member 2628 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2616 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2610 and 2628. In this manner, during the threaded coupling of the first and second tubular members 2610 and 2628, fluidic materials within the first and second tubular members may be vented from the tubular members.
[00250] As illustrated in Fig. 26, the first and second tubular members 2610 and 2628, and the tubular sleeve 2616 may then be positioned within another structure 2632 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2634 through and/or within the interiors of the first and second tubular members. The tapered portions 2620 and 2622, of the tubular sleeve 2616 facilitates the insertion and movement of the first and second tubular members within and through the structure 2632, and the displacement of the expansion device 2634 through the interiors of the first and second tubular members 2610 and 2628, may, for example, be from top to bottom or from bottom to top.
[00251] During the radial expansion and plastic deformation of the first and second tubular members 2610 and 2628, the tubular sleeve 2616 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2616 may be maintained in circumferential tension and the end portions 2614 and 2626, of the first and second tubular members 2610 and 2628, may be maintained in circumferential compression. [00252] Sleeve 2616 is covered by a thin walled cylinder of sacrificial material 2640.
Spaces 2623 and 2624, adjacent tapered portions 2620 and 2622, respectively, are also filled with an excess of the sacrificial material 2640. The material may be a metal or a synthetic, and is provided to facilitate the insertion and movement of the first and second tubular members 2610 and 2628, through the structure 2632.
[00253] The addition of the sacrificial material 2640, provided on sleeve 2616, avoids stress risers on the sleeve 2616 and the tubular member 2610. The excess of the sacrificial material 2640 adjacent tapered portions 2620 and 2622 are intended to wear or even become damaged, thus incurring such wear or damage which would otherwise be borne by sleeve 2616. Sleeve 2616 may be secured to tubular members 2610 and 2628 by a heat shrink fit.
[00254] In several exemplary embodiments, one or more portions of the first and second tubular members, 2610 and 2628, and the tubular sleeve 2616 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
[00255] Referring to Fig. 27, in an exemplary embodiment, a first tubular member
2710 includes an internally threaded connection 2712 at an end portion 2714. A first end of a tubular sleeve 2716 includes an internal flange 2718 and a tapered portion 2720. A second end of the sleeve 2716 includes an internal flange 2721 and a tapered portion 2722. An externally threaded connection 2724 of an end portion 2726 of a second tubular member 2728 having an annular recess 2730, is then positioned within the tubular sleeve 2716 and threadably coupled to the internally threaded connection 2712 of the end portion 2714 of the first tubular member 2710. The internal flange 2718 of the sleeve 2716 mates with and is received within the annular recess 2730.
[00256] The first tubular member 2710 includes a recess 2731. The internal flange
2721 mates with and is received within the annular recess 2731. Thus, the sleeve 2716 is coupled to and surrounds the external surfaces of the first and second tubular members
2710 and 2728. [00257] The internally threaded connection 2712 of the end portion 2714 of the first tubular member 2710 is a box connection, and the externally threaded connection 2724 of the end portion 2726 of the second tubular member 2728 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2716 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2710 and 2728. In this manner, during the threaded coupling of the first and second tubular members 2710 and 2728, fluidic materials within the first and second tubular members may be vented from the tubular members.
[00258] As illustrated in Fig. 27, the first and second tubular members 2710 and 2728, and the tubular sleeve 2716 may then be positioned within another structure 2732 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2734 through and/or within the interiors of the first and second tubular members. The tapered portions 2720 and 2722, of the tubular sleeve 2716 facilitates the insertion and movement of the first and second tubular members within and through the structure 2732, and the displacement of the expansion device 2734 through the interiors of the first and second tubular members 2710 and 2728, may be from top to bottom or from bottom to top.
[00259] During the radial expansion and plastic deformation of the first and second tubular members 2710 and 2728, the tubular sleeve 2716 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2716 may be maintained in circumferential tension and the end portions 2714 and 2726, of the first and second tubular members 2710 and 2728, may be maintained in circumferential compression. [00260] Sleeve 2716 has a variable thickness due to one or more reduced thickness portions 2790 and/or increased thickness portions 2792.
[00261] Varying the thickness of sleeve 2716 provides the ability to control or induce stresses at selected positions along the length of sleeve 2716 and the end portions 2724 and 2726. Sleeve 2716 may be secured to tubular members 2710 and 2728 by a heat shrink fit.
[00262] In several exemplary embodiments, one or more portions of the first and second tubular members, 2710 and 2728, and the tubular sleeve 2716 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
[00263] Referring to Fig. 28, in an alternative embodiment, instead of varying the thickness of sleeve 2716, the same result described above with reference to Fig. 27, may be achieved by adding a member 2740 which may be coiled onto the grooves 2739 formed in sleeve 2716, thus varying the thickness along the length of sleeve 2716. [00264] Referring to Fig. 29, in an exemplary embodiment, a first tubular member
2910 includes an internally threaded connection 2912 and an internal annular recess 2914 at an end portion 2916. A first end of a tubular sleeve 2918 includes an internal flange 2920, and a second end of the sleeve 2916 mates with and receives the end portion 2916 of the first tubular member 2910. An externally threaded connection 2922 of an end portion 2924 of a second tubular member 2926 having an annular recess 2928, is then positioned within the tubular sleeve 2918 and threadably coupled to the internally threaded connection 2912 of the end portion 2916 of the first tubular member 2910. The internal flange 2920 of the sleeve 2918 mates with and is received within the annular recess 2928. A sealing element 2930 is received within the internal annular recess 2914 of the end portion 2916 of the first tubular member 2910.
[00265] The internally threaded connection 2912 of the end portion 2916 of the first tubular member 2910 is a box connection, and the externally threaded connection 2922 of the end portion 2924 of the second tubular member 2926 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2918 is at least approximately .020" greater than the outside diameters of the first tubular member 2910. In this manner, during the threaded coupling of the first and second tubular members 2910 and 2926, fluidic materials within the first and second tubular members may be vented from the tubular members.
[00266] The first and second tubular members 2910 and 2926, and the tubular sleeve
2918 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members. [00267] During the radial expansion and plastic deformation of the first and second tubular members 2910 and 2926, the tubular sleeve 2918 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 2918 may be maintained in circumferential tension and the end portions 2916 and 2924, of the first and second tubular members 2910 and 2926, respectively, may be maintained in circumferential compression.
[00268] In an exemplary embodiment, before, during, and after the radial expansion and plastic deformation of the first and second tubular members 2910 and 2926, and the tubular sleeve 2918, the sealing element 2930 seals the interface between the first and second tubular members. In an exemplary embodiment, during and after the radial expansion and plastic deformation of the first and second tubular members 2910 and 2926, and the tubular sleeve 2918, a metal to metal seal is formed between at least one of: the first and second tubular members 2910 and 2926, the first tubular member and the tubular sleeve 2918, and/or the second tubular member and the tubular sleeve. In an exemplary embodiment, the metal to metal seal is both fluid tight and gas tight.
[00269] In several exemplary embodiments, one or more portions of the first and second tubular members, 2910 and 2926, the tubular sleeve 2918, and the sealing element
2930 have one or more of the material properties of one or more of the tubular members 12,
14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
[00270] Referring to Fig. 30a, in an exemplary embodiment, a first tubular member
3010 includes internally threaded connections 3012a and 3012b, spaced apart by a cylindrical internal surface 3014, at an end portion 3016. Externally threaded connections
3018a and 3018b, spaced apart by a cylindrical external surface 3020, of an end portion
3022 of a second tubular member 3024 are threadably coupled to the internally threaded connections, 3012a and 3012b, respectively, of the end portion 3016 of the first tubular member 3010. A sealing element 3026 is received within an annulus defined between the internal cylindrical surface 3014 of the first tubular member 3010 and the external cylindrical surface 3020 of the second tubular member 3024.
[00271] The internally threaded connections, 3012a and 3012b, of the end portion
3016 of the first tubular member 3010 are box connections, and the externally threaded connections, 3018a and 3018b, of the end portion 3022 of the second tubular member 3024 are pin connections. In an exemplary embodiment, the sealing element 3026 is an elastomeric and/or metallic sealing element.
[00272] The first and second tubular members 3010 and 3024 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
[00273] In an exemplary embodiment, before, during, and after the radial expansion and plastic deformation of the first and second tubular members 3010 and 3024, the sealing element 3026 seals the interface between the first and second tubular members. In an exemplary embodiment, before, during and/or after the radial expansion and plastic deformation of the first and second tubular members 3010 and 3024, a metal to metal seal is formed between at least one of: the first and second tubular members 3010 and 3024, the first tubular member and the sealing element 3026, and/or the second tubular member and the sealing element. In an exemplary embodiment, the metal to metal seal is both fluid tight and gas tight.
[00274] In an alternative embodiment, the sealing element 3026 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 3010 and 3024, a metal to metal seal is formed between the first and second tubular members. [00275] In several exemplary embodiments, one or more portions of the first and second tubular members, 3010 and 3024, the sealing element 3026 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
[00276] Referring to Fig. 30b, in an exemplary embodiment, a first tubular member
3030 includes internally threaded connections 3032a and 3032b, spaced apart by an undulating approximately cylindrical internal surface 3034, at an end portion 3036. Externally threaded connections 3038a and 3038b, spaced apart by a cylindrical external surface 3040, of an end portion 3042 of a second tubular member 3044 are threadably coupled to the internally threaded connections, 3032a and 3032b, respectively, of the end portion 3036 of the first tubular member 3030. A sealing element 3046 is received within an annulus defined between the undulating approximately cylindrical internal surface 3034 of the first tubular member 3030 and the external cylindrical surface 3040 of the second tubular member 3044.
[00277] The internally threaded connections, 3032a and 3032b, of the end portion
3036 of the first tubular member 3030 are box connections, and the externally threaded connections, 3038a and 3038b, of the end portion 3042 of the second tubular member 3044 are pin connections. In an exemplary embodiment, the sealing element 3046 is an elastomeric and/or metallic sealing element.
[00278] The first and second tubular members 3030 and 3044 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members. [00279] In an exemplary embodiment, before, during, and after the radial expansion and plastic deformation of the first and second tubular members 3030 and 3044, the sealing element 3046 seals the interface between the first and second tubular members. In an exemplary embodiment, before, during and/or after the radial expansion and plastic deformation of the first and second tubular members 3030 and 3044, a metal to metal seal is formed between at least one of: the first and second tubular members 3030 and 3044, the first tubular member and the sealing element 3046, and/or the second tubular member and the sealing element. In an exemplary embodiment, the metal to metal seal is both fluid tight and gas tight.
[00280] In an alternative embodiment, the sealing element 3046 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 3030 and 3044, a metal to metal seal is formed between the first and second tubular members. [00281] In several exemplary embodiments, one or more portions of the first and second tubular members, 3030 and 3044, the sealing element 3046 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
[00282] Referring to Fig. 30c, in an exemplary embodiment, a first tubular member
3050 includes internally threaded connections 3052a and 3052b, spaced apart by a cylindrical internal surface 3054 including one or more square grooves 3056, at an end portion 3058. Externally threaded connections 3060a and 3060b, spaced apart by a cylindrical external surface 3062 including one or more square grooves 3064, of an end portion 3066 of a second tubular member 3068 are threadably coupled to the internally threaded connections, 3052a and 3052b, respectively, of the end portion 3058 of the first tubular member 3050. A sealing element 3070 is received within an annulus defined between the cylindrical internal surface 3054 of the first tubular member 3050 and the external cylindrical surface 3062 of the second tubular member 3068. [00283] The internally threaded connections, 3052a and 3052b, of the end portion
3058 of the first tubular member 3050 are box connections, and the externally threaded connections, 3060a and 3060b, of the end portion 3066 of the second tubular member 3068 are pin connections. In an exemplary embodiment, the sealing element 3070 is an elastomeric and/or metallic sealing element.
[00284] The first and second tubular members 3050 and 3068 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members. [00285] In an exemplary embodiment, before, during, and after the radial expansion and plastic deformation of the first and second tubular members 3050 and 3068, the sealing element 3070 seals the interface between the first and second tubular members. In an exemplary embodiment, before, during and/or after the radial expansion and plastic deformation of the first and second tubular members, 3050 and 3068, a metal to metal seal is formed between at least one of: the first and second tubular members, the first tubular member and the sealing element 3070, and/or the second tubular member and the sealing element. In an exemplary embodiment, the metal to metal seal is both fluid tight and gas tight.
[00286] In an alternative embodiment, the sealing element 3070 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 950 and 968, a metal to metal seal is formed between the first and second tubular members. [00287] In several exemplary embodiments, one or more portions of the first and second tubular members, 3050 and 3068, the sealing element 3070 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
[00288] Referring to Fig. 31 , in an exemplary embodiment, a first tubular member
3110 includes internally threaded connections, 3112a and 3112b, spaced apart by a non- threaded internal surface 3114, at an end portion 3116. Externally threaded connections, 3118a and 3118b, spaced apart by a non-threaded external surface 3120, of an end portion 3122 of a second tubular member 3124 are threadably coupled to the internally threaded connections, 3112a and 3112b, respectively, of the end portion 3122 of the first tubular member 3124.
[00289] First, second, and/or third tubular sleeves, 3126, 3128, and 3130, are coupled the external surface of the first tubular member 3110 in opposing relation to the threaded connection formed by the internal and external threads, 3112a and 3118a, the interface between the non-threaded surfaces, 3114 and 3120, and the threaded connection formed by the internal and external threads, 3112b and 3118b, respectively. [00290] The internally threaded connections, 3112a and 3112b, of the end portion
3116 of the first tubular member 3110 are box connections, and the externally threaded connections, 3118a and 3118b, of the end portion 3122 of the second tubular member 3124 are pin connections.
[00291] The first and second tubular members 3110 and 3124, and the tubular sleeves 3126, 3128, and/or 3130, may then be positioned within another structure 3132 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 3134 through and/or within the interiors of the first and second tubular members.
[00292] During the radial expansion and plastic deformation of the first and second tubular members 3110 and 3124, the tubular sleeves 3126, 3128 and/or 3130 are also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeves 3126, 3128, and/or 3130 are maintained in circumferential tension and the end portions 3116 and 3122, of the first and second tubular members 3110 and 3124, may be maintained in circumferential compression.
[00293] The sleeves 3126, 3128, and/or 3130 may, for example, be secured to the first tubular member 3110 by a heat shrink fit.
[00294] In several exemplary embodiments, one or more portions of the first and second tubular members, 3110 and 3124, and the sleeves, 3126, 3128, and 3130, have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102,
104, 106, 108, 202 and/or 204. [00295] Referring to Fig. 32a, in an exemplary embodiment, a first tubular member
3210 includes an internally threaded connection 3212 at an end portion 3214. An externally threaded connection 3216 of an end portion 3218 of a second tubular member 3220 are threadably coupled to the internally threaded connection 3212 of the end portion 3214 of the first tubular member 3210.
[00296] The internally threaded connection 3212 of the end portion 3214 of the first tubular member 3210 is a box connection, and the externally threaded connection 3216 of the end portion 3218 of the second tubular member 3220 is a pin connection.
[00297] A tubular sleeve 3222 including internal flanges 3224 and 3226 is positioned proximate and surrounding the end portion 3214 of the first tubular member 3210. As illustrated in Fig. 32b, the tubular sleeve 3222 is then forced into engagement with the external surface of the end portion 3214 of the first tubular member 3210 in a conventional manner. As a result, the end portions, 3214 and 3218, of the first and second tubular members, 3210 and 3220, are upset in an undulating fashion.
[00298] The first and second tubular members 3210 and 3220, and the tubular sleeve
3222, may then be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
[00299] During the radial expansion and plastic deformation of the first and second tubular members 3210 and 3220, the tubular sleeve 3222 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, the tubular sleeve 3222 is maintained in circumferential tension and the end portions 3214 and 3218, of the first and second tubular members 3210 and 3220, may be maintained in circumferential compression.
[00300] In several exemplary embodiments, one or more portions of the first and second tubular members, 3210 and 3220, and the sleeve 3222 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204.
[00301] Referring to Fig. 33, in an exemplary embodiment, a first tubular member
3310 includes an internally threaded connection 3312 and an annular projection 3314 at an end portion 3316.
[00302] A first end of a tubular sleeve 3318 that includes an internal flange 3320 having a tapered portion 3322 and an annular recess 3324 for receiving the annular projection 3314 of the first tubular member 3310, and a second end that includes a tapered portion 3326, is then mounted upon and receives the end portion 3316 of the first tubular member 3310.
[00303] In an exemplary embodiment, the end portion 3316 of the first tubular member 3310 abuts one side of the internal flange 3320 of the tubular sleeve 3318 and the annular projection 3314 of the end portion of the first tubular member mates with and is received within the annular recess 3324 of the internal flange of the tubular sleeve, and the internal diameter of the internal flange 3320 of the tubular sleeve 3318 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310. An externally threaded connection
3326 of an end portion 3328 of a second tubular member 3330 having an annular recess
3332 is then positioned within the tubular sleeve 3318 and threadably coupled to the internally threaded connection 3312 of the end portion 3316 of the first tubular member
3310. In an exemplary embodiment, the internal flange 3332 of the tubular sleeve 3318 mates with and is received within the annular recess 3332 of the end portion 3328 of the second tubular member 3330. Thus, the tubular sleeve 3318 is coupled to and surrounds the external surfaces of the first and second tubular members, 3310 and 3328.
[00304] The internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310 is a box connection, and the externally threaded connection 3326 of the end portion 3328 of the second tubular member 3330 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 3318 is at least approximately .020" greater than the outside diameters of the first and second tubular members, 3310 and 3330. In this manner, during the threaded coupling of the first and second tubular members, 3310 and 3330, fluidic materials within the first and second tubular members may be vented from the tubular members.
[00305] As illustrated in Fig. 33, the first and second tubular members, 3310 and
3330, and the tubular sleeve 3318 may be positioned within another structure 3334 such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device 3336 within and/or through the interiors of the first and second tubular members. The tapered portions,
3322 and 3326, of the tubular sleeve 3318 facilitate the insertion and movement of the first and second tubular members within and through the structure 3334, and the movement of the expansion device 3336 through the interiors of the first and second tubular members,
3310 and 3330, may, for example, be from top to bottom or from bottom to top.
[00306] During the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330, the tubular sleeve 3318 is also radially expanded and plastically deformed. As a result, the tubular sleeve 3318 may be maintained in circumferential tension and the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, may be maintained in circumferential compression.
[00307] Sleeve 3316 increases the axial compression loading of the connection between tubular members 3310 and 3330 before and after expansion by the expansion device 3336. Sleeve 3316 may be secured to tubular members 3310 and 3330, for example, by a heat shrink fit.
[00308] In several alternative embodiments, the first and second tubular members,
3310 and 3330, are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global
Technology L.L.C.
[00309] The use of the tubular sleeve 3318 during (a) the coupling of the first tubular member 3310 to the second tubular member 3330, (b) the placement of the first and second tubular members in the structure 3334, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits. For example, the tubular sleeve 3318 protects the exterior surfaces of the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, during handling and insertion of the tubular members within the structure 3334. In this manner, damage to the exterior surfaces of the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, is avoided that could otherwise result in stress concentrations that could cause a catastrophic failure during subsequent radial expansion operations.
Furthermore, the tubular sleeve 3318 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 3330 to the first tubular member 3310. In this manner, misalignment that could result in damage to the threaded connections, 3312 and 3326, of the first and second tubular members, 3310 and 3330, may be avoided. In addition, during the relative rotation of the second tubular member with respect to the first tubular member, required during the threaded coupling of the first and second tubular members, the tubular sleeve 3318 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the tubular sleeve 3318 can be easily rotated, that would indicate that the first and second tubular members, 3310 and 3330, are not fully threadably coupled and in intimate contact with the internal flange 3320 of the tubular sleeve. Furthermore, the tubular sleeve 3318 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330. In this manner, failure modes such as, for example, longitudinal cracks in the end portions, 3316 and 3328, of the first and second tubular members may be limited in severity or eliminated all together. In addition, after completing the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330, the tubular sleeve 3318 may provide a fluid tight metal-to-metal seal between interior surface of the tubular sleeve 3318 and the exterior surfaces of the end portions, 3316 and 3328, of the first and second tubular members. In this manner, fluidic materials are prevented from passing through the threaded connections, 3312 and 3326, of the first and second tubular members, 3310 and 3330, into the annulus between the first and second tubular members and the structure 3334. Furthermore, because, following the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330, the tubular sleeve 3318 may be maintained in circumferential tension and the end portions,
3316 and 3328, of the first and second tubular members, 3310 and 3330, may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.
[00310] In several exemplary embodiments, one or more portions of the first and second tubular members, 3310 and 3330, and the sleeve 3318 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204.
[00311] Referring to Figs. 34a, 34b, and 34c, in an exemplary embodiment, a first tubular member 3410 includes an internally threaded connection 1312 and one or more external grooves 3414 at an end portion 3416.
[00312] A first end of a tubular sleeve 3418 that includes an internal flange 3420 and a tapered portion 3422, a second end that includes a tapered portion 3424, and an intermediate portion that includes one or more longitudinally aligned openings 3426, is then mounted upon and receives the end portion 3416 of the first tubular member 3410.
[00313] In an exemplary embodiment, the end portion 3416 of the first tubular member 3410 abuts one side of the internal flange 3420 of the tubular sleeve 3418, and the internal diameter of the internal flange 3420 of the tubular sleeve 3416 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 3412 of the end portion 3416 of the first tubular member 3410. An externally threaded connection
3428 of an end portion 3430 of a second tubular member 3432 that includes one or more internal grooves 3434 is then positioned within the tubular sleeve 3418 and threadably coupled to the internally threaded connection 3412 of the end portion 3416 of the first tubular member 3410. In an exemplary embodiment, the internal flange 3420 of the tubular sleeve
3418 mates with and is received within an annular recess 3436 defined in the end portion
3430 of the second tubular member 3432. Thus, the tubular sleeve 3418 is coupled to and surrounds the external surfaces of the first and second tubular members, 3410 and 3432.
[00314] The first and second tubular members, 3410 and 3432, and the tubular sleeve
3418 may be positioned within another structure such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device within and/or through the interiors of the first and second tubular members. The tapered portions, 3422 and 3424, of the tubular sleeve 3418 facilitate the insertion and movement of the first and second tubular members within and through the structure, and the movement of the expansion device through the interiors of the first and second tubular members, 3410 and 3432, may be from top to bottom or from bottom to top.
[00315] During the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, the tubular sleeve 3418 is also radially expanded and plastically deformed. As a result, the tubular sleeve 3418 may be maintained in circumferential tension and the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, may be maintained in circumferential compression.
[00316] Sleeve 3416 increases the axial compression loading of the connection between tubular members 3410 and 3432 before and after expansion by the expansion device. The sleeve 3418 may be secured to tubular members 3410 and 3432, for example, by a heat shrink fit.
[00317] During the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, the grooves 3414 and/or 3434 and/or the openings 3426 provide stress concentrations that in turn apply added stress forces to the mating threads of the threaded connections, 3412 and 3428. As a result, during and after the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, the mating threads of the threaded connections, 3412 and 3428, are maintained in metal to metal contact thereby providing a fluid and gas tight connection. In an exemplary embodiment, the orientations of the grooves 3414 and/or 3434 and the openings 3426 are orthogonal to one another. In an exemplary embodiment, the grooves 3414 and/or 3434 are helical grooves.
[00318] In several alternative embodiments, the first and second tubular members,
3410 and 3432, are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global
Technology L.L.C.
[00319] The use of the tubular sleeve 3418 during (a) the coupling of the first tubular member 3410 to the second tubular member 3432, (b) the placement of the first and second tubular members in the structure, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits. For example, the tubular sleeve 3418 protects the exterior surfaces of the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, during handling and insertion of the tubular members within the structure. In this manner, damage to the exterior surfaces of the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, is avoided that could otherwise result in stress concentrations that could cause a catastrophic failure during subsequent radial expansion operations. Furthermore, the tubular sleeve 3418 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 3432 to the first tubular member 3410. In this manner, misalignment that could result in damage to the threaded connections, 3412 and 3428, of the first and second tubular members, 3410 and 3432, may be avoided. In addition, during the relative rotation of the second tubular member with respect to the first tubular member, required during the threaded coupling of the first and second tubular members, the tubular sleeve 3416 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the tubular sleeve 3418 can be easily rotated, that would indicate that the first and second tubular members, 3410 and 3432, are not fully threadably coupled and in intimate contact with the internal flange 3420 of the tubular sleeve. Furthermore, the tubular sleeve 3418 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 3410 and
3432. In this manner, failure modes such as, for example, longitudinal cracks in the end portions, 3416 and 3430, of the first and second tubular members may be limited in severity or eliminated all together. In addition, after completing the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, the tubular sleeve
3418 may provide a fluid and gas tight metal-to-metal seal between interior surface of the tubular sleeve 3418 and the exterior surfaces of the end portions, 3416 and 3430, of the first and second tubular members. In this manner, fluidic materials are prevented from passing through the threaded connections, 3412 and 3430, of the first and second tubular members,
3410 and 3432, into the annulus between the first and second tubular members and the structure. Furthermore, because, following the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, the tubular sleeve 3418 may be maintained in circumferential tension and the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.
[00320] In several exemplary embodiments, the first and second tubular members described above with reference to Figs. 1 to 34c are radially expanded and plastically deformed using the expansion device in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following: The present application is related to the following: (1) U.S. patent application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, (2) U.S. patent application serial no.
09/510,913, attorney docket no. 25791.7.02, filed on 2/23/2000, (3) U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, (4) U.S. patent application serial no. 09/440,338, attorney docket no. 25791.9.02, filed on 11/15/1999, (5)
U.S. patent application serial no. 09/523,460, attorney docket no. 25791.11.02, filed on 3/10/2000, (6) U.S. patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, (7) U.S. patent application serial no. 09/511 ,941 , attorney docket no. 25791.16.02, filed on 2/24/2000, (8) U.S. patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, (9) U.S. patent application serial no.
09/559,122, attorney docket no. 25791.23.02, filed on 4/26/2000, (10) PCT patent application serial no. PCT/US00/18635, attorney docket no. 25791.25.02, filed on 7/9/2000,
(11 ) U.S. provisional patent application serial no. 60/162,671 , attorney docket no. 25791.27, filed on 11/1/1999, (12) U.S. provisional patent application serial no. 60/154,047, attorney docket no. 25791.29, filed on 9/16/1999, (13) U.S. provisional patent application serial no.
60/159,082, attorney docket no. 25791.34, filed on 10/12/1999, (14) U.S. provisional patent application serial no. 60/159,039, attorney docket no. 25791.36, filed on 10/12/1999, (15)
U.S. provisional patent application serial no. 60/159,033, attorney docket no. 25791.37, filed on 10/12/1999, (16) U.S. provisional patent application serial no. 60/212,359, attorney docket no. 25791.38, filed on 6/19/2000, (17) U.S. provisional patent application serial no.
60/165,228, attorney docket no. 25791.39, filed on 11/12/1999, (18) U.S. provisional patent application serial no. 60/221 ,443, attorney docket no. 25791.45, filed on 7/28/2000, (19) U.S. provisional patent application serial no. 60/221 ,645, attorney docket no. 25791.46, filed on
7/28/2000, (20) U.S. provisional patent application serial no. 60/233,638, attorney docket no.
25791.47, filed on 9/18/2000, (21) U.S. provisional patent application serial no. 60/237,334, attorney docket no. 25791.48, filed on 10/2/2000, (22) U.S. provisional patent application serial no. 60/270,007, attorney docket no. 25791.50, filed on 2/20/2001, (23) U.S. provisional patent application serial no. 60/262,434, attorney docket no. 25791.51 , filed on 1/17/2001 ,
(24) U.S, provisional patent application serial no. 60/259,486, attorney docket no. 25791.52, filed on 1/3/2001 , (25) U.S. provisional patent application serial no. 60/303,740, attorney docket no. 25791.61 , filed on 7/6/2001 , (26) U.S. provisional patent application serial no.
60/313,453, attorney docket no. 25791.59, filed on 8/20/2001 , (27) U.S. provisional patent application serial no. 60/317,985, attorney docket no. 25791.67, filed on 9/6/2001 , (28) U.S. provisional patent application serial no. 60/3318,386, attorney docket no. 25791.67.02, filed on 9/10/2001 , (29) U.S. utility patent application serial no. 09/969,922, attorney docket no.
25791.69, filed on 10/3/2001 , (30) U.S. utility patent application serial no. 10/016,467, attorney docket no. 25791.70, filed on December 10, 2001 , (31 ) U.S. provisional patent application serial no. 60/343,674, attorney docket no. 25791.68, filed on 12/27/2001; and
(32) U.S. provisional patent application serial no. 60/346,309, attorney docket no. 25791.92, filed on 01/07/02, the disclosures of which are incorporated herein by reference.
[00321] Referring to Fig. 35a an exemplary embodiment of an expandable tubular member 3500 includes a first tubular region 3502 and a second tubular portion 3504. In an exemplary embodiment, the material properties of the first and second tubular regions, 3502 and 3504, are different. In an exemplary embodiment, the yield points of the first and second tubular regions, 3502 and 3504, are different. In an exemplary embodiment, the yield point of the first tubular region 3502 is less than the yield point of the second tubular region 3504. In several exemplary embodiments, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 incorporate the tubular member 3500.
[00322] Referring to Fig. 35b, in an exemplary embodiment, the yield point within the first and second tubular regions, 3502a and 3502b, of the expandable tubular member 3502 vary as a function of the radial position within the expandable tubular member. In an exemplary embodiment, the yield point increases as a function of the radial position within the expandable tubular member 3502. In an exemplary embodiment, the relationship between the yield point and the radial position within the expandable tubular member 3502 is a linear relationship. In an exemplary embodiment, the relationship between the yield point and the radial position within the expandable tubular member 3502 is a non-linear relationship. In an exemplary embodiment, the yield point increases at different rates within the first and second tubular regions, 3502a and 3502b, as a function of the radial position within the expandable tubular member 3502. In an exemplary embodiment, the functional relationship, and value, of the yield points within the first and second tubular regions, 3502a and 3502b, of the expandable tubular member 3502 are modified by the radial expansion and plastic deformation of the expandable tubular member.
[00323] In several exemplary embodiments, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502, prior to a radial expansion and plastic deformation, include a microstructure that is a combination of a hard phase, such as martensite, a soft phase, such as ferrite, and a transitionary phase, such as retained austentite. In this manner, the hard phase provides high strength, the soft phase provides ductility, and the transitionary phase transitions to a hard phase, such as martensite, during a radial expansion and plastic deformation. Furthermore, in this manner, the yield point of the tubular member increases as a result of the radial expansion and plastic deformation. Further, in this manner, the tubular member is ductile, prior to the radial expansion and plastic deformation, thereby facilitating the radial expansion and plastic deformation. In an exemplary embodiment, the composition of a dual-phase expandable tubular member includes (weight percentages): about 0.1% C, 1.2% Mn, and 0.3% Si.
[00324] In an exemplary experimental embodiment, as illustrated in Figs. 36a-36c, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202,
204 and/or 3502 are processed in accordance with a method 3600, in which, in step 3602, an expandable tubular member 3602a is provided that is a steel alloy having following material composition (by weight percentage): 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01 %Mo, 0.01% Nb, and 0.01% Ti. In an exemplary experimental embodiment, the expandable tubular member 3602a provided in step 3602 has a yield strength of 45 ksi, and a tensile strength of 69 ksi.
[00325] In an exemplary experimental embodiment, as illustrated in Fig. 36b, in step
3602, the expandable tubular member 3602a includes a microstructure that includes martensite, peariite, and V, Ni, and/or Ti carbides.
[00326] In an exemplary embodiment, the expandable tubular member 3602a is then heated at a temperature of 790 °C for about 10 minutes in step 3604.
[00327] In an exemplary embodiment, the expandable tubular member 3602a is then quenched in water in step 3606.
[00328] In an exemplary experimental embodiment, as illustrated in Fig. 36c, following the completion of step 3606, the expandable tubular member 3602a includes a microstructure that includes new ferrite, grain peariite, martensite, and ferrite. In an exemplary experimental embodiment, following the completion of step 3606, the expandable tubular member 3602a has a yield strength of 67 ksi, and a tensile strength of 95 ksi.
[00329] In an exemplary embodiment, the expandable tubular member 3602a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above. In an exemplary embodiment, following the radial expansion and plastic deformation of the expandable tubular member 3602a, the yield strength of the expandable tubular member is about 95 ksi.
[00330] In an exemplary experimental embodiment, as illustrated in Figs. 37a-37c, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202,
204 and/or 3502 are processed in accordance with a method 3700, in which, in step 3702, an expandable tubular member 3702a is provided that is a steel alloy having following material composition (by weight percentage): 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,
0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01 %Mo, 0.03% Nb, and 0.01% Ti. In an exemplary experimental embodiment, the expandable tubular member 3702a provided in step 3702 has a yield strength of 60 ksi, and a tensile strength of 80 ksi.
[00331] In an exemplary experimental embodiment, as illustrated in Fig. 37b, in step
3702, the expandable tubular member 3702a includes a microstructure that includes peariite and peariite striation.
[00332] In an exemplary embodiment, the expandable tubular member 3702a is then heated at a temperature of 790 °C for about 10 minutes in step 3704.
[00333] In an exemplary embodiment, the expandable tubular member 3702a is then quenched in water in step 3706. [00334] In an exemplary experimental embodiment, as illustrated in Fig. 37c, following the completion of step 3706, the expandable tubular member 3702a includes a microstructure that includes ferrite, martensite, and bainite. In an exemplary experimental embodiment, following the completion of step 3706, the expandable tubular member 3702a has a yield strength of 82 ksi, and a tensile strength of 130 ksi.
[00335] In an exemplary embodiment, the expandable tubular member 3702a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above. In an exemplary embodiment, following the radial expansion and plastic deformation of the expandable tubular member 3702a, the yield strength of the expandable tubular member is about 130 ksi.
[00336] In an exemplary experimental embodiment, as illustrated in Figs. 38a-38c, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202,
204 and/or 3502 are processed in accordance with a method 3800, in which, in step 3802, an expandable tubular member 3802a is provided that is a steel alloy having following material composition (by weight percentage): 0.08% C, 0.82% Mn, 0.006% P, 0.003% S,
0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03%Mo, 0.01% Nb, and 0.01% Ti. In an exemplary experimental embodiment, the expandable tubular member 3802a provided in step 3802 has a yield strength of 56 ksi, and a tensile strength of 75 ksi.
[00337] In an exemplary experimental embodiment, as illustrated in Fig. 38b, in step
3802, the expandable tubular member 3802a includes a microstructure that includes grain peariite, widmanstatten martensite and carbides of V, Ni, and/or Ti.
[00338] In an exemplary embodiment, the expandable tubular member 3802a is then heated at a temperature of 790 °C for about 10 minutes in step 3804.
[00339] In an exemplary embodiment, the expandable tubular member 3802a is then quenched in water in step 3806.
[00340] In an exemplary experimental embodiment, as illustrated in Fig. 38c, following the completion of step 3806, the expandable tubular member 3802a includes a microstructure that includes bainite, peariite, and new ferrite. In an exemplary experimental embodiment, following the completion of step 3806, the expandable tubular member 3802a has a yield strength of 60 ksi, and a tensile strength of 97 ksi.
[00341] In an exemplary embodiment, the expandable tubular member 3802a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above. In an exemplary embodiment, following the radial expansion and plastic deformation of the expandable tubular member 3802a, the yield strength of the expandable tubular member is about 97 ksi.
[00342] In several exemplary embodiments, the teachings of the present disclosure are combined with one or more of the teachings disclosed in FR 2 841 626, filed on 6/28/2002, and published on 1/2/2004, the disclosure of which is incorporated herein by reference.
[00343] Referring to Figs. 39a-39f, an exemplary embodiment of an expansion system
3900 includes an adjustable expansion device 3902 and a hydroforming expansion device
3904 that are both coupled to a support member 3906.
[00344] In several exemplary embodiments, the adjustable expansion device 3902 includes one or more elements of conventional adjustable expansion devices and/or one or more elements of the adjustable expansion devices disclosed in one or more of the related applications referenced above and/or one or more elements of the conventional commercially available adjustable expansion devices available from Baker Hughes,
Weatherford International, Schlumberger, and/or Enventure Global Technology L.L.C. In several exemplary embodiments, the hydroforming expansion device 3904 includes one or more elements of conventional hydroforming expansion devices and/or one or more elements of the hydroforming expansion devices disclosed in one or more of the related applications referenced above and/or one or more elements of the conventional commercially available hydroforming devices available from Baker Hughes, Weatherford
International, Schlumberger, and/or Enventure Global Technology L.L.C. and/or one or more elements of the hydroforming expansion devices disclosed in U.S. Patent No. 5,901,594, the disclosure of which is incorporated herein by reference. In several exemplary embodiments, the adjustable expansion device 3902 and the hydroforming expansion device 3904 may be combined in a single device and/or include one or more elements of each other.
[00345] In an exemplary embodiment, during the operation of the expansion system
3900, as illustrated in Figs. 39a and 39b, the expansion system is positioned within an expandable tubular assembly that includes first and second tubular members, 3908 and
3910, that are coupled end to end and positioned and supported within a preexisting structure such as, for example, a wellbore 3912 that traverses a subterranean formation
3914. In several exemplary embodiments, the first and second tubular members, 3908 and
3910, include one or more of the characteristics of the expandable tubular members described in the present application.
[00346] In an exemplary embodiment, as illustrated in Fig. 39c, the hydroforming expansion device 3904 may then be operated to radially expand and plastically deform a portion of the second tubular member 3910.
[00347] In an exemplary embodiment, as illustrated in Fig. 39d, the hydroforming expansion device 3904 may then be disengaged from the second tubular member 3910.
[00348] In an exemplary embodiment, as illustrated in Fig. 39e, the adjustable expansion device 3902 may then be positioned within the radially expanded portion of the second tubular member 3910 and the size the adjustable expansion device increased. [00349] In an exemplary embodiment, as illustrated in Fig. 39f, the adjustable expansion device 3902 may then be operated to radially expand and plastically deform one or more portions of the first and second tubular members, 3908 and 3910.
[00350] Referring to Figs. 40a-40g, an exemplary embodiment of an expansion system 4000 includes a hydroforming expansion device 4002 that is coupled to a support member 4004.
[00351] In several exemplary embodiments, the hydroforming expansion device 4002 includes one or more elements of conventional hydroforming expansion devices and/or one or more elements of the hydroforming expansion devices disclosed in one or more of the related applications referenced above and/or one or more elements of the conventional commercially available hydroforming devices available from Baker Hughes, Weatherford
International, Schlumberger, and/or Enventure Global Technology L.L.C. and/or one or more elements of the hydroforming expansion devices disclosed in U.S. Patent No. 5,901 ,594, the disclosure of which is incorporated herein by reference.
[00352] In an exemplary embodiment, during the operation of the expansion system
4000, as illustrated in Figs. 40a and 40b, the expansion system is positioned within an expandable tubular assembly that includes first and second tubular members, 4006 and
4008, that are coupled end to end and positioned and supported within a preexisting structure such as, for example, a wellbore 4010 that traverses a subterranean formation
4012. In several exemplary embodiments, the first and second tubular members, 4004 and
4006, include one or more of the characteristics of the expandable tubular members described in the present application.
[00353] In an exemplary embodiment, as illustrated in Figs. 40c to 40f, the hydroforming expansion device 4002 may then be repeatedly operated to radially expand and plastically deform one or more portions of the first and second tubular members, 4008 and 4010.
[00354] Referring to Figs. 41a-41h, an exemplary embodiment of an expansion system 4100 includes an adjustable expansion device 4102 and a hydroforming expansion device 4104 that are both coupled to a tubular support member 4106.
[00355] In several exemplary embodiments, the adjustable expansion device 4102 includes one or more elements of conventional adjustable expansion devices and/or one or more elements of the adjustable expansion devices disclosed in one or more of the related applications referenced above and/or one or more elements of the conventional commercially available adjustable expansion devices available from Baker Hughes,
Weatherford International, Schlumberger, and/or Enventure Global Technology L.L.C. In several exemplary embodiments, the hydroforming expansion device 4104 includes one or more elements of conventional hydroforming expansion devices and/or one or more elements of the hydroforming expansion devices disclosed in one or more of the related applications referenced above and/or one or more elements of the conventional commercially available hydroforming devices available from Baker Hughes, Weatherford International, Schlumberger, and/or Enventure Global Technology L.L.C. and/or one or more elements of the hydroforming expansion devices disclosed in U.S. Patent No. 5,901 ,594, the disclosure of which is incorporated herein by reference. In several exemplary embodiments, the adjustable expansion device 4102 and the hydroforming expansion device 4104 may be combined in a single device and/or include one or more elements of each other. [00356] In an exemplary embodiment, during the operation of the expansion system
4100, as illustrated in Figs. 41a and 41b, the expansion system is positioned within an expandable tubular assembly that includes first and second tubular members, 4108 and 4110, that are coupled end to end and positioned and supported within a preexisting structure such as, for example, a wellbore 4112 that traverses a subterranean formation 4114. In an exemplary embodiment, a shoe 4116 having a valveable passage 4118 is coupled to the lower portion of the second tubular member 4110. In several exemplary embodiments, the first and second tubular members, 4108 and 4110, include one or more of the characteristics of the expandable tubular members described in the present application. [00357] In an exemplary embodiment, as illustrated in Fig. 41c, the hydroforming expansion device 4104 may then be operated to radially expand and plastically deform a portion of the second tubular member 4110.
[00358] In an exemplary embodiment, as illustrated in Fig. 41 d, the hydroforming expansion device 4104 may then be disengaged from the second tubular member 4110. [00359] In an exemplary embodiment, as illustrated in Figs. 41 e and 41f, the adjustable expansion device 4102 may then be positioned within the radially expanded portion of the second tubular member 4110 and the size the adjustable expansion device increased. The valveable passage 4118 of the shoe 4116 may then be closed, for example, by placing a ball 4120 within the passage in a conventional manner. [00360] In an exemplary embodiment, as illustrated in Fig. 41g, the adjustable expansion device 4102 may then be operated to radially expand and plastically deform one or more portions of the first and second tubular members, 4108 and 4110, above the shoe 4116.
[00361] In an exemplary embodiment, as illustrated in Fig. 41 h, the expansion system
4100 may then be removed from the tubular assembly and the lower, radially unexpanded, portion of the second tubular member 4110 and the shoe 4116 may be machined away. [00362] Referring to Figs. 42a-42e, an exemplary embodiment of an expansion system 4200 includes a hydroforming expansion device 4202 that is coupled to a tubular support member 4204. An expandable tubular member 4206 is coupled to and supported by the hydroforming expansion device 4202.
[00363] In several exemplary embodiments, the hydroforming expansion device 4202 includes one or more elements of conventional hydroforming expansion devices and/or one or more elements of the hydroforming expansion devices disclosed in one or more of the related applications referenced above and/or one or more elements of the conventional commercially available hydroforming devices available from Baker Hughes, Weatherford
International, Schlumberger, and/or Enventure Global Technology L.L.C. and/or one or more elements of the hydroforming expansion devices disclosed in U.S. Patent No. 5,901 ,594, the disclosure of which is incorporated herein by reference.
[00364] In several exemplary embodiments, the expandable tubular member 4206 includes one or more of the characteristics of the expandable tubular members described in the present application.
[00365] In an exemplary embodiment, during the operation of the expansion system
4200, as illustrated in Figs. 42a and 42b, the expansion system is positioned within an expandable tubular assembly that includes first and second tubular members, 4208 and
4210, that are coupled end to end and positioned and supported within a preexisting structure such as, for example, a wellbore 4212 that traverses a subterranean formation
4214. In an exemplary embodiment, the second tubular member 4210 includes one or more radial passages 4212. In an exemplary embodiment, the expandable tubular member 4206 is positioned in opposing relation to the radial passages 4212 of the second tubular member
4210.
[00366] In an exemplary embodiment, as illustrated in Fig. 42c, the hydroforming expansion device 4202 may then be operated to radially expand and plastically deform the expandable tubular member 4206 into contact with the interior surface of the second tubular member 4210 thereby covering and sealing off the radial passages 4212 of the second tubular member.
[00367] In an exemplary embodiment, as illustrated in Fig. 42d, the hydroforming expansion device 4202 may then be disengaged from the expandable tubular member 4206.
[00368] In an exemplary embodiment, as illustrated in Figs. 42e, the expansion system 4200 may then be removed from the wellbore 4212.
[00369] Referring to Fig. 43, an exemplary embodiment of a hydroforming expansion system 4300 includes an expansion element 4302 that is provided substantially as disclosed in U.S. Patent No. 5,901 ,594, the disclosure of which is incorporated herein by reference.
[00370] A flow line 4304 is coupled to the inlet of the expansion element 4302 and the outlet of conventional 2-way/2-position flow control valve 4306. A flow line 4308 is coupled to an inlet of the flow control valve 4306 and an outlet of a conventional accumulator 4310, and a flow line 4312 is coupled to another inlet of the flow control valve and a fluid reservoir
4314.
[00371] A flow line 4316 is coupled to the flow line 4308 and an the inlet of a conventional pressure relief valve 4318, and a flow line 4320 is coupled to the outlet of the pressure relief valve and the fluid reservoir 4314. A flow line 4322 is coupled to the inlet of the accumulator 4310 and the outlet of a conventional check valve 4324.
[00372] A flow line 4326 is coupled to the inlet of the check valve 4324 and the outlet of a conventional pump 4328. A flow line 4330 is coupled to the flow line 4326 and the inlet of a conventional pressure relief valve 4332.
[00373] A flow line 4334 is coupled to the outlet of the pressure relief valve 4332 and the fluid reservoir 4314, and a flow line 4336 is coupled to the inlet of the pump 4328 and the fluid reservoir.
[00374] A controller 4338 is operably coupled to the flow control valve 4306 and the pump 4328 for controlling the operation of the flow control valve and the pump. In an exemplary embodiment, the controller 4338 is a programmable general purpose controller.
Conventional pressure sensors, 4340, 4342 and 4344, are operably coupled to the expansion element 4302, the accumulator 4310, and the flow line 4326, respectively, and the controller 4338. A conventional user interface 4346 is operably coupled to the controller
4338.
[00375] During operation of the hydroforming expansion system 4300, as illustrated in
Figs. 44a-44b, the system implements a method of operation 4400 in which, in step 4402, the user may select expansion of an expandable tubular member. If the user selects expansion in step 4402, then the controller 4338 determines if the operating pressure of the accumulator 4310, as sensed by the pressure sensor 4342, is greater than or equal to a predetermined value in step 4404.
[00376] If the operating pressure of the accumulator 4310, as sensed by the pressure sensor 4342, is not greater than or equal to the predetermined value in step 4404, then the controller 4338 operates the pump 4328 to increase the operating pressure of the accumulator in step 4406. The controller 4338 then determines if the operating pressure of the accumulator 4310, as sensed by the pressure sensor 4342, is greater than or equal to a predetermined value in step 4408. If the operating pressure of the accumulator 4310, as sensed by the pressure sensor 4342, in step 4408, is not greater than or equal to the predetermined value, then the controller 4338 continues to operate the pump 4328 to increase the operating pressure of the accumulator in step 4406.
[00377] If the operating pressure of the accumulator 4310, as sensed by the pressure sensor 4342, in steps 4404 or 4408, is greater than or equal to the predetermined value, then the controller 4338 operates the flow control valve 4306 to pressurize the expansion element 4302 in step 4410 by positioning the flow control valve to couple the flow lines 4304 and 4308 to one another. If the expansion operation has been completed in step 4412, then the controller 4338 operates the flow control valve 4306 to de-pressurize the expansion element 4302 in step 4414 by positioning the flow control valve to couple the flow lines 4304 and 4312 to one another.
[00378] In several exemplary embodiments, one or more of the hydroforming expansion devices 4002, 4104, and 4202, incorporate one or more elements of the hydroforming expansion system 4300 and/or the operational steps of the method 4400.
[00379] Referring to Fig. 45a, an exemplary embodiment of a liner hanger system
4500 includes a tubular support member 4502 that defines a passage 4502a and includes an externally threaded connection 4502b at an end. An internally threaded connection
4504a of an end of an outer tubular mandrel 4504 that defines a passage 4504b, and includes an external flange 4504c, an internal annular recess 4504d, an external annular recess 4504e, an external annular recess 4504f, an external flange 4504g, an external annular recess 4504h, an internal flange 4504i, an external flange 4504j, and a plurality of circumferentially spaced apart longitudinally aligned teeth 4504k at another end, is coupled to and receives the externally threaded connection 4502b of the end of the tubular support member 4502.
[00380] An end of a tubular liner hanger 4506 that abuts and mates with an end face of the external flange 4504c of the outer tubular mandrel 4504 receives and mates with the outer tubular mandrel, and includes internal teeth 4506a, a plurality of circumferentially spaced apart longitudinally aligned internal teeth 4506b, an internal flange 4506c, and an external threaded connection 4506d at another end. In an exemplary embodiment, at least a portion of the tubular liner hanger 4506 includes one or more of the characteristics of the expandable tubular members described in the present application.
[00381] An internal threaded connection 4508a of an end of a tubular liner 4508 receives and is coupled to the external threaded connection 4506d of the tubular liner hanger 4506. Spaced apart elastomeric sealing elements, 4510, 4512, and 4514, are coupled to the exterior surface of the end of the tubular liner hanger 4506
[00382] An external flange 4516a of an end of an inner tubular mandrel 4516 that defines a longitudinal passage 4516b having a throat 4516ba and a radial passage 4516c and includes a sealing member 4516d mounted upon the external flange for sealingly engaging the inner annular recess 4504d of the outer tubular mandrel 4504, an external flange 4516e at another end that includes a plurality of circumferentially spaced apart teeth
4516f that mate with and engage the teeth, 4504k and 4506b, of the outer tubular mandrel
4504 and the tubular liner hanger 4506, respectively, for transmitting torsional loads therebetween, and another end that is received within and mates with the internal flange 4506c of the tubular liner hanger 4506 mates with and is received within the inner annular recess 4504d of the outer tubular mandrel 4504. A conventional rupture disc 4518 is received within and coupled to the radial passage 4516c of the inner tubular mandrel 4516. [00383] A conventional packer cup 4520 is mounted within and coupled to the external annular recess 4504e of the outer tubular mandrel 4504 for sealingly engaging the interior surface of the tubular liner hanger 4506. A locking assembly 4522 is mounted upon and coupled to the outer tubular mandrel 4504 proximate the external flange 4504g in opposing relation to the internal teeth 4506a of the tubular liner hanger 4506 for controliably engaging and locking the position of the tubular liner hanger relative to the outer tubular mandrel 4504. In several exemplary embodiments, the locking assembly 4522 may be a conventional locking device for locking the position of a tubular member relative to another member. In several alternative embodiments, the locking assembly 4522 may include one or more elements of the locking assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on 9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number 25791.260.02, filed on 3/26/2004, (11 ) PCT patent application serial number PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number 25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14) PCT patent application serial number PCT/US2004/01 1973, attorney docket number 25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00384] An adjustable expansion device assembly 4524 is mounted upon and coupled to the outer tubular mandrel 4504 between the locking assembly 4522 and the external flange 4504j for controliably radially expanding and plastically deforming the tubular liner hanger 4506. In several exemplary embodiments, the adjustable expansion device assembly 4524 may be a conventional adjustable expansion device assembly for radially expanding and plastically deforming tubular members that may include one or more elements of conventional adjustable expansion cones, mandrels, rotary expansion devices, hydroforming expansion devices and/or one or more elements of the one or more of the commercially available adjustable expansion devices of Enventure Global Technology LLC, Baker Hughes, Weatherford International, and/or Schlumberger and/or one or more elements of the adjustable expansion devices disclosed in one or more of the published patent applications and/or issued patents of Enventure Global Technology LLC, Baker Hughes, Weatherford International, Shell Oil Co. and/or Schlumberger. In several alternative embodiments, the adjustable expansion device assembly 4524 may include one or more elements of the adjustable expansion device assemblies disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on 9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number 25791.260.02, filed on 3/26/2004, (11 ) PCT patent application serial number PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number 25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14) PCT patent application serial number PCT/US2004/011973, attorney docket number 25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00385] A conventional SSR plug set 4526 is mounted within and coupled to the internal flange 4506c of the tubular liner hanger 4506.
[00386] In an exemplary embodiment, during operation of the system 4500, as illustrated in Fig. 45a, the system is positioned within a wellbore 4528 that traverses a subterranean formation 4530 and includes a preexisting wellbore casing 4532 coupled to and positioned within the wellbore. In an exemplary embodiment, the system 4500 is positioned such that the tubular liner hanger 4506 overlaps with the casing 4532. [00387] Referring to Fig. 45b, in an exemplary embodiment, a ball 4534 is then positioned in the throat passage 4516ba by injecting fluidic materials 4536 into the system 4500 through the passages 4502a, 4504b, and 4516b, of the tubular support member 4502, outer tubular mandrel 4504, and inner tubular mandrel 4516, respectively. [00388] Referring to Fig. 45c, in an exemplary embodiment, the continued injection of the fluidic materials 4536 into the system 4500, following the placement of the ball 4534 in the throat passage 4516ba, pressurizes the passage 4516b of the inner tubular mandrel 4516 such that the rupture disc 4518 is ruptured thereby permitting the fluidic materials to pass through the radial passage 4516c of the inner tubular mandrel. As a result, the interior of the tubular liner hanger 4506 is pressurized.
[00389] Referring to Fig. 45d, in an exemplary embodiment, the continued injection of the fluidic materials 4536 into the interior of the tubular liner hanger 4506 radially expands and plastically deforms at least a portion of the tubular liner hanger. In an exemplary embodiment, the continued injection of the fluidic materials 4536 into the interior of the tubular liner hanger 4506 radially expands and plastically deforms a portion of the tubular liner hanger positioned in opposition to the adjustable expansion device assembly 4524. In an exemplary embodiment, the continued injection of the fluidic materials 4536 into the interior of the tubular liner hanger 4506 radially expands and plastically deforms a portion of the tubular liner hanger positioned in opposition to the adjustable expansion device assembly 4524 into engagement with the wellbore casing 4532.
[00390] Referring to Fig. 45e, in an exemplary embodiment, the size of the adjustable expansion device assembly 4524 is then increased within the radially expanded portion of the tubular liner hanger 4506, and the locking assembly 4522 is operated to unlock the tubular liner hanger from engagement with the locking assembly. In an exemplary embodiment, the locking assembly 4522 and the adjustable expansion device assembly 4524 are operated using the operating pressure provided by the continued injection of the fluidic materials 4536 into the system 4500. In an exemplary embodiment, the adjustment of the adjustable expansion device assembly 4524 to a larger size radially expands and plastically deforms at least a portion of the tubular liner hanger 4506.
[00391] Referring to Fig. 45f, in an exemplary embodiment, the adjustable expansion device assembly 4524 is displaced in a longitudinal direction relative to the tubular liner hanger 4506 thereby radially expanding and plastically deforming the tubular liner hanger.
In an exemplary embodiment, the tubular liner hanger 4506 is radially expanded and plastically deformed into engagement with the casing 4532. In an exemplary embodiment, the adjustable expansion device assembly 4524 is displaced in a longitudinal direction relative to the tubular liner hanger 4506 due to the operating pressure within the tubular liner hanger generated by the continued injection of the fluidic materials 4536. In an exemplary embodiment, the adjustable expansion device assembly 4524 is displaced in a longitudinal direction relative to the tubular liner hanger 4506 due to the operating pressure within the tubular liner hanger below the packer cup 4520 generated by the continued injection of the fluidic materials 4536. In this manner, the adjustable expansion device assembly 4524 is pulled through the tubular liner hanger 4506 by the operation of the packer cup 4520. In an exemplary embodiment, the adjustable expansion device assembly 4524 is displaced in a longitudinal direction relative to the tubular liner hanger 4506 thereby radially expanding and plastically deforming the tubular liner hanger until the internal flange 4504i of the outer tubular mandrel 4504 engages the external flange 4516a of the end of the inner tubular mandrel 4516.
[00392] Referring to Fig. 45g, in an exemplary embodiment, the 4504, due to the engagement of the internal flange 4504i of the outer tubular mandrel 4504 with the external flange 4516a of the end of the inner tubular mandrel 4516, the inner tubular mandrel and the
SSR plug set 4526 may be removed from the wellbore 4528. As a result, the tubular liner
4508 is suspended within the wellbore 4528 by virtue of the engagement of the tubular liner hanger 4506 with the wellbore casing 4532.
[00393] In several alternative embodiments, during the operation of the system 4500, a hardenable fluidic sealing material such as, for example, cement, may injected through the system 4500 before, during or after the radial expansion of the liner hanger 4506 in order to form an annular barrier between the wellbore 4528 and the tubular liner 4508.
[00394] In several alternative embodiments, during the operation of the system 4500, the size of the adjustable expansion device 4524 is increased prior to, during, or after the hydroforming expansion of the tubular liner hanger 4506 caused by the injection of the fluidic materials 4536 into the interior of the tubular liner hanger.
[00395] In several alternative embodiments, at least a portion of the tubular liner hanger 4506 includes a plurality of nested expandable tubular members bonded together by, for example, amorphous bonding. [00396] In several alternative embodiments, at least a portion of the tubular liner hanger 4506 is fabricated for materials particularly suited for subsequent drilling out operations such as, for example, aluminum and/or copper based materials and alloys.
[00397] In several alternative embodiments, during the operation of the system 4500, the portion of the tubular liner hanger 4506 positioned below the adjustable expansion device 4524 is radially expanded and plastically deformed by displacing the adjustable expansion device downwardly.
[00398] In several alternative embodiments, at least a portion of the tubular liner hanger 4506 is fabricated for materials particularly suited for subsequent drilling out operations such as, for example, aluminum and/or copper based materials and alloys. In several alternative embodiments, during the operation of the system 4500, the portion of the tubular liner hanger 4506 fabricated for materials particularly suited for subsequent drilling out operations is not hydroformed by the injection of the fluidic materials 4536.
[00399] In several alternative embodiments, during the operation of the system 4500, at least a portion of the tubular liner hanger 4506 is hydroformed by the injection of the fluidic materials 4536, the remaining portion of the tubular liner hanger above the initial position of the adjustable expansion device 4524 is then radially expanded and plastically deformed by displacing the adjustable expansion device upwardly, and the portion of the tubular liner hanger below the initial position of the adjustable expansion device is radially expanded by then displacing the adjustable expansion device downwardly.
[00400] In several alternative embodiments, during the operation of the system 4500, the portion of the tubular liner hanger 4506 that is radially expanded and plastically deformed is radially expanded and plastically deformed solely by hydroforming caused by the injection of the fluidic materials 4536.
[00401] In several alternative embodiments, during the operation of the system 4500, the portion of the tubular liner hanger 4506 that is radially expanded and plastically deformed is radially expanded and plastically deformed solely by the adjustment of the adjustable expansion device 4524 to an increased size and the subsequent displacement of the adjustable expansion device relative to the tubular liner hanger.
[00402] Referring to Fig. 46a, an exemplary embodiment of a system 4600 for radially expanding a tubular member includes a tubular support member 4602 that defines a passage 4602a. An end of a conventional tubular safety sub 4604 that defines a passage
4604a is coupled to an end of the tubular support member 4602, and another end of the safety sub 4604 is coupled to an end of a tubular casing lock assembly 4606 that defines a passage 4606a.
[00403] In several exemplary embodiments, the lock assembly 4606 may be a conventional locking device for locking the position of a tubular member relative to another member. In several alternative embodiments, the lock assembly 4606 may include one or more elements of the locking assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on
9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number
PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number
PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number
25791.260.02, filed on 3/26/2004, (11) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number
25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14)
PCT patent application serial number PCT/US2004/011973, attorney docket number
25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00404] A end of a tubular support member 4608 that defines a passage 4608a and includes an outer annular recess 4608b is coupled to another end of the lock assembly
4606, and another end of the tubular support member 4608 is coupled to an end of a tubular support member 4610 that defines a passage 4610a, a radial passage 4610b, and includes an outer annular recess 4610c, an inner annular recess 461 Od, and circumferentially spaced apart teeth 461 Oe at another end.
[00405] An adjustable expansion device assembly 4612 is mounted upon and coupled to the outer annular recess 4610c of the tubular support member 4610. In several exemplary embodiments, the adjustable expansion device assembly 4612 may be a conventional adjustable expansion device assembly for radially expanding and plastically deforming tubular members that may include one or more elements of conventional adjustable expansion cones, mandrels, rotary expansion devices, hydroforming expansion devices and/or one or more elements of the one or more of the commercially available adjustable expansion devices of Enventure Global Technology LLC, Baker Hughes, Weatherford International, and/or Schlumberger and/or one or more elements of the adjustable expansion devices disclosed in one or more of the published patent applications and/or issued patents of Enventure Global Technology LLC, Baker Hughes, Weatherford International, Shell Oil
Co. and/or Schlumberger. In several alternative embodiments, the adjustable expansion device assembly 4524 may include one or more elements of the adjustable expansion device assemblies disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
(2) PCT patent application serial number PCT/US02/36267, attorney docket number
25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on
9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number
PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number
PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number
25791.260.02, filed on 3/26/2004, (11 ) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number
25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14)
PCT patent application serial number PCT/US2004/011973, attorney docket number
25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00406] An end of a float shoe 4614 that defines a passage 4614a having a throat
4614aa and includes a plurality of circumferentially spaced apart teeth 4614b at an end that mate with and engage the teeth 461 Oe of the tubular support member 4610 for transmitting torsional loads therebetween and an external threaded connection 4614c is received within the inner annular recess 461 Od of the tubular support member.
[00407] An end of an expandable tubular member 4616 is coupled to the external threaded connection 4614c of the float shoe 4614 and another portion of the expandable tubular member is coupled to the lock assembly 4606. In an exemplary embodiment, at least a portion of the expandable tubular member 4616 includes one or more of the characteristics of the expandable tubular members described in the present application. In an exemplary embodiment, the portion of the expandable tubular member 4616 proximate and positioned in opposition to the adjustable expansion device assembly 4612 includes an outer expansion limiter sleeve 4618 for limiting the amount of radial expansion of the portion of the expandable tubular member proximate and positioned in opposition to the adjustable expansion device assembly. In an exemplary embodiment, at least a portion of the outer expansion limiter sleeve 4618 includes one or more of the characteristics of the expandable tubular members described in the present application.
[00408] A cup seal assembly 4620 is coupled to and positioned within the outer annular recess 4608b of the tubular support member 4608 for sealingly engaging the interior surface of the expandable tubular member 4616. A rupture disc 4622 is positioned within and coupled to the radial passage 4610b of the tubular support member 4610.
[00409] In an exemplary embodiment, during operation of the system 4600, as illustrated in Fig. 46a, the system is positioned within a wellbore 4624 that traverses a subterranean formation 4626 and includes a preexisting wellbore casing 4628 coupled to and positioned within the wellbore. In an exemplary embodiment, the system 4600 is positioned such that the expandable tubular member 4616 overlaps with the casing 4628.
[00410] Referring to Fig. 46b, in an exemplary embodiment, a plug 4630 is then positioned in the throat passage 4614aa of the float shoe 4614 by injecting fluidic materials
4632 into the system 4600 through the passages 4602a, 4604a, 4606a, 4608a, and 4610a, of the tubular support member 4602, safety sub 4604, lock assembly 4606, tubular support member 4608, and tubular support member 4610, respectively.
[00411] Referring to Fig. 46c, in an exemplary embodiment, the continued injection of the fluidic materials 4632 into the system 4600, following the placement of the plug 4630 in the throat passage 4614aa, pressurizes the passage 4610a of the tubular support member
4610 such that the rupture disc 4622 is ruptured thereby permitting the fluidic materials to pass through the radial passage 4610b of the tubular support member. As a result, the interior of the expandable tubular member 4616 proximate the adjustable expansion device assembly 4612 is pressurized.
[00412] Referring to Fig. 45d, in an exemplary embodiment, the continued injection of the fluidic materials 4632 into the interior of the expandable tubular member 4616 radially expands and plastically deforms at least a portion of the expandable tubular member. In an exemplary embodiment, the continued injection of the fluidic materials 4632 into the interior of the expandable tubular member 4616 radially expands and plastically deforms a portion of the expandable tubular member positioned in opposition to the adjustable expansion device assembly 4612. In an exemplary embodiment, the continued injection of the fluidic materials
4632 into the interior of the expandable tubular member 4616 radially expands and plastically deforms a portion of the expandable tubular member positioned in opposition to the adjustable expansion device assembly 4612 into engagement with the wellbore casing
4628. In an exemplary embodiment, the transformation of the material properties of the expansion limiter sleeve 4618, during the radial expansion process, limit the extent to which the expandable tubular member 4616 may be radially expanded.
[00413] Referring to Fig. 46e, in an exemplary embodiment, the size of the adjustable expansion device assembly 4612 is then increased within the radially expanded portion of the expandable tubular member 4616, and the lock assembly 4606 is operated to unlock the expandable tubular member from engagement with the lock assembly. In an exemplary embodiment, the lock assembly 4606 and the adjustable expansion device assembly 4612 are operated using the operating pressure provided by the continued injection of the fluidic materials 4632 into the system 4600. In an exemplary embodiment, the adjustment of the adjustable expansion device assembly 4612 to a larger size radially expands and plastically deforms at least a portion of the expandable tubular member 4616.
[00414] Referring to Fig. 46f, in an exemplary embodiment, the adjustable expansion device assembly 4612 is displaced in a longitudinal direction relative to the expandable tubular member 4616 thereby radially expanding and plastically deforming the expandable tubular member. In an exemplary embodiment, the expandable tubular member
4616 is radially expanded and plastically deformed into engagement with the casing 4628.
In an exemplary embodiment, the adjustable expansion device assembly 4612 is displaced in a longitudinal direction relative to the expandable tubular member 4616 due to the operating pressure within the expandable tubular member generated by the continued injection of the fluidic materials 4632.
[00415] In several alternative embodiments, during the operation of the system 4600, a hardenable fluidic sealing material such as, for example, cement, may injected through the system 4600 before, during or after the radial expansion of the expandable tubular member
4616 in order to form an annular barrier between the wellbore 4624 and/or the wellbore casing 4628 and the expandable tubular member.
[00416] In several alternative embodiments, during the operation of the system 4600, the size of the adjustable expansion device 4612 is increased prior to, during, or after the hydroforming expansion of the expandable tubular member 4616 caused by the injection of the fluidic materials 4632 into the interior of the expandable tubular member.
[00417] In several alternative embodiments, at least a portion of the expandable tubular member 4616 includes a plurality of nested expandable tubular members bonded together by, for example, amorphous bonding.
[00418] In several alternative embodiments, at least a portion of the expandable tubular member 4616 is fabricated for materials particularly suited for subsequent drilling out operations such as, for example, aluminum and/or copper based materials and alloys. [00419] In several alternative embodiments, during the operation of the system 4600, the portion of the expandable tubular member 4616 positioned below the adjustable expansion device 4612 is radially expanded and plastically deformed by displacing the adjustable expansion device downwardly.
[00420] In several alternative embodiments, at least a portion of the expandable tubular member 4616 is fabricated for materials particularly suited for subsequent drilling out operations such as, for example, aluminum and/or copper based materials and alloys. In several alternative embodiments, during the operation of the system 4600, the portion of the expandable tubular member 4616 fabricated for materials particularly suited for subsequent drilling out operations is not hydroformed by the injection of the fluidic materials 4632. [00421] In several alternative embodiments, during the operation of the system 4600, at least a portion of the expandable tubular member 4616 is hydroformed by the injection of the fluidic materials 4632, the remaining portion of the expandable tubular member above the initial position of the adjustable expansion device 4612 is then radially expanded and plastically deformed by displacing the adjustable expansion device upwardly, and the portion of the expandable tubular member below the initial position of the adjustable expansion device is radially expanded by then displacing the adjustable expansion device downwardly. [00422] In several alternative embodiments, during the operation of the system 4600, the portion of the expandable tubular member 4616 that is radially expanded and plastically deformed is radially expanded and plastically deformed solely by hydroforming caused by the injection of the fluidic materials 4632.
[00423] In several alternative embodiments, during the operation of the system 4600, the portion of the expandable tubular member 4616 that is radially expanded and plastically deformed is radially expanded and plastically deformed solely by the adjustment of the adjustable expansion device 4612 to an increased size and the subsequent displacement of the adjustable expansion device relative to the expandable tubular member. [00424] In an exemplary experimental embodiment, expandable tubular members fabricated from tellurium copper, leaded naval brass, phosphorous bronze, and aluminum- silicon bronze were successfully hydroformed and thereby radially expanded and plastically deformed by up to about 30% radial expansion, all of which were unexpected results. [00425] Referring to Fig. 46g, in an exemplary embodiment, at least a portion of the expansion limiter sleeve 4618, prior to the radial expansion and plastic deformation of the expansion limiter sleeve by operation of the system 4600, includes one or more diamond shaped slots 4618a. Referring to Fig. 46h, in an exemplary embodiment, during the radial expansion and plastic deformation of the expansion limiter sleeve by operation of the system 4600, the diamond shaped slots 4618a are deformed such that further radial expansion of the expansion limiter sleeve requires increased force. More generally, the expansion limiter sleeve 4618 may be manufactured with slots whose cross sectional areas are decreased by the radial expansion and plastic deformation of the expansion limited sleeve thereby increasing the amount of force required to further radially expand the expansion limiter sleeve. In this manner, the extent to which the expandable tubular member 4616 may be radially expanded is limited. In several alternative embodiments, at least a portion of the expandable tubular member 4616 includes slots whose cross sectional areas are decreased by the radial expansion and plastic deformation of the expandable tubular member thereby increasing the amount of force required to further radially expand the expandable tubular member.
[00426] Referring to Figs. 46i and 46ia, in an exemplary embodiment, at least a portion of the expansion limiter sleeve 4618, prior to the radial expansion and plastic deformation of the expansion limiter sleeve by operation of the system 4600, includes one or more wavy circumferentially oriented spaced apart bands 4618b. Referring to Fig. 46j, in an exemplary embodiment, during the radial expansion and plastic deformation of the expansion limiter sleeve by operation of the system 4600, the bands 4618b are deformed such that the further radial expansion of the expansion limiter sleeve requires added force. More generally, the expansion limiter sleeve 4618 may be manufactured with a circumferential bands whose orientation becomes more and more aligned with a direction that is orthogonal to the longitudinal axis of the sectional areas as a result of the radial expansion and plastic deformation of the bands thereby increasing the amount of force required to further radially expand the expansion limiter sleeve. In this manner, the extent to which the expandable tubular member 4616 may be radially expanded is limited. In several alternative embodiments, at least a portion of the expandable tubular member 4616 includes circumferential bands whose orientation becomes more and more aligned with a direction that is orthogonal to the longitudinal axis of the sectional areas as a result of the radial expansion and plastic deformation of the bands thereby increasing the amount of force required to further radially expand the expandable tubular member.
[00427] In several exemplary embodiments, the design of the expansion limiter sleeve
4618 provides a restraining force that limits the extent to which the expandable tubular member 4616 may be radially expanded and plastically deformed. Furthermore, in several exemplary embodiments, the design of the expansion limiter sleeve 4618 provides a variable restraining force that limits the extent to which the expandable tubular member 4616 may be radially expanded and plastically deformed. In several exemplary embodiments, the variable restraining force of the expansion limiter sleeve 4618 increases in proportion to the degree to which the expandable tubular member 4616 has been radially expanded. [00428] Referring to Fig. 47a, an exemplary embodiment of a system 4700 for radially expanding a tubular member includes a tubular support member 4702 that defines a passage 4702a. An end of a conventional tubular safety sub 4704 that defines a passage 4704a is coupled to an end of the tubular support member 4702, and another end of the safety sub 4704 is coupled to an end of a tubular ball gripper assembly 4706 that defines a passage 4706a.
[00429] In several exemplary embodiments, the ball gripper assembly 4706 may be a conventional device for limiting movement of tubular member relative to another member that employs, for example, one or more separate discrete ball-like elements to controliably engage and limit relative movement of the tubular member in one or more directions. In several alternative embodiments, the ball gripper assembly 4706 may include one or more elements of the ball grabber assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on 9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number 25791.260.02, filed on 3/26/2004, (11 ) PCT patent application serial number PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number 25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14) PCT patent application serial number PCT/US2004/011973, attorney docket number 25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00430] An end of a tubular casing lock assembly 4708 that defines a passage 4708a is coupled to the other end of the ball gripper assembly 4706. In several exemplary embodiments, the casing lock assembly 4708 may be a conventional device for limiting movement of a tubular member relative to another member. In several alternative embodiments, the casing lock assembly 4708 may include one or more elements of the casing lock assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on 9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number 25791.260.02, filed on 3/26/2004, (11) PCT patent application serial number PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number 25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14) PCT patent application serial number PCT/US2004/011973, attorney docket number 25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00431] An end of a tubular tension actuator assembly 4710 that defines a passage 4710a and one or more external mounting holes 4710b and includes an internal annular recess 4710c at one end is coupled to the other end of the casing lock assembly 4708. In several exemplary embodiments, the tubular tension actuator assembly 4710 may be a conventional device for displacing a member relative to another member. In several alternative embodiments, the tubular tension actuator assembly 4710 may include one or more elements of the tension actuator assemblies disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number
25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number
PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on
2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no.
25791.102.02, filed on 9/22/2003, (5) PCT patent application serial number
PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number PCT/US04/07711 , attorney docket number 25791.253.02, filed on
3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number 25791.260.02, filed on 3/26/2004, (11) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number
25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14)
PCT patent application serial number PCT/US2004/011973, attorney docket number
25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00432] A primary solid tubular expansion cone 4712 that includes a tapered external surface 4712a at one end 4712b is coupled to the other end of the tubular tension actuator assembly 4710. An expandable tubular casing 4714 that defines one or more mounting holes 4714a at one end receives and mates with the safety sub 4704, ball gripper assembly
4706, casing lock assembly 4708, tension actuator assembly 4710. The end of the tubular casing 4714 receives and mates with the non-tapered end and a portion of the tapered end
4712b of the tubular expansion cone 4712. As a result, the end of the tubular casing 4714 that receives and mates with the portion of the tapered end 4712b of the tubular expansion cone 4712 is flared. In an exemplary embodiment, the outside diameter of the flared tapered end of the tubular casing 4714 is less than or equal to the maximum outside diameter of the tapered end 4712b of the tubular expansion cone 4712. An end of a mounting pin 4716 is received within and coupled to the mounting hole 4710b of the tension actuator assembly
4710, and another end of the mounting pin is received within and coupled to the mounting hole 4714a of the tubular casing 4714. In an exemplary embodiment, the expandable tubular casing 4714 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j. In an exemplary embodiment, during the operation of the system 4700, the mounting pin 4716 permits torque to be transmitted between the expandable tubular casing 4714 and the tension actuator assembly
4710.
[00433] An end of a secondary tubular expansion cone 4718 that defines a passage
4718a and includes an external annular recess 4718b, that mates with and is received within the end of the tension actuator assembly 4710 and the primary tubular expansion cone
4712, and a tapered external surface 4718c, an internal annular recess 4718d, and a plurality of circumferentially spaced apart teeth 4718e at another end is coupled to the end of the tension actuator assembly 4710. An expandable tubular sleeve 4720 that includes a first end 4720a including an external annular recess 4720aa, an intermediate portion 4720b, and a second end 4720c having an internal threaded connection 4720d mates with and receives the secondary tubular expansion cone 4718. In an exemplary embodiment, the expandable tubular sleeve 4720 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j. A sealing member
4722 is received within and coupled to the external annular recess 4720aa of the first end
4720a of the expandable tubular sleeve 4720. In an exemplary embodiment, the wall thickness of the first end 4720a of the tubular sleeve 4720 is greater than the wall thickness of the second end 4720c of the tubular sleeve, and the wall thickness of the intermediate portion 4720b of the tubular sleeve is tapered. In an exemplary embodiment, the outside diameter of the intermediate portion 4720b and the second end 4720c of the tubular sleeve
4720 are both less than or equal to the maximum outside diameter of the tapered end 4712b of the tubular expansion cone 4712. In an exemplary embodiment, the outside diameter of the sealing member 4722 is less than or equal to the maximum outside diameter of the tapered end 4712b of the tubular expansion cone 4712.
[00434] A float shoe 4724 that defines a passage 4724a having a throat 4724aa and a passage 4724b and includes an external annular recess 4724c at one end that is received within and mates with the internal annular recess 4718d of the end of the secondary tubular expansion cone 4718, a plurality of circumferentially spaced apart shoulders 4724d at another end, a plurality of circumferentially spaced apart teeth 4724e for engaging the circumferentially spaced apart teeth 4718e of the secondary tubular expansion cone 4718, and a conventional float element 4724f is received within, mates with, and is coupled to the internal threaded connection 4720d of the end of the expandable tubular sleeve 4720. In an exemplary embodiment, the outside diameter of the spaced apart shoulders 4724d of the float shoe 4724 are greater than the outside diameter of the maximum outside diameter of the tapered end 4712b of the tubular expansion cone 4712. In an exemplary embodiment, during the operation of the system 4700, the interaction of the circumferentially spaced apart teeth 4724e of the float shoe 4724 with the circumferentially spaced apart teeth 4718e of the secondary tubular expansion cone 4718 permits torque loads to be transmitted there between. In an exemplary embodiment, during the operation of the system 4700, the circumferentially spaced apart shoulders 4724d further define circumferentially spaced apart axial flow passages there between.
[00435] In an exemplary embodiment, during operation of the system 4700, as illustrated in Fig. 47a, the system is positioned within a wellbore 4726 that traverses a subterranean formation 4728. A hardenable fluidic sealing material 4730 such as, for example, cement may then be injected into the system 4700 through the passages 4702a,
4704a, 4706a, 4708a, 4710a, 4718a, and 4724a. The fluidic material 4730 may then be conveyed past the float element 4724f of the float shoe 4724 and through the passage
4724b into an annulus 4732 between the system 4700 and the interior surface of the wellbore 4726. The fluidic material 4730 within the annulus 4732 may then be allowed to at least partially cure.
[00436] In an exemplary embodiment, during the operation of the system 4700, as illustrated in Fig. 47b, a conventional plug 4734 is then positioned within the throat 4724aa of the passage 4724a of the float shoe 4724 by injecting fluidic material 4736 into the system
4700 through the passages 4702a, 4704a, 4706a, 4708a, 4710a, 4718a, and 4724a. As a result, the passage 4724a of the float shoe 4724 is blocked and the passages 4702a, 4704a,
4706a, 4708a, 4710a, and 4718a may be pressurized by the continued injection of the fluidic material 4736.
[00437] In an exemplary embodiment, during the operation of the system 4700, as illustrated in Fig. 47c, the passages 4702a, 4704a, 4706a, 4708a, 4710a, and 4718a may be pressurized by the continued injection of the fluidic material 4736 into the system. As a result, the casing lock assembly 4708 is operated to engage the expandable tubular casing
4714and the tension actuator assembly 4710 is operated to displace the primary tubular expansion cone 4712, secondary tubular expansion cone 4718, expandable tubular sleeve
4720, sealing member 4722, and float shoe 4724 upwardly in a longitudinal direction 4738 relative to the expandable tubular casing 4714. As a result, the end of the expandable tubular casing 4714 is radially expanded and plastically deformed by the tapered external surface 4712a of the primary tubular expansion cone 4712. Furthermore, as a result, the radially expanded and plastically deformed end of the tubular casing 4714 receives and mates with the expandable tubular sleeve 4720 and the sealing member 4722. Furthermore, as a result, the mounting pin 4716 is sheared. In an exemplary embodiment, the of the expandable tubular casing 4714 is radially expanded and plastically deformed by the tapered external surface 4712a of the primary tubular expansion cone 4712 until the end of the expandable tubular casing impacts the end face of the shoulders 4724d of the float shoe
4724. [00438] In an exemplary embodiment, during the operation of the system 4700, as illustrated in Fig. 47d, the passages 4702a, 4704a, 4706a, 4708a, 4710a, and 4718a may continue to be pressurized by the continued injection of the fluidic material 4736 into the system. As a result, the casing lock assembly 4708 and the tension actuator assembly 4710 may continue to be operated in the manner described above with reference to Fig. 47c. Furthermore, as a result, the primary tubular expansion cone 4712 is further displaced upwardly in the longitudinal direction 4738 relative to the expandable tubular casing 4714, and the secondary tubular expansion cone 4718 is displaced upwardly relative to the expandable tubular sleeve 4720, and the sealing member 4722 in the longitudinal direction 4738. Note that the further upward displacement of the expandable tubular sleeve 4720, the sealing member 4722, and the float shoe 4724, during the continued operation of the tension actuator assembly 4710, is prevented due to the interaction between the end of the expandable tubular casing 4714 and the end face of the shoulders 4724d of the float shoe 4724. Furthermore, as a result, the end of the expandable tubular casing 4714 is further radially expanded and plastically deformed by the tapered external surface 4712a of the primary tubular expansion cone 4712, and portions, 4720a and 4720b, of the expandable tubular sleeve 4720 are radially expanded and plastically deformed by the tapered external surface 4718c of the secondary tubular expansion cone 4718 within the expandable tubular casing. As a result, the sealing member 4722 engages and fluidicly seals the interface between the expandable tubular casing 4714 and the expandable tubular sleeve 4720. Furthermore, in an exemplary embodiment, as a result of the radial expansion and plastic deformation of the portions, 4720a and 4720b, of the expandable tubular sleeve 4720 within the expandable tubular casing 4714, a metal to metal, fluid tight seal is formed between the interior surface of the expandable tubular casing and the exterior surface of the expandable tubular sleeve. In an exemplary embodiment, once the portions, 4720a and 4720b, of the expandable tubular sleeve 4720 are completely radially expanded and plastically deformed by the tapered external surface 4718c of the secondary tubular expansion cone 4718, the casing lock assembly 4708 releases the expandable tubular casing 4714. [00439] In an exemplary embodiment, during the operation of the system 4700, as illustrated in Fig. 47e, following the release of the expandable tubular casing 4714 from the casing lock assembly 4708, the continued injection of the fluidic material 4736 into the passages of the system will further displace the primary tubular expansion cone 4712 upwardly in the longitudinal direction 4738 relative to the expandable tubular casing 4714. As a result, the expandable tubular casing 4714 is further radially expanded and plastically deformed by the tapered external surface 4712a of the primary tubular expansion cone 4712. [00440] In several alternative embodiments, the tension actuator assembly 4710 may be operated to radially expand and plastically deform the expandable tubular sleeve 4720 by operating the tension actuator assembly in a first stroke to radially expand and plastically deform a portion of the expandable tubular sleeve 4720. After completing the first stroke of the tension actuator assembly 4710, the casing lock assembly 4708 is operated to release the expandable tubular casing 4714, such as, for example, by reducing the operating pressure of the fluidic material 4736. The tension actuator assembly 4710 is then re-set to an initial position by displacing the tubular support member 4702, the tubular safety sub 4704, the ball gripper assembly 4706, the casing lock assembly, and the portion of the tension actuator assembly rigidly coupled to the end of the casing lock assembly upwardly relative to the expandable tubular casing 4714. The operating pressure of the fluidic material 4736 is increased, and the tension actuator assembly is then operated in a second stroke to radially expand and plastically deform a further portion of the expandable tubular sleeve 4720. In several exemplary embodiments, this process may be repeated as often as required in order to radially expand and plastically deform the desired portions of the expandable tubular sleeve 4720. In an exemplary embodiment, during the first stroke, resetting of, and/or the second stroke of the tension actuator assembly 4710, the ball gripper assembly 4706 is also operated to limit displacement of the expandable tubular casing 4714 in one or more longitudinal directions by, for example, adjusting the operating pressure of the fluidic material 4736.
[00441] In an exemplary embodiment, the maximum outside diameter of the system
4700, during the placement of the system within the wellbore 4726, is defined by the maximum outside diameter of the expandable tubular casing 4714.
[00442] In several alternative embodiments, the system 4700 includes the ball gripper assembly 4706 and/or the casing lock assembly 4708.
[00443] In several alternative embodiments, the casing lock assembly 4708 is omitted from the system 4700. As a result, the system 4700 relies only upon the ball gripper assembly 4706 to limit displacement of the expandable tubular casing 4714. [00444] In several exemplary embodiments of the system 4700, the operation of the ball gripper assembly 4706 and/or the casing lock assembly 4708 may be replaced with, or enhanced by, the use of conventional hydraulic or mechanical slips. [00445] In several exemplary embodiments of the system 4700, the expandable tubular sleeve 4720 is fabricated from materials particularly suited to being removed using a drilling device such as, for example, aluminum or brass.
[00446] In several exemplary embodiments of the system 4700, the float shoe 4724 may include a sliding sleeve valve for controlling the flow of fluidic materials through the float shoe. In several exemplary embodiments of the system 4700, the secondary tubular expansion cone 4718 includes a conventional stinger attached thereto for manipulating and thereby controlling the operation of the sliding sleeve valve.
[00447] Referring to Fig. 48a, an exemplary embodiment of a system 4800 for radially expanding a tubular member includes a tubular support member 4802 that defines a passage 4802a. An end of a conventional tubular safety sub 4804 that defines a passage
4804a is coupled to an end of the tubular support member 4802, and another end of the safety sub 4804 is coupled to an end of a tubular ball gripper assembly 4806 that defines a passage 4806a.
[00448] In several exemplary embodiments, the ball gripper assembly 4806 may be a conventional device for limiting movement of tubular member relative to another member that employs, for example, one or more separate discrete ball-like elements to controliably engage and limit relative movement of the tubular member in one or more directions. In several alternative embodiments, the ball gripper assembly 4806 may include one or more elements of the ball gripper assemblies disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on
9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number
PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number
PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number
25791.260.02, filed on 3/26/2004, (11 ) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number
25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14)
PCT patent application serial number PCT/US2004/011973, attorney docket number
25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00449] An end of a tubular casing lock assembly 4808 that defines a passage 4808a is coupled to the other end of the ball gripper assembly 4806. In several exemplary embodiments, the casing lock assembly 4808 may be a conventional device for limiting movement of a tubular member relative to another member. In several alternative embodiments, the casing lock assembly 4808 may include one or more elements of the casing lock assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
(2) PCT patent application serial number PCT/US02/36267, attorney docket number
25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on
9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 1 1/13/2003, (6) PCT patent application serial number
PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number
PCT/US04/07711, attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number
25791.260.02, filed on 3/26/2004, (11) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number
25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14)
PCT patent application serial number PCT/US2004/011973, attorney docket number
25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00450] An end of a tubular tension actuator assembly 4810 that defines a passage
4810a is coupled to the other end of the casing lock assembly 4808. In several exemplary embodiments, the tubular tension actuator assembly 4810 may be a conventional device for displacing a member relative to another member. In several alternative embodiments, the tubular tension actuator assembly 4810 may include one or more elements of the tension actuator assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
(2) PCT patent application serial number PCT/US02/36267, attorney docket number
25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on
9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number
PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number
PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number
25791.260.02, filed on 3/26/2004, (11) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number
25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14)
PCT patent application serial number PCT/US2004/011973, attorney docket number
25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00451] An end of a tubular support member 4812 that defines a passage 4812a and includes an external annular recess 4812b is coupled to the other end of the tubular tension actuator assembly 4810. A sealing cup assembly 4814 is positioned within and coupled to the external annular recess 4812b of the 4812. In several exemplary embodiments, the sealing cup assembly 4814 may include one or more conventional sealing cup assemblies and/or one or more of the elements of one or more of the sealing cup assemblies disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3)
PCT patent application serial number PCT/US03/04837, attorney docket number
25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on 9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6)
PCT patent application serial number PCT/US03/18530, attorney docket number
25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number
PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number
PCT/US2004/009434, attorney docket number 25791.260.02, filed on 3/26/2004, (11) PCT patent application serial number PCT/US2004/010317, attorney docket number
25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number 25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number PCT/US2004/010762, attorney docket number
25791.273.02, filed on 4/6/2004, and/or (14) PCT patent application serial number
PCT/US2004/011973, attorney docket number 25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00452] An end of an expansion device assembly 4816 that defines a passage 4816a and a mounting hole 4816aa and includes an adjustable expansion device 4816b at one end, an external annular recess 4816c, a tapered external expansion surface 4816d, an internal annular recess 4816e, and a plurality of circumferentially spaced apart teeth 4816f at another end is coupled to the other end of the tubular support member 4812. In several exemplary embodiments, the adjustable expansion device 4816b may be a conventional adjustable expansion device that may include a tapered outer expansion surface whose shape, size, and/or position is adjustable, a rotary expansion device, one or more of the elements of the conventional commercially available expansion devices of Baker Hughes,
Halliburton, Schlumberger, Weatherford, and/or Enventure Global Technology, L.L.C. and/or one or more of the elements of the issued patents and published patent applications assigned or licensed to Baker Hughes, Halliburton, Schlumberger, Weatherford, and/or
Enventure Global Technology, L.L.C. In several exemplary embodiments, the adjustable expansion device 4816b includes one or more elements of one or more of the adjustable expansion devices disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
(2) PCT patent application serial number PCT/US02/36267, attorney docket number
25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on
9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number
PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number
PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number
25791.260.02, filed on 3/26/2004, (11) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number
25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14)
PCT patent application serial number PCT/US2004/011973, attorney docket number
25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00453] An end of a mounting pin 4818 is received within and coupled to the mounting hole 4816aa of the expansion device assembly 4816, and another of the mounting pin is received within a mounting hole 4820a defined within an expandable tubular casing 4820 that receives the tubular support member 4802, the tubular safety sub 4804, the tubular ball gripper assembly 4806, the tubular casing lock assembly 4808, the tubular tension actuator assembly 4810, the tubular support member 4812, the sealing cup assembly 4814, and the end of the expansion device assembly 4816.
[00454] In an exemplary embodiment, the expandable tubular casing 4820 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j. In an exemplary embodiment, during the operation of the system
4800, the mounting pin 4818 permits torque to be transmitted between the expandable tubular casing 4820 and the expansion device assembly 4816. In an exemplary embodiment, the torque pin 4818 is fabricated from a drillable material such as, for example, brass or aluminum. In an exemplary embodiment, the sealing cup assembly 4814 sealingly engages the internal diameter of the expandable tubular casing 4820 during the operation of the system 4800.
[00455] An expandable tubular sleeve 4822 that includes a first end 4822a including an external annular recess 4822aa, an intermediate portion 4822b, and a second end 4822c having an internal threaded connection 4822d mates with and is received within the external annular recess 4816c of the expansion device assembly 4816. In an exemplary embodiment, the wall thickness of the first end 4822a of the expandable tubular sleeve 4822 is greater than the wall thickness of the second end 4822c of the expandable tubular sleeve, and the wall thickness of the intermediate portion 4822b of the expandable tubular sleeve is tapered. In an exemplary embodiment, the intermediate portion 4822b of the expandable tubular sleeve 4822 mates with and receives the external tapered surface 4816d of the expansion device assembly 4816. In an exemplary embodiment, the expandable tubular sleeve 4822 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j.
[00456] A sealing member 4824 is received within and coupled to the external annular recess 4822aa of the first end 4822a of the expandable tubular sleeve 4822. In an exemplary embodiment, the outside diameter of the intermediate portion 4822b and the second end 4822c of the tubular sleeve 4822 are both less than or equal to the maximum outside diameter of the expandable tubular casing 4822. In an exemplary embodiment, the outside diameter of the sealing member 4824 is less than or equal to the maximum outside diameter of the expandable tubular casing 4820.
[00457] A float shoe 4826 that defines a passage 4826a having a throat 4826aa and a passage 4826b and includes an external annular recess 4826c at one end that is received within and mates with the internal annular recess 4816e of the end of the expansion device assembly 4816, a plurality of circumferentially spaced apart shoulders 4826d at another end, a plurality of circumferentially spaced apart teeth 4826e for engaging the circumferentially spaced apart teeth 4816f of the end of the expansion device assembly 4816, and a conventional float element 4826f is received within, mates with, and is coupled to the internal threaded connection 4822d of the end of the expandable tubular sleeve 4822. In an exemplary embodiment, the outside diameter of the spaced apart shoulders 4826d of the float shoe 4826 are greater than the outside diameters of both the expandable tubular casing
4820 and the expandable tubular sleeve 4822. In an exemplary embodiment, during the operation of the system 4800, the interaction of the circumferentially spaced apart teeth
4826e of the float shoe 4826 with the circumferentially spaced apart teeth 4816f of the expansion device assembly 4816 permits torque loads to be transmitted there between. In an exemplary embodiment, during the operation of the system 4800, the circumferentially spaced apart shoulders 4826d further define circumferentially spaced apart axial flow passages there between.
[00458] In an exemplary embodiment, during operation of the system 4800, as illustrated in Fig. 48a, the system is positioned within a wellbore 4828 that traverses a subterranean formation 4830. A hardenable fluidic sealing material 4832 such as, for example, cement may then be injected into the system 4800 through the passages 4802a,
4804a, 4806a, 4808a, 4810a, 4812a, 4816a, and 4826a. The fluidic material 4832 may then be conveyed past the float element 4826f of the float shoe 4826 and through the passage
4826b into an annulus 4834 between the system 4800 and the interior surface of the wellbore 4828. The fluidic material 4832 within the annulus 4834 may then be allowed to at least partially cure.
[00459] In an exemplary embodiment, during the operation of the system 4800, as illustrated in Fig. 48b, a conventional plug 4836 is then positioned within the throat 4826aa of the passage 4826a of the float shoe 4826 by injecting fluidic material 4838 into the system
4800 through the passages 4802a, 4804a, 4806a, 4808a, 4810a, 4812a, and 4816a. As a result, the passage 4826a of the float shoe 4826 is blocked and the passages 4802a, 4804a,
4806a, 4808a, 4810a, 4812a, and 4816a may be pressurized by the continued injection of the fluidic material 4838.
[00460] In an exemplary embodiment, during the operation of the system 4800, as illustrated in Fig. 48c, the passages 4802a, 4804a, 4806a, 4808a, 4810a, 4812a and 4816a may be pressurized by the continued injection of the fluidic material 4838 into the system.
As a result, the casing lock assembly 4808 is operated to engage the expandable tubular casing 4820 and the outside diameter of the adjustable expansion device 4816b of the expansion device assembly 4816 is increased. In an exemplary embodiment, the adjustable expansion device 4816b of the expansion device assembly 4816 includes one or more external expansion surfaces 4816ba for engaging and radially expanding and plastically deforming the expandable tubular casing 4820.
[00461] In an exemplary embodiment, during the operation of the system 4800, as illustrated in Fig. 48d, the passages 4802a, 4804a, 4806a, 4808a, 4810a, 4812a and 4816a may continue to be pressurized by the continued injection of the fluidic material 4838 into the system. As a result, the casing lock assembly 4808 continues to be operated to engage the expandable tubular casing 4820 and the tension actuator assembly 4810 is operated to displace the expansion device assembly 4816, expandable tubular sleeve 4822, sealing member 4824, and float shoe 4826 upwardly in a longitudinal direction 4840 relative to the expandable tubular casing 4820. As a result, the end of the expandable tubular casing 4820 is radially expanded and plastically deformed by the external expansion surfaces 4816ba of the adjustable expansion device 4816b of the expansion device assembly 4816.
Furthermore, as a result, the radially expanded and plastically deformed end of the tubular casing 4820 receives and mates with the expandable tubular sleeve 4822 and the sealing member 4824. Furthermore, as a result, the mounting pin 4818 is sheared. In an exemplary embodiment, the end of the expandable tubular casing 4820 is radially expanded and plastically deformed by the external expansion surfaces 4816ba of the adjustable expansion device 4816b of the expansion device assembly 4816 until the end of the expandable tubular casing impacts the end face of the shoulders 4826d of the float shoe 4826.
[00462] In an exemplary embodiment, during the operation of the system 4800, as illustrated in Fig. 48e, the passages 4802a, 4804a, 4806a, 4808a, 4810a, 4812a, and 4816a may continue to be pressurized by the continued injection of the fluidic material 4838 into the system. As a result, the casing lock assembly 4808 and the tension actuator assembly 4810 may continue to be operated in the manner described above with reference to Fig. 48d.
Furthermore, as a result, the adjustable expansion device 4816b of the expansion device assembly 4816 is further displaced upwardly in the longitudinal direction 4840 relative to the expandable tubular casing 4820, and the tapered external expansion surface 4816d of the expansion device assembly is displaced upwardly relative to the expandable tubular sleeve
4822, and the sealing member 4824 in the longitudinal direction 4838. Note that the further upward displacement of the expandable tubular sleeve 4822, the sealing member 4824, and the float shoe 4826, during the continued operation of the tension actuator assembly 4810, is prevented due to the interaction between the end of the expandable tubular casing 4820 and the end face of the shoulders 4826d of the float shoe 4826. Furthermore, as a result, the end of the expandable tubular casing 4820 is further radially expanded and plastically deformed by the external expansion surfaces 4816ba of the adjustable expansion device
4816b of the expansion device assembly 4816, and portions, 4822a and 4822b, of the expandable tubular sleeve 4822 are radially expanded and plastically deformed by the tapered external expansion surface 4816d of the expansion device assembly within the end of the expandable tubular casing. As a result, the sealing member 4824 engages and fluidicly seals the interface between the expandable tubular casing 4820 and the expandable tubular sleeve 4822. Furthermore, in an exemplary embodiment, as a result of the radial expansion and plastic deformation of the portions, 4822a and 4822b, of the expandable tubular sleeve 4822 within the end of the expandable tubular casing 4820, a metal to metal, fluid tight seal is formed between the interior surface of the expandable tubular casing and the exterior surface of the expandable tubular sleeve. In an exemplary embodiment, once the portions, 4822a and 4822b, of the expandable tubular sleeve 4822 are completely radially expanded and plastically deformed by the tapered external expansion surface 4816d of the expansion device assembly 4816, the casing lock assembly 4808 releases the expandable tubular casing 4820.
[00463] In an exemplary embodiment, during the operation of the system 4800, as illustrated in Fig. 48f, following the release of the expandable tubular casing 4820 from the casing lock assembly 4808, the continued injection of the fluidic material 4838 into the passages of the system will further displace the adjustable expansion device 4816b of the expansion device assembly 4816 upwardly in the longitudinal direction 4840 relative to the expandable tubular casing 4820. In an exemplary embodiment, during the displacement of the adjustable expansion device 4816b of the expansion device assembly 4816 upwardly in the longitudinal direction 4840 relative to the expandable tubular casing 4820, the sealing cup assembly 4814 sealingly engage the internal surface of the expandable tubular casing
4820. As a result, the annulus within the expandable tubular casing 4820 below and proximate to the sealing cup assembly 4814 is pressurized by the injection of the fluidic material 4838 into the system 4800 thereby applying an upward axial force to the tubular support member 4812. As a result, the adjustable expansion device 4816b of the expansion device assembly 4816 is pulled through the expandable tubular casing 4820. As a result, the expandable tubular casing 4820 is further radially expanded and plastically deformed by the external expansion surfaces 4816ba of the adjustable expansion device 4816b of the expansion device assembly 4816.
[00464] In several alternative embodiments, the tension actuator assembly 4810 may be operated to radially expand and plastically deform the expandable tubular sleeve 4822 by operating the tension actuator assembly in a first stroke to radially expand and plastically deform a portion of the expandable tubular sleeve 4822. After completing the first stroke of the tension actuator assembly 4810, the casing lock assembly 4808 is operated to release the expandable tubular casing 4820, such as, for example, by reducing the operating pressure of the fluidic material 4838. The tension actuator assembly 4810 is then re-set to an initial position by displacing the tubular support member 4802, the tubular safety sub 4804, the ball gripper assembly 4806, the casing lock assembly 4808, and the portion of the tension actuator assembly rigidly coupled to the end of the casing lock assembly upwardly relative to the expandable tubular casing 4820. The operating pressure of the fluidic material 4838 is increased, and the tension actuator assembly 4810 is then operated in a second stroke to radially expand and plastically deform a further portion of the expandable tubular sleeve 4822. In several exemplary embodiments, this process may be repeated as often as required in order to radially expand and plastically deform the desired portions of the expandable tubular sleeve 4822. In an exemplary embodiment, during the first stroke, re-setting of, and/or the second stroke of the tension actuator assembly 4810, the ball gripper assembly 4806 is also operated to limit displacement of the expandable tubular casing 4820 in one or more longitudinal directions by, for example, adjusting the operating pressure of the fluidic material 4838.
[00465] In an exemplary embodiment, the maximum outside diameter of the system
4800, during the placement of the system within the wellbore 4828, is defined by the maximum outside diameter of the expandable tubular casing 4820.
[00466] In several alternative embodiments, the system 4800 includes the ball gripper assembly 4806 and/or the casing lock assembly 4808.
[00467] In several alternative embodiments, the casing lock assembly 4808 is omitted from the system 4800. As a result, the system 4800 relies only upon the ball gripper assembly 4806 to limit displacement of the expandable tubular casing 4820. [00468] In several exemplary embodiments of the system 4800, the operation of the ball gripper assembly 4806 and/or the casing lock assembly 4808 may be replaced with, or enhanced by, the use of conventional hydraulic or mechanical slips. [00469] In several exemplary embodiments of the system 4800, the expandable tubular sleeve 4822 is fabricated from materials particularly suited to being removed using a drilling device such as, for example, aluminum or brass.
[00470] In several exemplary embodiments of the system 4800, the float shoe 4826 may include a sliding sleeve valve for controlling the flow of fluidic materials through the float shoe. In several exemplary embodiments of the system 4800, the end of the expansion device assembly 4816 includes a conventional stinger attached thereto for manipulating and thereby controlling the operation of the sliding sleeve valve. [00471] In several exemplary embodiments, the sealing cup assembly 4814 may be positioned above or below the casing lock assembly 4808.
[00472] Referring to Fig. 49a, an exemplary embodiment of a system 4900 for radially expanding a tubular member includes a tubular support member 4902 that defines a passage 4902a. An end of a conventional tubular safety sub 4904 that defines a passage
4904a is coupled to an end of the tubular support member 4902, and another end of the safety sub 4904 is coupled to an end of a tubular ball gripper assembly 4906 that defines a passage 4906a.
[00473] In several exemplary embodiments, the ball gripper assembly 4906 may be a conventional device for limiting movement of tubular member relative to another member that employs, for example, one or more separate discrete ball-like elements to controliably engage and limit relative movement of the tubular member in one or more directions. In several alternative embodiments, the ball gripper assembly 4906 may include one or more elements of the ball gripper assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on
9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number
PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number
PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number
25791.260.02, filed on 3/26/2004, (11) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number
25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14)
PCT patent application serial number PCT/US2004/011973, attorney docket number
25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00474] An end of a tubular casing lock assembly 4908 that defines a passage 4908a is coupled to the other end of the ball gripper assembly 4908. In several exemplary embodiments, the casing lock assembly 4908 may be a conventional device for limiting movement of a tubular member relative to another member. In several alternative embodiments, the casing lock assembly 4908 may include one or more elements of the casing lock assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
(2) PCT patent application serial number PCT/US02/36267, attorney docket number
25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on
9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number
PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number
PCT/US04/07711, attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number
25791.260.02, filed on 3/26/2004, (11) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number
25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14)
PCT patent application serial number PCT/US2004/011973, attorney docket number
25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00475] An end of a tubular tension actuator assembly 4910 that defines a passage
4910a is coupled to the other end of the casing lock assembly 4908. In several exemplary embodiments, the tubular tension actuator assembly 4910 may be a conventional device for displacing a member relative to another member. In several alternative embodiments, the tubular tension actuator assembly 4910 may include one or more elements of the tension actuator assemblies disclosed in one or more of the following: (1 ) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
(2) PCT patent application serial number PCT/US02/36267, attorney docket number
25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on
9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number
PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number
PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number
25791.260.02, filed on 3/26/2004, (11) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number
25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14)
PCT patent application serial number PCT/US2004/011973, attorney docket number
25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00476] An end of a tubular support member 4912 that defines a passage 4912a and includes an external annular recess 4912b is coupled to the other end of the tubular tension actuator assembly 4910. A sealing cup assembly 4914 is positioned within and coupled to the external annular recess 4912b of the tubular support member 4912. In several exemplary embodiments, the sealing cup assembly 4914 may include one or more conventional sealing cup assemblies and/or one or more of the elements of one or more of the sealing cup assemblies disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on
11/12/2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on
9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number
PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number
PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number
25791.260.02, filed on 3/26/2004, (11) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number
25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14)
PCT patent application serial number PCT/US2004/011973, attorney docket number
25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00477] An end of an expansion device assembly 4916 that defines a passage 4916a and a mounting hole 4916aa and includes an adjustable expansion device 4916b at one end, an external annular recess 4916c, a tapered external expansion surface 4916d, an internal annular recess 4916e, and a plurality of circumferentially spaced apart teeth 4916f at another end is coupled to the other end of the tubular support member 4912. In several exemplary embodiments, the adjustable expansion device 4916b may be a conventional adjustable expansion device that may include a tapered outer expansion surface whose shape, size, and/or position is adjustable, a rotary expansion device, one or more of the elements of the conventional commercially available expansion devices of Baker Hughes,
Halliburton, Schlumberger, Weatherford, and/or Enventure Global Technology, L.L.C. and/or one or more of the elements of the issued patents and published patent applications assigned or licensed to Baker Hughes, Halliburton, Schlumberger, Weatherford, and/or
Enventure Global Technology, L.L.C. In several exemplary embodiments, the adjustable expansion device 4916b includes one or more elements of one or more of the adjustable expansion devices disclosed in one or more of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on 11/12/2002,
(2) PCT patent application serial number PCT/US02/36267, attorney docket number
25791.88.02, filed on 11/12/2002, (3) PCT patent application serial number
PCT/US03/04837, attorney docket number 25791.95.02, filed on 2/29/2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on
9/22/2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on 11/13/2003, (6) PCT patent application serial number
PCT/US03/18530, attorney docket number 25791.108.02, filed on 6/11/2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on 9/23/2003, filed on 9/22/2003, (9) PCT patent application serial number
PCT/US04/07711 , attorney docket number 25791.253.02, filed on 3/11/2004, (10) PCT patent application serial number PCT/US2004/009434, attorney docket number
25791.260.02, filed on 3/26/2004, (1 1) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on 4/2/2004, (12) PCT patent application serial number PCT/US2004/010712, attorney docket number 25791.272.02, filed on 4/7/2004, (13) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on 4/6/2004, and/or (14)
PCT patent application serial number PCT/US2004/011973, attorney docket number
25791.277.02, filed on April 15, 2004, the disclosures of which are incorporated herein by reference.
[00478] An end of a mounting pin 4918 is received within and coupled to the mounting hole 4916aa of the expansion device assembly 4916, and another of the mounting pin is received within a mounting hole 4920a defined within an expandable tubular casing 4920 that receives the tubular support member 4902, the tubular safety sub 4904, the tubular ball gripper assembly 4906, the tubular casing lock assembly 4908, the tubular tension actuator assembly 4910, the tubular support member 4912, the sealing cup assembly 4914, and the end of the expansion device assembly 4916.
[00479] In an exemplary embodiment, the expandable tubular casing 4920 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j. In an exemplary embodiment, during the operation of the system
4900, the mounting pin 4918 permits torque to be transmitted between the expandable tubular casing 4920 and the expansion device assembly 4816. In an exemplary embodiment, the torque pin 4918 is fabricated from a drillable material such as, for example, brass or aluminum. In an exemplary embodiment, the sealing cup assembly 4914 sealingly engages the internal diameter of the expandable tubular casing 4920 during the operation of the system 4900.
[00480] An end of a tubular slotted sleeve 4921 that receives the end of the expansion device assembly 4916, including the adjustable expansion device 4916b, is coupled to an end of the expandable tubular casing 4920 and the other end of the tubular slotted sleeve includes a tapered end face 4921a. In several exemplary embodiments, the tubular slotted sleeve 4921 includes one or more perforations that may, for example, includes slots, circular holes, or other perforations.
[00481] An expandable tubular sleeve 4922 that includes a first end 4922a including a tapered external annular recess 4922aa that mates with the tapered end face 4921a of the tubular slotted sleeve 4921 , an external annular recess 4922ab spaced apart from the tapered external annular recess, an intermediate portion 4922b, and a second end 4922c having an internal threaded connection 4922d mates with and is received within the external annular recess 4916c of the expansion device assembly 4916. In an exemplary embodiment, the wall thickness of the first end 4922a of the expandable tubular sleeve 4922 is greater than the wall thickness of the second end 4922c of the expandable tubular sleeve, and the wall thickness of the intermediate portion 4922b of the expandable tubular sleeve is tapered. In an exemplary embodiment, the intermediate portion 4922b of the expandable tubular sleeve 4922 mates with and receives the external tapered surface 4916d of the expansion device assembly 4916. In an exemplary embodiment, the expandable tubular sleeve 4922 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j.
[00482] A sealing member 4924 is received within and coupled to the external annular recess 4922ab of the first end 4922a of the expandable tubular sleeve 4922. In an exemplary embodiment, the outside diameters of the intermediate portion 4922b and the second end 4922c of the tubular sleeve 4922 are both less than or equal to the maximum outside diameter of the expandable tubular casing 4920. In an exemplary embodiment, the outside diameter of the sealing member 4924 is less than or equal to the maximum outside diameter of the expandable tubular casing 4920.
[00483] A float shoe 4926 that defines a passage 4926a having a throat 4926aa and a passage 4926b and includes an external annular recess 4926c at one end that is received within and mates with the internal annular recess 4916e of the end of the expansion device assembly 4916, a plurality of circumferentially spaced apart shoulders 4926d at another end, a plurality of circumferentially spaced apart teeth 4926e for engaging the circumferentially spaced apart teeth 4916f of the end of the expansion device assembly 4916, and a conventional float element 4926f is received within, mates with, and is coupled to the internal threaded connection 4922d of the end of the expandable tubular sleeve 4922. In an exemplary embodiment, the outside diameter of the spaced apart shoulders 4926d of the float shoe 4926 are greater than the outside diameters of both the expandable tubular casing
4920 and the expandable tubular sleeve 4922. In an exemplary embodiment, during the operation of the system 4900, the interaction of the circumferentially spaced apart teeth
4926e of the float shoe 4926 with the circumferentially spaced apart teeth 4916f of the expansion device assembly 4916 permits torque loads to be transmitted there between. In an exemplary embodiment, during the operation of the system 4900, the circumferentially spaced apart shoulders 4926d further define circumferentially spaced apart axial flow passages there between.
[00484] In an exemplary embodiment, during operation of the system 4900, as illustrated in Fig. 49a, the system is positioned within a wellbore 4928 that traverses a subterranean formation 4930. In an exemplary embodiment, during operation of the system
4900, the tubular slotted sleeve 4921 prevents debris within the wellbore 4928 from damaging the adjustable expansion device 4916b of the expansion device assembly 4916.
A hardenable fluidic sealing material 4932 such as, for example, cement may then be injected into the system 4900 through the passages 4902a, 4904a, 4906a, 4908a, 4910a,
4912a, 4916a, and 4926a. The fluidic material 4932 may then be conveyed past the float element 4926f of the float shoe 4926 and through the passage 4926b into an annulus 4934 between the system 4900 and the interior surface of the wellbore 4928. The fluidic material
4932 within the annulus 4934 may then be allowed to at least partially cure.
[00485] In an exemplary embodiment, during the operation of the system 4900, as illustrated in Fig. 49b, a conventional plug 4936 is then positioned within the throat 4926aa of the passage 4926a of the float shoe 4926 by injecting fluidic material 4938 into the system
4900 through the passages 4902a, 4904a, 4906a, 4908a, 4910a, 4912a, and 4916a. As a result, the passage 4926a of the float shoe 4926 is blocked and the passages 4902a, 4904a,
4906a, 4908a, 4910a, 4912a, and 4916a may be pressurized by the continued injection of the fluidic material 4938.
[00486] In an exemplary embodiment, during the operation of the system 4900, as illustrated in Fig. 49c, the passages 4902a, 4904a, 4906a, 4908a, 4910a, 4912a and 4916a may be pressurized by the continued injection of the fluidic material 4938 into the system.
As a result, the casing lock assembly 4908 is operated to engage the expandable tubular casing 4920 and the outside diameter of the adjustable expansion device 4916b of the expansion device assembly 4916 is increased. As a result, the portion of the tubular slotted sleeve 4921 that receives the adjustable expansion device 4916b is radially expanded and plastically deformed. In an exemplary embodiment, the adjustable expansion device 4916b of the expansion device assembly 4916 includes one or more external expansion surfaces
4916ba for engaging and radially expanding and plastically deforming the tubular slotted sleeve 4921 and the expandable tubular casing 4920.
[00487] In an exemplary embodiment, during the operation of the system 4900, as illustrated in Fig. 49d, the passages 4902a, 4904a, 4906a, 4908a, 4910a, 4912a and 4916a may continue to be pressurized by the continued injection of the fluidic material 4938 into the system. As a result, the casing lock assembly 4908 continues to be operated to engage the expandable tubular casing 4920 and the tension actuator assembly 4910 is operated to displace the expansion device assembly 4916, expandable tubular sleeve 4922, sealing member 4924, and float shoe 4926 upwardly in a longitudinal direction 4940 relative to the expandable tubular casing 4920 and the tubular slotted sleeve 4921. As a result, the tubular slotted sleeve 4921 and the end of the expandable tubular casing 4920 are radially expanded and plastically deformed by the external expansion surfaces 4816ba of the adjustable expansion device 4816b of the expansion device assembly 4816. Furthermore, as a result, the tubular slotted sleeve 4921 engages the tapered end face of the shoulders
4926d of the float shoe 4926 and is thereby further radially expanded and plastically deformed. Furthermore, as a result, the radially expanded and plastically deformed end of the tubular casing 4920 receives and mates with the expandable tubular sleeve 4922 and the sealing member 4924. Furthermore, as a result, the mounting pin 4918 is sheared. In an exemplary embodiment, the end of the expandable tubular casing 4920 is radially expanded and plastically deformed by the external expansion surfaces 4916ba of the adjustable expansion device 4916b of the expansion device assembly 4916 until the end of the expandable tubular casing impacts the end faces of the shoulders 4926d of the float shoe 4926.
[00488] In an exemplary embodiment, during the operation of the system 4900, as illustrated in Fig. 49e, the passages 4902a, 4904a, 4906a, 4908a, 4910a, 4912a, and 4916a may continue to be pressurized by the continued injection of the fluidic material 4938 into the system. As a result, the casing lock assembly 4908 and the tension actuator assembly 4910 may continue to be operated in the manner described above with reference to Fig. 49d.
Furthermore, as a result, the adjustable expansion device 4916b of the expansion device assembly 4916 is further displaced upwardly in the longitudinal direction 4940 relative to the expandable tubular casing 4920, and the tapered external expansion surface 4916d of the expansion device assembly is displaced upwardly relative to the expandable tubular sleeve
4922, and the sealing member 4924 in the longitudinal direction 4938. Note that the further upward displacement of the expandable tubular sleeve 4922, the sealing member 4924, and the float shoe 4926, during the continued operation of the tension actuator assembly 4910, is prevented due to the interaction between the end of the expandable tubular casing 4920 and the end faces of the shoulders 4926d of the float shoe 4926. Furthermore, as a result, the end of the expandable tubular casing 4920 is further radially expanded and plastically deformed by the external expansion surfaces 4916ba of the adjustable expansion device
4916b of the expansion device assembly 4916, and portions, 4922a and 4922b, of the expandable tubular sleeve 4922 are radially expanded and plastically deformed by the tapered external expansion surface 4916d of the expansion device assembly within the end of the expandable tubular casing. As a result, the sealing member 4924 engages and fluidicly seals the interface between the expandable tubular casing 4920 and the expandable tubular sleeve 4922. Furthermore, in an exemplary embodiment, as a result of the radial expansion and plastic deformation of the portions, 4922a and 4922b, of the expandable tubular sleeve 4922 within the end of the expandable tubular casing 4920, a metal to metal, fluid tight seal is formed between the interior surface of the expandable tubular casing and the exterior surface of the expandable tubular sleeve. In an exemplary embodiment, once the portions, 4922a and 4922b, of the expandable tubular sleeve 4922 are completely radially expanded and plastically deformed by the tapered external expansion surface 4916d of the expansion device assembly 4916, the casing lock assembly 4908 releases the expandable tubular casing 4920.
[00489] In an exemplary embodiment, during the operation of the system 4900, as illustrated in Fig. 49f, following the release of the expandable tubular casing 4920 from the casing lock assembly 4908, the continued injection of the fluidic material 4938 into the passages of the system will further displace the adjustable expansion device 4916b of the expansion device assembly 4916 upwardly in the longitudinal direction 4940 relative to the expandable tubular casing 4920. In an exemplary embodiment, during the displacement of the adjustable expansion device 4916b of the expansion device assembly 4916 upwardly in the longitudinal direction 4940 relative to the expandable tubular casing 4920, the sealing cup assembly 4914 sealingly engage the internal surface of the expandable tubular casing
4920. As a result, the annulus within the expandable tubular casing 4920 below and proximate to the sealing cup assembly 4914 is pressurized by the injection of the fluidic material 4938 into the system 4900 thereby applying an upward axial force to the tubular support member 4912. As a result, the adjustable expansion device 4916b of the expansion device assembly 4916 is pulled through the expandable tubular casing 4920. As a result, the expandable tubular casing 4920 is further radially expanded and plastically deformed by the external expansion surfaces 4916ba of the adjustable expansion device 4916b of the expansion device assembly 4916.
[00490] In several alternative embodiments, the tension actuator assembly 4910 may be operated to radially expand and plastically deform the expandable tubular sleeve 4922 by operating the tension actuator assembly in a first stroke to radially expand and plastically deform a portion of the expandable tubular sleeve 4922. After completing the first stroke of the tension actuator assembly 4910, the casing lock assembly 4908 is operated to release the expandable tubular casing 4920, such as, for example, by reducing the operating pressure of the fluidic material 4938. The tension actuator assembly 4910 is then re-set to an initial position by displacing the tubular support member 4902, the tubular safety sub
4904, the ball gripper assembly 4906, the casing lock assembly 4908, and the portion of the tension actuator assembly rigidly coupled to the end of the casing lock assembly upwardly relative to the expandable tubular casing 4920. The operating pressure of the fluidic material 4938 is increased, and the tension actuator assembly 4910 is then operated in a second stroke to radially expand and plastically deform a further portion of the expandable tubular sleeve 4922. In several exemplary embodiments, this process may be repeated as often as required in order to radially expand and plastically deform the desired portions of the expandable tubular sleeve 4922. In an exemplary embodiment, during the first stroke, re-setting of, and/or the second stroke of the tension actuator assembly 4910, the ball gripper assembly 4906 is also operated to limit displacement of the expandable tubular casing 4920 in one or more longitudinal directions by, for example, adjusting the operating pressure of the fluidic material 4938.
[00491] In an exemplary embodiment, the maximum outside diameter of the system
4900, during the placement of the system within the wellbore 4928, is defined by the maximum outside diameter of the expandable tubular casing 4920. [00492] In several alternative embodiments, the system 4900 includes the ball gripper assembly 4906 and/or the casing lock assembly 4908.
[00493] In several alternative embodiments, the casing lock assembly 4908 is omitted from the system 4900. As a result, the system 4900 relies only upon the ball gripper assembly 4906 to limit displacement of the expandable tubular casing 4920.
[00494] In several exemplary embodiments of the system 4900, the operation of the ball gripper assembly 4906 and/or the casing lock assembly 4908 may be replaced with, or enhanced by, the use of conventional hydraulic or mechanical slips.
[00495] In several exemplary embodiments of the system 4900, the expandable tubular sleeve 4922 is fabricated from materials particularly suited to being removed using a drilling device such as, for example, aluminum or brass.
[00496] In several exemplary embodiments of the system 4900, the float shoe 4926 may include a sliding sleeve valve for controlling the flow of fluidic materials through the float shoe. In several exemplary embodiments of the system 4900, the end of the expansion device assembly 4916 includes a conventional stinger attached thereto for manipulating and thereby controlling the operation of the sliding sleeve valve.
[00497] In several exemplary embodiments, the sealing cup assembly 4914 may be positioned above or below the casing lock assembly 4908.
[00498] Referring to Figs. 50a, 50aa, and 50ab, an exemplary embodiment of a system 5000 for radially expanding a tubular member includes a tubular support member
5002 that defines a passage 5002a, one or more radial openings 5002b, and one or more mounting holes 5002c, and includes an internal annular recess 5002d, an internal annular recess 5002e, and an internal annular recess 5002f. An end of a tubular support member
5004 that defines a passage 5004a, a mounting hole 5004b, a radial passage 5004c, a radial passage 5004d, a radial passage 5004e, and mounting hole 5004f, and includes an external annular recess 5004g, an external annular recess 5004h, an external annular recess 5004i including external circumferentially spaced apart splines 5004j, an external threaded connection 5004k, an external threaded connection 5004I, an external flange
5004m, a tapered external flange 5004n including circumferentially spaced apart T-shaped slots 5004o, and an external flange 5004p at another end including circumferentially spaced apart teeth 5004q, is received within and mates with the internal annular recess 5002d of the tubular support member 5002. In an exemplary embodiment, the tapered external flange
5004n of the tubular support member 5004 includes a plurality of faceted surfaces 5004na.
[00499] Locking dogs 5006 that include internal spaced-apart flanges, 5006a and
5006b, external locking teeth 5006c, and spring arms, 5006d and 5006e, for biasing the locking dogs radially inwardly, are received within and mate with corresponding radial openings 5002b of the tubular support member 5002. A tubular locking dog retainer sleeve 5008 that includes external spaced-apart flanges, 5008a and 5008b, positioned in opposition to the spaced-apart flanges, 5006a and 5006b, respectively, of the locking dogs 5006 receives and mates with an end of the tubular support member 5004.
[00500] An end of an expandable tubular member 5010 that includes internal teeth
5010a for engaging the external locking teeth 5006c of the locking dogs, and an upset portion 5010b, having a locally reduced internal diameter, adjacent another end, receives and mates with the tubular support member 5002. In several exemplary embodiments, the tubular member 5010 is provided and includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j. An end of an expansion sleeve 5012 that includes an internal threaded connection 5012a at one end is coupled to the other end of the expandable tubular member 5010. In several exemplary embodiments, the expansion sleeve 5012 is fabricated from aluminum and/or brass and/or alloys of one or both and/or includes one or more of the properties of the expandable tubulars described above with reference to Figs. 1 to 46j.
[00501] An end of an emergency release tubular sleeve 5014 that defines a radial passage 5014a and includes an internal annular recess 5014b that mates with the tubular support member 5004 receives and mates with the external annular recess 5004g of the end of the tubular support member 5004. A rupture disk 5016 is positioned within and coupled to the mounting hole 5004b of the tubular support member 5004.
[00502] An end of a tubular load transfer sleeve 5018 that defines a mounting hole
5018a and includes an external flange 5018b and an internal flange 5018c, including circumferentially spaced apart internal splines 5018d that mate with the external splines
5004j of the tubular support member 5004, at another end, mates with, is coupled to, and is received within the internal annular recess 5002f of the end of the tubular support member
5002. A mounting pin 5020 is received within and coupled to the mounting hole 5002c of the tubular support member 5002 and the mounting hole 5018a of the sleeve 5018 for transmitting torque loads there between.
[00503] An upper tubular sealing cup retainer 5022 that includes an internal threaded connection 5022a that is coupled to the external threaded connection 5004k of the tubular support member 5004 and an angled end face 5022b and an external tapered flange 5022c at another end that engages the interior surface of the expandable tubular member 5010 is positioned proximate an end face of the external splines 5004j of the tubular support member 5004.
[00504] A float shoe 5024 defines a passage 5024a having a throat 5024aa and a passage 5024b and includes an external annular recess 5024c, circumferentially spaced apart teeth 5024d for engaging the circumferentially spaced apart teeth 5004q of the tubular support member 5004, an external threaded connection 5024e coupled to the internal threaded connection 5012a of the end of the expansion sleeve 5012, and a conventional float element 5024f. A lower tubular sealing cup retainer 5026 that defines a plurality of circumferentially spaced apart internal longitudinal passages 5026a includes an internal threaded connection 5026b that is coupled to the external threaded connection 5004I of the tubular support member 5004.
[00505] A lower tubular cup seal support 5028 that receives, mates with, and is coupled to the tubular support member 5004 is positioned proximate the lower tubular sealing cup retainer 5026. A lower cup seal 5030 that receives, mates with, and is coupled to the tubular support member 5004 and sealingly engages the interior surface of the expandable tubular member 5010 is positioned proximate the lower tubular sealing cup retainer 5026. A lower cup seal support 5032 receives, mates with, and is coupled to the tubular support member 5004 and receives, mates with, and supports the lower cup seal 5030. A lower back-up cup seal 5034 that receives, mates with, and is coupled to the tubular support member 5004 and sealingly engages the interior surface of the expandable tubular member 5010 receives and mates with the lower cup seal 5030 and the lower cup seal support 5032. A lower tubular cup seal support 5036 that receives, mates with, and is coupled to the tubular support member 5004 is positioned proximate to, mates with, and supports, the lower back-up cup seal 5034.
[00506] An upper tubular cup seal support 5038 that receives, mates with, and is coupled to the tubular support member 5004 is positioned proximate the lower tubular cup seal support 5036. An upper cup seal 5040 that receives, mates with, and is coupled to the tubular support member 5004 and sealingly engages the interior surface of the expandable tubular member 5010 is positioned proximate the upper tubular cup seal support 5038. An upper cup seal support 5042 receives, mates with, and is coupled to the tubular support member 5004 and receives, mates with, and supports the upper cup seal 5040. An upper back-up cup seal 5044 that receives, mates with, and is coupled to the tubular support member 5004 and sealingly engages the interior surface of the expandable tubular member 5010 receives and mates with the upper cup seal 5040 and the upper cup seal support 5042.
[00507] A tubular expansion cone retainer 5046 that defines circumferentially spaced apart internal passages 5046a that are fluidicly coupled to the circumferentially spaced apart internal longitudinal passages 5026a of the lower tubular sealing cup retainer 5026 and circumferentially spaced apart internal longitudinal passages 5046a and circumferentially spaced apart radially directed T-shaped grooves 5046b, and includes a tapered shoulder 5046c at one end and an internal annular recess 5046d that mates with and receives the external flange 5004m of the tubular support member 5004. A rupture disc 5048 is positioned within and coupled to the mounting hole 5004f of the tubular support member
5004.
[00508] Circumferentially spaced apart expansion cone segments 5050 include T- shaped mounting elements 5050a that are slidably received within and mate with corresponding T-shaped grooves 5046b of the tubular expansion cone retainer 5046 and T- shaped mounting elements 5050b that are slidably received within and mate with corresponding T-shaped slots 5004o of the tubular support member 5004. In an exemplary embodiment, each expansion cone segment 5050 is mounted upon a corresponding faceted surface 5004na of the tapered flange 5004n of the tubular support member 5004. In an exemplary embodiment, the expansion cone segments 5050 define a substantially contiguous outer expansion surface when displaced to a final radial outward position.
[00509] In an exemplary embodiment, the tubular support member 5004, the tubular expansion cone retainer 5046, and the expansion cone segments 5050 together provide an adjustable expansion device 5052. In several exemplary embodiments, the adjustable expansion device 5052, which provides expansion surfaces whose radial extent are adjustable, includes one or more elements of the adjustable expansion devices disclosed in
WIPO International Publication WO 03/023178 A2, the disclosure of which is incorporated herein by reference.
[00510] In an exemplary embodiment, during operation of the system 5000, as illustrated in Figs. 50a, 50aa, and 50ab, the system is positioned within a wellbore 5054 that traverses a subterranean formation 5056. A hardenable fluidic sealing material 5058 such as, for example, cement may then be injected into the system 5000 through the passages
5002a, 5004a, and 5024a. The fluidic material 5058 may then be conveyed past the float element 5024f of the float shoe 5024 and through the passage 5024b into an annulus 5060 between the system 5000 and the interior surface of the wellbore 5054. The fluidic material
5058 within the annulus 5060 may then be allowed to at least partially cure.
[00511] In an exemplary embodiment, during the operation of the system 5000, as illustrated in Fig. 50b, a conventional plug 5062 is then positioned within the throat 5024aa of the passage 5024a of the float shoe 5024 by injecting fluidic material 5064 into the system
5000 through the passages 5002a, 5004a, and 5024a. As a result, the passage 5024a of the float shoe 5024 is blocked and the passages 5002a and 5004a may be pressurized by the continued injection of the fluidic material 5064.
[00512] In an exemplary embodiment, during the operation of the system 5000, as illustrated in Figs. 50c, 50ca, and 50cb, the passages 5002a and 5002b may be pressurized by the continued injection of the fluidic material 5064 into the system. As a result, the rupture disc 5048 is burst thereby permitting the pressurized fluidic material 5064 to be conveyed through the radial passage 5004f of the tubular support member 5004 and into the annulus defined between the tubular support member 5004 and the tubular expansion cone retainer 5046. As a result, the expansion cone segments 5050 are displaced in a longitudinal direction 5066. As a result, because the expansion cone segments 5050 are slidably mounted for movement on the T-shaped slots 5004o of the tapered external flange
5004n of the tubular support member 5004, the expansion cone segments 5050 are also displaced outwardly in a radial direction and thereby engage and radially expand and plastically deform the expansion sleeve 5012. In an exemplary embodiment, the outward radial displacement of the expansion cone segments 5050 also radially expands and plastically deforms the expandable tubular member 5010. In this manner, the size of the adjustable expansion device 5052 is increased.
[00513] In an exemplary embodiment, during the operation of the system 5000, as illustrated in Fig. 50d, the passages 5002a and 5002b may continue to be pressurized by the continued injection of the fluidic material 5064 into the system. As a result, the pressurized fluidic material 5064 conveyed through the radial passage 5004f of the tubular support member 5004 and into the annulus defined between the tubular support member 5004 and the tubular expansion cone retainer 5046 pressurizes an annulus defined by the tubular support member 5004 and the expandable tubular member 5010 below the lower cup seal
5030. As a result, the pressurized fluidic material 5064 within the annulus defined by the tubular support member 5004 and the expandable tubular member 5010 below the lower cup seal 5030 applies a longitudinal force to the tubular support member 5004 in a direction
5068. As a result, the tubular support member 5004, the tubular sleeve 5014, and the locking dog retainer sleeve 5008 are displaced in the direction 5068 relative to the tubular support member 5002 and the locking dogs 5006 thereby releasing the flanges, 5006a and
5006b, of the locking dogs 5006 from engagement with the flanges, 5008a and 5008b, of the locking dog retainer sleeve 5008. As a result, the spring arms, 5006d and 5006e, of the locking dogs 5006 displace the locking dogs radially inward and out of locking engagement with the expandable tubular member 5010. In this manner, the tubular support member 5004 is pulled by the lower cup seal 5030 in the direction 5068 relative to the expandable tubular member 5010. Furthermore, in this manner, a further portion of the expandable tubular member 5010 is radially expanded and plastically deformed by the adjustable expansion device 5052.
[00514] In an exemplary embodiment, during the operation of the system 5000, as illustrated in Fig. 50e, the passages 5002a and 5002b may continue to be pressurized by the continued injection of the fluidic material 5064 into the system. As a result, the pressurized fluidic material 5064 conveyed through the radial passage 5004f of the tubular support member 5004 and into the annulus defined between the tubular support member 5004 and the tubular expansion cone retainer 5046 continues to pressurize the annulus defined by the tubular support member 5004 and the expandable tubular member 5010 below the lower cup seal 5030. As a result, the pressurized fluidic material 5064 within the annulus defined by the tubular support member 5004 and the expandable tubular member 5010 below the lower cup seal 5030 continues to apply a longitudinal force to the tubular support member
5004 in the direction 5068. As a result, the tubular support member 5004 and the adjustable expansion device 5052 are displaced in the direction 5068 relative to the expandable tubular member 5010 thereby radially expanding and plastically deforming the expandable tubular member.
[00515] In an exemplary embodiment, as illustrated in Fig. 50f, following the placement of the plug 5062 within the throat 5024aa of the passage 5024a of the float shoe
5024, the expandable tubular member 5010 may be released from engagement with the locking dogs 5006. In particular, following the placement of the plug 5062 within the throat
5024aa of the passage 5024a of the float shoe 5024, the operating pressure of the injected fluidic material 5064 may be increased sufficiently to burst the rupture disk 5016 thereby permitting the fluidic material to be conveyed through the passage 5004b into the annulus defined between the tubular support member 5004 and the emergency release tubular sleeve 5014. As a result, the emergency release tubular sleeve 5014 is displaced in a direction 5070 relative to the tubular support member 5004. As a result, the locking dog retainer sleeve 5008 is displaced in the direction 5070 relative to the locking dogs 5006 thereby releasing the flanges, 5006a and 5006b, of the locking dogs 5006 from engagement with the flanges, 5008a and 5008b, of the locking dog retainer sleeve 5008. As a result, the spring arms, 5006d and 5006e, of the locking dogs 5006 displace the locking dogs radially inward and out of locking engagement with the expandable tubular member 5010. In this manner, the expandable tubular member 5010 may be controliably released from engagement with the locking dogs 5006.
[00516] In several exemplary embodiments, the tubular support member 5002 includes one or more elements of a conventional safety sub.
[00517] In several exemplary embodiments, the tubular support member 5002, the tubular support member 5004, the locking dogs 5006, and the locking dog retainer sleeve
5008 provide a locking assembly for controliably locking the expandable tubular member
5010 to the tubular support member 5002. In several exemplary embodiments, conventional casing locking tools may be substituted for, or used in addition to, the locking assembly.
[00518] In several exemplary embodiments, the lower tubular cup seal support 5028, the lower cup seal 5030, the lower cup seal support 5032, the lower back-up cup seal 5034, the lower tubular cup seal support 5036, the upper tubular cup seal support 5038, the upper cup seal 5040, the upper cup seal support 5042, and the upper back-up cup seal 5044 provide a sealing assembly for sealing the interface between the tubular support member 5004 and the expandable tubular member 5010. In this manner, an annulus is defined between the tubular support member 5004 and the expandable tubular member 5010, below the sealing assembly, that may be pressurized thereby permitting the sealing assembly to apply a tensile upward force to the tubular support member 5004. In this manner, the tubular support member 5004 may be pulled upwardly out of the expandable tubular member 5010. Furthermore, in this manner, the adjustable expansion device 5052 may be pulled upwardly through the expandable tubular member 5010 to thereby radially expand and plastically deform the expandable tubular member.
[00519] In several exemplary embodiments, the adjustable expansion device 5052 is used to expand a portion of the expandable tubular member 5010 and/or the expandable sleeve 5012, and another expansion device, which may be fixed or adjustable in size, may be used to radially expand and plastically deform the remaining portions of the expandable tubular member and/or the expandable sleeve.
[00520] in several exemplary embodiments, the expandable sleeve 5012 is fabricated from a drillable material such as, for example, aluminum or copper, and is coupled to the end of the expandable tubular member 5010 by, for example, amorphous bonding. In an exemplary embodiment, the amount of force required to radially expand the expandable sleeve 5012 is significantly less than the amount of force required to radially expand the expandable tubular member 5010. In an exemplary embodiment, following the completion of the operations described above with reference to Figs. 50a to 50e, any unexpanded portions of the expandable sleeve 5012 are removed by, for example, drilling.
[00521] In an exemplary embodiment, the float element 5024f of the float shoe 5024 is fabricated from drillable materials such as, for example, aluminum, brass, composite materials, and/or concrete in order to facilitate its subsequent removal. In an exemplary embodiment, the float shoe 5024 includes a pressure balanced sliding sleeve valve, or other equivalent valve, to permit the control of the passage of fluidic materials through the passages of the float shoe, before or after the place of the plug 5062 within the throat
5024aa of the passage 5024a of the float shoe. In this manner, the hardenable fluidic sealing material 5058 may be injected into the annulus 5060 at any point during the operation of the system 5000.
[00522] In an alternative embodiment, the locking assembly may be released from engagement with the expandable tubular member 5010 before the size of the adjustable expansion device 5052 is increased.
[00523] In an exemplary embodiment, the adjustable expansion device 5052 includes a stinger for manipulating, and thereby controlling the operation of, the float shoe 5024.
[00524] In several exemplary embodiments, following the completion of the operations described above with reference to Figs. 50a to 50c, the tubular support members, 5002 and 5004, and the adjustably expansion device 5052 are lowered relative to the expandable tubular member 5010 and expandable sleeve 5012 thereby radially expanding and plastically deforming further portions of the expandable sleeve 5012. The adjustable expansion device 5052 is then displaced upwardly relative to the expandable tubular member as described above with reference to Figs. 50d and 50e.
[00525] In several exemplary embodiments, following the completion of the operations described above with reference to Figs. 50a to 50e, the tubular support members, 5002 and
5004, and the adjustably expansion device 5052 are lowered relative to the expandable tubular member 5010 and expandable sleeve 5012 thereby radially expanding and plastically deforming further portions of the expandable sleeve 5012.
[00526] In several exemplary embodiments, the operations of Figs. 50a to 50e may be repeated by overlapping a second expandable tubular member with the expandable tubular member 5010. In this manner, a wellbore casing, including a plurality of overlapping radially expanded wellbore casings, may be provided that has a constant internal diameter.
[00527] A method of forming a tubular liner within a preexisting structure has been described that includes positioning a tubular assembly within the preexisting structure; and radially expanding and plastically deforming the tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the method further includes positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings include the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings include the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members include the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings include slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly is a first steel alloy including: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si, 0.01 % Cu, 0.01 %
Ni, and 0.02 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a second steel alloy including: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 % Si, 0.01 %
Cu, 0.01 % Ni, and 0.03 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a third steel alloy including: 0.08 % C, 0.82 % Mn, 0.006 % P,
0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a fourth steel alloy including: 0.02 %
C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about
61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36. In an exemplary embodiment, a yield point of an inner tubular portion of at least a portion of the tubular assembly is less than a yield point of an outer tubular portion of the portion of the tubular assembly. In an exemplary embodiment, yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a transitional phase structure. In an exemplary embodiment, the hard phase structure comprises martensite. In an exemplary embodiment, the soft phase structure comprises ferrite. In an exemplary embodiment, the transitional phase structure comprises retained austentite. In an exemplary embodiment, the hard phase structure comprises martensite; wherein the soft phase structure comprises ferrite; and wherein the transitional phase structure comprises retained austentite. In an exemplary embodiment, the portion of the tubular assembly comprising a microstructure comprising a hard phase structure and a soft phase structure comprises, by weight percentage, about 0.1% C, about 1.2% Mn, and about 0.3% Si.
[00528] An expandable tubular member has been described that includes a steel alloy including: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr. In an exemplary embodiment, a yield point of the tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and a yield point of the tubular member is at least about 65.9 ksi after the radial expansion and plastic deformation.
In an exemplary embodiment, the yield point of the tubular member after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the tubular member prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00529] An expandable tubular member has been described that includes a steel alloy including: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr. In an exemplary embodiment, a yield point of the tubular member is at most about 57.8 ksi prior to a radial expansion and plastic deformation; and the yield point of the tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation.
In an exemplary embodiment, a yield point of the of the tubular member after a radial expansion and plastic deformation is at least about 28 % greater than the yield point of the tubular member prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00530] An expandable tubular member has been described that includes a steel alloy including: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr. In an exemplary embodiment, the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00531] An expandable tubular member has been described that includes a steel alloy including: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr.
In an exemplary embodiment, the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00532] An expandable tubular member has been described, wherein the yield point of the expandable tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00533] An expandable tubular member has been described, wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about
40 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00534] An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00535] An expandable tubular member has been described, wherein the yield point of the expandable tubular member is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00536] An expandable tubular member has been described, wherein the yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 28 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00537] An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00538] An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00539] An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00540] An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00541] An expandable tubular member has been described, wherein the yield point of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support. [00542] An expandable tubular member has been described, wherein the expandability coefficient of the expandable tubular member, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00543] An expandable tubular member has been described, wherein the expandability coefficient of the expandable tubular member is greater than the expandability coefficient of another portion of the expandable tubular member. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00544] An expandable tubular member has been described, wherein the tubular member has a higher ductility and a lower yield point prior to a radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00545] A method of radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member has been described that includes radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00546] A system for radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member has been described that includes means for radially expanding the tubular assembly within a preexisting structure; and means for using less power to radially expand each unit length of the first tubular member than required to radially expand each unit length of the second tubular member. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00547] A method of manufacturing a tubular member has been described that includes processing a tubular member until the tubular member is characterized by one or more intermediate characteristics; positioning the tubular member within a preexisting structure; and processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the preexisting structure includes a wellbore that traverses a subterranean formation. In an exemplary embodiment, the characteristics are selected from a group consisting of yield point and ductility. In an exemplary embodiment, processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics includes: radially expanding and plastically deforming the tubular member within the preexisting structure.
[00548] An apparatus has been described that includes an expandable tubular assembly; and an expansion device coupled to the expandable tubular assembly; wherein a predetermined portion of the expandable tubular assembly has a lower yield point than another portion of the expandable tubular assembly. In an exemplary embodiment, the expansion device includes a rotary expansion device, an axially displaceable expansion device, a reciprocating expansion device, a hydroforming expansion device, and/or an impulsive force expansion device. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point than another portion of the expandable tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility than another portion of the expandable tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point than another portion of the expandable tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of predetermined portions of the tubular assembly.
In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots.
In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1 In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1 ; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than
0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a first steel alloy including: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si,
0.01 % Cu, 0.01 % Ni, and 0.02 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is about
1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a second steel alloy including: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 %
Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a third steel alloy including: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 % S,
0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a fourth steel alloy including: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and
18.7 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than
0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36. In an exemplary embodiment, a yield point of an inner tubular portion of at least a portion of the tubular assembly is less than a yield point of an outer tubular portion of the portion of the tubular assembly. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an nonlinear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a transitional phase structure. In an exemplary embodiment, wherein the hard phase structure comprises martensite. In an exemplary embodiment, wherein the soft phase structure comprises ferrite. In an exemplary embodiment, wherein the transitional phase structure comprises retained austentite. In an exemplary embodiment, the hard phase structure comprises martensite; wherein the soft phase structure comprises ferrite; and wherein the transitional phase structure comprises retained austentite. In an exemplary embodiment, the portion of the tubular assembly comprising a microstructure comprising a hard phase structure and a soft phase structure comprises, by weight percentage, about 0.1% C, about 1.2% Mn, and about 0.3% Si. In an exemplary embodiment, at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, the portion of the tubular assembly comprises, by weight percentage, 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni,
0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01 %Ti. In an exemplary embodiment, the portion of the tubular assembly comprises, by weight percentage, 0.18% C, 1.28% Mn,
0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03%
Nb, and 0.01 %Ti. In an exemplary embodiment, the portion of the tubular assembly comprises, by weight percentage, 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si,
0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01 % Nb, and 0.01 %Ti. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: martensite, peariite, vanadium carbide, nickel carbide, or titanium carbide. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: peariite or peariite striation. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: grain peariite, widmanstatten martensite, vanadium carbide, nickel carbide, or titanium carbide. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: ferrite, grain peariite, or martensite. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: ferrite, martensite, or bainite. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: bainite, peariite, or ferrite. In an exemplary embodiment, the portion of the tubular assembly comprises a yield strength of about 67ksi and a tensile strength of about 95 ksi. In an exemplary embodiment, the portion of the tubular assembly comprises a yield strength of about 82 ksi and a tensile strength of about 130 ksi. In an exemplary embodiment, the portion of the tubular assembly comprises a yield strength of about 60 ksi and a tensile strength of about 97 ksi.
[00549] An expandable tubular member has been described, wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about
5.8 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00550] A method of determining the expandability of a selected tubular member has been described that includes determining an anisotropy value for the selected tubular member, determining a strain hardening value for the selected tubular member; and multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member. In an exemplary embodiment, an anisotropy value greater than 0.12 indicates that the tubular member is suitable for radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
[00551] A method of radially expanding and plastically deforming tubular members has been described that includes selecting a tubular member; determining an anisotropy value for the selected tubular member; determining a strain hardening value for the selected tubular member; multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member; and if the anisotropy value is greater than 0.12, then radially expanding and plastically deforming the selected tubular member. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, radially expanding and plastically deforming the selected tubular member includes: inserting the selected tubular member into a preexisting structure; and then radially expanding and plastically deforming the selected tubular member. In an exemplary embodiment, the preexisting structure includes a wellbore that traverses a subterranean formation.
[00552] A radially expandable multiple tubular member apparatus has been described that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; a sleeve overlapping and coupling the first and second tubular members at the joint; the sleeve having opposite tapered ends and a flange engaged in a recess formed in an adjacent tubular member; and one of the tapered ends being a surface formed on the flange. In an exemplary embodiment, the recess includes a tapered wall in mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the sleeve includes a flange at each tapered end and each tapered end is formed on a respective flange. In an exemplary embodiment, each tubular member includes a recess. In an exemplary embodiment, each flange is engaged in a respective one of the recesses. In an exemplary embodiment, each recess includes a tapered wall in mating engagement with the tapered end formed on a respective one of the flanges. [00553] A method of joining radially expandable multiple tubular members has also been described that includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange; and mounting the sleeve for overlapping and coupling the first and second tubular members at the joint, wherein the flange is engaged in a recess formed in an adjacent one of the tubular members. In an exemplary embodiment, the method further includes providing a tapered wall in the recess for mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the method further includes providing a flange at each tapered end wherein each tapered end is formed on a respective flange. In an exemplary embodiment, the method further includes providing a recess in each tubular member. In an exemplary embodiment, the method further includes engaging each flange in a respective one of the recesses. In an exemplary embodiment, the method further includes providing a tapered wall in each recess for mating engagement with the tapered end formed on a respective one of the flanges.
[00554] A radially expandable multiple tubular member apparatus has been described that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein at least a portion of the sleeve is comprised of a frangible material.
[00555] A radially expandable multiple tubular member apparatus has been described that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein the wall thickness of the sleeve is variable. [00556] A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve comprising a frangible material; and mounting the sleeve for overlapping and coupling the first and second tubular members at the joint. [00557] A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve comprising a variable wall thickness; and mounting the sleeve for overlapping and coupling the first and second tubular members at the joint.
[00558] An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for increasing the axial compression loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
[00559] An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for increasing the axial tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
[00560] An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for increasing the axial compression and tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
[00561] An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for avoiding stress risers in the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
[00562] An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
[00563] In several exemplary embodiments of the apparatus described above, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
[00564] In several exemplary embodiments of the method described above, the method further includes maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression before, during, and/or after the radial expansion and plastic deformation of the first and second tubular members. [00565] An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, a first threaded connection for coupling a portion of the first and second tubular members, a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members, a tubular sleeve coupled to and receiving end portions of the first and second tubular members, and a sealing element positioned between the first and second spaced apart threaded connections for sealing an interface between the first and second tubular member, wherein the sealing element is positioned within an annulus defined between the first and second tubular members. In an exemplary embodiment, the annulus is at least partially defined by an irregular surface. In an exemplary embodiment, the annulus is at least partially defined by a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material.
[00566] A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, providing a second tubular member, providing a sleeve, mounting the sleeve for overlapping and coupling the first and second tubular members, threadably coupling the first and second tubular members at a first location, threadably coupling the first and second tubular members at a second location spaced apart from the first location, and sealing an interface between the first and second tubular members between the first and second locations using a compressible sealing element. In an exemplary embodiment, the sealing element includes an irregular surface. In an exemplary embodiment, the sealing element includes a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material.
[00567] An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, a first threaded connection for coupling a portion of the first and second tubular members, a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members, and a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members. In an exemplary embodiment, at least one of the tubular sleeves is positioned in opposing relation to the first threaded connection; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded connection. In an exemplary embodiment, at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded connections. [00568] A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, providing a second tubular member, threadably coupling the first and second tubular members at a first location, threadably coupling the first and second tubular members at a second location spaced apart from the first location, providing a plurality of sleeves, and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members. In an exemplary embodiment, at least one of the tubular sleeves is positioned in opposing relation to the first threaded coupling; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded coupling. In an exemplary embodiment, at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded couplings.
[00569] An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, and a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members.
[00570] A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, providing a second tubular member, providing a plurality of sleeves, coupling the first and second tubular members, and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members.
[00571] An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, a threaded connection for coupling a portion of the first and second tubular members, and a tubular sleeves coupled to and receiving end portions of the first and second tubular members, wherein at least a portion of the threaded connection is upset. In an exemplary embodiment, at least a portion of tubular sleeve penetrates the first tubular member.
[00572] A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, providing a second tubular member, threadably coupling the first and second tubular members, and upsetting the threaded coupling. In an exemplary embodiment, the first tubular member further comprises an annular extension extending therefrom, and the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member. In an exemplary embodiment, the first tubular member further comprises an annular extension extending therefrom; and the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member.
[00573] A radially expandable multiple tubular member apparatus has been described that includes a first tubular member, a second tubular member engaged with the first tubular member forming a joint, a sleeve overlapping and coupling the first and second tubular members at the joint, and one or more stress concentrators for concentrating stresses in the joint. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve. [00574] A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, engaging a second tubular member with the first tubular member to form a joint, providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange, and concentrating stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member, the second tubular member, and the sleeve to concentrate stresses within the joint.
[00575] A system for radially expanding and plastically deforming a first tubular member coupled to a second tubular member by a mechanical connection has been described that includes means for radially expanding the first and second tubular members, and means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members.
[00576] A system for radially expanding and plastically deforming a first tubular member coupled to a second tubular member by a mechanical connection has been described that includes means for radially expanding the first and second tubular members; and means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members.
[00577] A system for radially expanding and plastically deforming a first tubular member coupled to a second tubular member by a mechanical connection has been described that includes means for radially expanding the first and second tubular members; means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members; and means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members.
[00578] A radially expandable tubular member apparatus has been described that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus. In an exemplary embodiment, the carbon content of the predetermined portion of the apparatus is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the apparatus is less than 0.21.
In an exemplary embodiment, the carbon content of the predetermined portion of the apparatus is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the apparatus is less than 0.36. In an exemplary embodiment, the apparatus further includes means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members; and means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes one or more stress concentrators for concentrating stresses in the joint. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member.
In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, the first tubular member further comprises an annular extension extending therefrom; and wherein the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member. In an exemplary embodiment, the apparatus further includes a threaded connection for coupling a portion of the first and second tubular members; wherein at least a portion of the threaded connection is upset. In an exemplary embodiment, at least a portion of tubular sleeve penetrates the first tubular member. In an exemplary embodiment, the apparatus further includes means for increasing the axial compression loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for increasing the axial tension loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for increasing the axial compression and tension loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for avoiding stress risers in the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for increasing the axial compression loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for increasing the axial tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for increasing the axial compression and tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for avoiding stress risers in the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, at least a portion of the sleeve is comprised of a frangible material. In an exemplary embodiment, the wall thickness of the sleeve is variable. In an exemplary embodiment, the predetermined portion of the apparatus has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the apparatus further includes positioning another apparatus within the preexisting structure in overlapping relation to the apparatus; and radially expanding and plastically deforming the other apparatus within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the apparatus, a predetermined portion of the other apparatus has a lower yield point than another portion of the other apparatus. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the apparatus is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of spaced apart predetermined portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of other portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of spaced apart other portions of the apparatus. In an exemplary embodiment, the apparatus comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the apparatus; and wherein the tubular members comprise the other portion of the apparatus. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the apparatus. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1 ; and wherein the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the predetermined portion of the apparatus comprises a first steel alloy comprising: 0.065 %
C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the apparatus comprises a second steel alloy comprising: 0.18 %
C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the apparatus comprises a third steel alloy comprising: 0.08 % C,
0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the apparatus comprises a fourth steel alloy comprising: 0.02 %
C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.04.
In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus is greater than the expandability coefficient of the other portion of the apparatus. In an exemplary embodiment, the apparatus comprises a wellbore casing. In an exemplary embodiment, the apparatus comprises a pipeline. In an exemplary embodiment, the apparatus comprises a structural support.
[00579] A radially expandable tubular member apparatus has been described that includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; a sleeve overlapping and coupling the first and second tubular members at the joint; the sleeve having opposite tapered ends and a flange engaged in a recess formed in an adjacent tubular member; and one of the tapered ends being a surface formed on the flange; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus. In an exemplary embodiment, the recess includes a tapered wall in mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the sleeve includes a flange at each tapered end and each tapered end is formed on a respective flange. In an exemplary embodiment, each tubular member includes a recess. In an exemplary embodiment, each flange is engaged in a respective one of the recesses. In an exemplary embodiment, each recess includes a tapered wall in mating engagement with the tapered end formed on a respective one of the flanges. In an exemplary embodiment, the predetermined portion of the apparatus has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the apparatus further includes positioning another apparatus within the preexisting structure in overlapping relation to the apparatus; and radially expanding and plastically deforming the other apparatus within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the apparatus, a predetermined portion of the other apparatus has a lower yield point than another portion of the other apparatus. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the apparatus is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of spaced apart predetermined portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of other portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of spaced apart other portions of the apparatus. In an exemplary embodiment, the apparatus comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the apparatus; and wherein the tubular members comprise the other portion of the apparatus. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the apparatus. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1 ; and wherein the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the predetermined portion of the apparatus comprises a first steel alloy comprising: 0.065 %
C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the apparatus comprises a second steel alloy comprising: 0.18 %
C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the apparatus comprises a third steel alloy comprising: 0.08 % C,
0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the apparatus comprises a fourth steel alloy comprising: 0.02 %
C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.04.
In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus is greater than the expandability coefficient of the other portion of the apparatus. In an exemplary embodiment, the apparatus comprises a wellbore casing. In an exemplary embodiment, the apparatus comprises a pipeline. In an exemplary embodiment, the apparatus comprises a structural support.
[00580] A method of joining radially expandable tubular members has been provided that includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36. In an exemplary embodiment, the method further includes: maintaining portions of the first and second tubular member in circumferential compression following a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the method further includes: concentrating stresses within the joint during a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the method further includes: maintaining portions of the first and second tubular member in circumferential compression following a radial expansion and plastic deformation of the first and second tubular members; and concentrating stresses within the joint during a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the method further includes: concentrating stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member, the second tubular member, and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, at least a portion of the sleeve is comprised of a frangible material. In an exemplary embodiment, the sleeve comprises a variable wall thickness. In an exemplary embodiment, the method further includes maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression. In an exemplary embodiment, the method further includes maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression. In an exemplary embodiment, the method further includes: maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression. In an exemplary embodiment, the method further includes: threadably coupling the first and second tubular members at a first location; threadably coupling the first and second tubular members at a second location spaced apart from the first location; providing a plurality of sleeves; and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members. In an exemplary embodiment, at least one of the tubular sleeves is positioned in opposing relation to the first threaded coupling; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded coupling. In an exemplary embodiment, at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded couplings. In an exemplary embodiment, the method further includes: threadably coupling the first and second tubular members; and upsetting the threaded coupling. In an exemplary embodiment, the first tubular member further comprises an annular extension extending therefrom; and wherein the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly. In an exemplary embodiment, the method further includes: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises an end portion of the tubular assembly.
In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots.
In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1 ; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than
0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24
% Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40
% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18 % C, 1.28 % Mn,
0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 %
Ni, and 18.7 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about
1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about
1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a wellbore casing. In an exemplary embodiment, the tubular assembly comprises a pipeline. In an exemplary embodiment, the tubular assembly comprises a structural support.
[00581] A method of joining radially expandable tubular members has been described that includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint, wherein the flange is engaged in a recess formed in an adjacent one of the tubular members; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly. In an exemplary embodiment, the method further includes: providing a tapered wall in the recess for mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the method further includes: providing a flange at each tapered end wherein each tapered end is formed on a respective flange. In an exemplary embodiment, the method further includes: providing a recess in each tubular member. In an exemplary embodiment, the method further includes: engaging each flange in a respective one of the recesses. In an exemplary embodiment, the method further includes: providing a tapered wall in each recess for mating engagement with the tapered end formed on a respective one of the flanges. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly. In an exemplary embodiment, the method further includes: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises an end portion of the tubular assembly.
In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots.
In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1 ; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than
0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24
% Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40
% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18 % C, 1.28 % Mn,
0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 %
Ni, and 18.7 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about
1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about
1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a wellbore casing. In an exemplary embodiment, the tubular assembly comprises a pipeline. In an exemplary embodiment, the tubular assembly comprises a structural support.
[00582] An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; a first threaded connection for coupling a portion of the first and second tubular members; a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members; a tubular sleeve coupled to and receiving end portions of the first and second tubular members; and a sealing element positioned between the first and second spaced apart threaded connections for sealing an interface between the first and second tubular member; wherein the sealing element is positioned within an annulus defined between the first and second tubular members; and wherein, prior to a radial expansion and plastic deformation of the assembly, a predetermined portion of the assembly has a lower yield point than another portion of the apparatus. In an exemplary embodiment, the predetermined portion of the assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the assembly has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the assembly further includes: positioning another assembly within the preexisting structure in overlapping relation to the assembly; and radially expanding and plastically deforming the other assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the assembly, a predetermined portion of the other assembly has a lower yield point than another portion of the other assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other assembly. In an exemplary embodiment, the predetermined portion of the assembly comprises an end portion of the assembly. In an exemplary embodiment, the predetermined portion of the assembly comprises a plurality of predetermined portions of the assembly. In an exemplary embodiment, the predetermined portion of the assembly comprises a plurality of spaced apart predetermined portions of the assembly. In an exemplary embodiment, the other portion of the assembly comprises an end portion of the assembly. In an exemplary embodiment, the other portion of the assembly comprises a plurality of other portions of the assembly. In an exemplary embodiment, the other portion of the assembly comprises a plurality of spaced apart other portions of the assembly. In an exemplary embodiment, the assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the assembly; and wherein the tubular members comprise the other portion of the assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the assembly. In an exemplary embodiment, the predetermined portion of the assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the assembly is greater than
0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the assembly is greater than 1 ; and wherein the strain hardening exponent for the predetermined portion of the assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the assembly comprises a first steel alloy comprising: 0.065 %
C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the assembly comprises a second steel alloy comprising: 0.18 % C,
1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the assembly comprises a third steel alloy comprising: 0.08 % C,
0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the assembly comprises a fourth steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation.
In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the assembly is greater than the expandability coefficient of the other portion of the assembly. In an exemplary embodiment, the assembly comprises a wellbore casing. In an exemplary embodiment, the assembly comprises a pipeline. In an exemplary embodiment, the assembly comprises a structural support. In an exemplary embodiment, the annulus is at least partially defined by an irregular surface. In an exemplary embodiment, the annulus is at least partially defined by a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material.
[00583] A method of joining radially expandable tubular members is provided that includes providing a first tubular member; providing a second tubular member; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members; threadably coupling the first and second tubular members at a first location; threadably coupling the first and second tubular members at a second location spaced apart from the first location; sealing an interface between the first and second tubular members between the first and second locations using a compressible sealing element, wherein the first tubular member, second tubular member, sleeve, and the sealing element define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly. In an exemplary embodiment, the sealing element includes an irregular surface. In an exemplary embodiment, the sealing element includes a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly. In an exemplary embodiment, the method further includes: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1 ; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 %
S, 0.24 % Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01
% Ni, and 0.03 % Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003
% S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02 % C, 1.31 %
Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about
61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a wellbore casing. In an exemplary embodiment, the tubular assembly comprises a pipeline. In an exemplary embodiment, the tubular assembly comprises a structural support. In an exemplary embodiment, the sleeve comprises: a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members. In an exemplary embodiment, the first tubular member comprises a first threaded connection; wherein the second tubular member comprises a second threaded connection; wherein the first and second threaded connections are coupled to one another; wherein at least one of the tubular sleeves is positioned in opposing relation to the first threaded connection; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded connection. In an exemplary embodiment, the first tubular member comprises a first threaded connection; wherein the second tubular member comprises a second threaded connection; wherein the first and second threaded connections are coupled to one another; and wherein at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded connections. In an exemplary embodiment, the carbon content of the tubular member is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.21. In an exemplary embodiment, the tubular member comprises a wellbore casing.
[00584] An expandable tubular member has been described, wherein the carbon content of the tubular member is greater than 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.36. In an exemplary embodiment, the tubular member comprises a wellbore casing.
[00585] A method of selecting tubular members for radial expansion and plastic deformation has been described that includes: selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is less than or equal to 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.21 , then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
[00586] A method of selecting tubular members for radial expansion and plastic deformation has been described that includes: selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is greater than 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.36, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
[00587] An expandable tubular member has been described that includes: a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body.
In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
[00588] A method of manufacturing an expandable tubular member has been described that includes: providing a tubular member; heat treating the tubular member; and quenching the tubular member; wherein following the quenching, the tubular member comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, the provided tubular member comprises, by weight percentage,
0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05%
V, 0.01% Mo, 0.01% Nb, and 0.01 %Ti. In an exemplary embodiment, the provided tubular member comprises, by weight percentage, 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,
0.29% Si, 0.01% Cu, 0.01 % Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01 %Ti. In an exemplary embodiment, the provided tubular member comprises, by weight percentage,
0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03%
V, 0.03% Mo, 0.01% Nb, and 0.01 %Ti. In an exemplary embodiment, the provided tubular member comprises a microstructure comprising one or more of the following: martensite, peariite, vanadium carbide, nickel carbide, or titanium carbide. In an exemplary embodiment, the provided tubular member comprises a microstructure comprising one or more of the following: peariite or peariite striation. In an exemplary embodiment, the provided tubular member comprises a microstructure comprising one or more of the following: grain peariite, widmanstatten martensite, vanadium carbide, nickel carbide, or titanium carbide. In an exemplary embodiment, the heat treating comprises heating the provided tubular member for about 10 minutes at 790 °C. In an exemplary embodiment, the quenching comprises quenching the heat treated tubular member in water. In an exemplary embodiment, following the quenching, the tubular member comprises a microstructure comprising one or more of the following: ferrite, grain peariite, or martensite. In an exemplary embodiment, following the quenching, the tubular member comprises a microstructure comprising one or more of the following: ferrite, martensite, or bainite. In an exemplary embodiment, following the quenching, the tubular member comprises a microstructure comprising one or more of the following: bainite, peariite, or ferrite. In an exemplary embodiment, following the quenching, the tubular member comprises a yield strength of about 67ksi and a tensile strength of about 95 ksi. In an exemplary embodiment, following the quenching, the tubular member comprises a yield strength of about 82 ksi and a tensile strength of about 130 ksi. In an exemplary embodiment, following the quenching, the tubular member comprises a yield strength of about 60 ksi and a tensile strength of about 97 ksi. In an exemplary embodiment, the method further includes: positioning the quenched tubular member within a preexisting structure; and radially expanding and plastically deforming the tubular member within the preexisting structure.
[00589] A method of radially expanding a tubular assembly has been described that includes radially expanding and plastically deforming a lower portion of the tubular assembly by pressurizing the interior of the lower portion of the tubular assembly; and then, radially expanding and plastically deforming the remaining portion of the tubular assembly by contacting the interior of the tubular assembly with an expansion device. In an exemplary embodiment, the expansion device is an adjustable expansion device. In an exemplary embodiment, the expansion device is a hydroforming expansion device. In an exemplary embodiment, the expansion device is a rotary expansion device. In an exemplary embodiment, the lower portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the remaining portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
In an exemplary embodiment, the lower portion of the tubular assembly includes a shoe defining a valveable passage.
[00590] A system for radially expanding a tubular assembly has been described that includes means for radially expanding and plastically deforming a lower portion of the tubular assembly by pressurizing the interior of the lower portion of the tubular assembly; and then, means for radially expanding and plastically deforming the remaining portion of the tubular assembly by contacting the interior of the tubular assembly with an expansion device. In an exemplary embodiment, the lower portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the remaining portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
[00591] A method of repairing a tubular assembly has been described that includes positioning a tubular patch within the tubular assembly; and radially expanding and plastically deforming a tubular patch into engagement with the tubular assembly by pressurizing the interior of the tubular patch. In an exemplary embodiment, the tubular patch has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. [00592] A system for repairing a tubular assembly has been described that includes means for positioning a tubular patch within the tubular assembly; and means for radially expanding and plastically deforming a tubular patch into engagement with the tubular assembly by pressurizing the interior of the tubular patch. In an exemplary embodiment, the tubular patch has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. [00593] A method of radially expanding a tubular member has been described that includes accumulating a supply of pressurized fluid; and controliably injecting the pressurized fluid into the interior of the tubular member. In an exemplary embodiment, accumulating the supply of pressurized fluid includes: monitoring the operating pressure of the accumulated fluid; and if the operating pressure of the accumulated fluid is less than a predetermined amount, injecting pressurized fluid into the accumulated fluid. In an exemplary embodiment, controliably injecting the pressurized fluid into the interior of the tubular member includes: monitoring the operating condition of the tubular member; and if the tubular member has been radial expanded, releasing the pressurized fluid from the interior of the tubular member.
[00594] A system for radially expanding a tubular member has been described that includes means for accumulating a supply of pressurized fluid; and means for controliably injecting the pressurized fluid into the interior of the tubular member. In an exemplary embodiment, means for accumulating the supply of pressurized fluid includes: means for monitoring the operating pressure of the accumulated fluid; and if the operating pressure of the accumulated fluid is less than a predetermined amount, means for injecting pressurized fluid into the accumulated fluid. In an exemplary embodiment, means for controliably injecting the pressurized fluid into the interior of the tubular member includes: means for monitoring the operating condition of the tubular member; and if the tubular member has been radial expanded, means for releasing the pressurized fluid from the interior of the tubular member.
[00595] An apparatus for radially expanding a tubular member has been described that includes a fluid reservoir; a pump for pumping fluids out of the fluid reservoir; an accumulator for receiving and accumulating the fluids pumped from the reservoir; a flow control valve for controliably releasing the fluids accumulated within the reservoir; and an expansion element for engaging the interior of the tubular member to define a pressure chamber within the tubular member and receiving the released accumulated fluids into the pressure chamber.
[00596] An apparatus for radially expanding a tubular member has been described that includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device; and an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
In an exemplary embodiment, the apparatus further includes: means for transmitting torque between the expandable tubular member and the tubular support member. In an exemplary embodiment, the apparatus further includes: means for sealing the interface between the expandable tubular member and the tubular support member. In an exemplary embodiment, the apparatus further includes: another tubular support member received within the tubular support member releasably coupled to the expandable tubular member. In an exemplary embodiment, the apparatus further includes: means for transmitting torque between the expandable tubular member and the other tubular support member. In an exemplary embodiment, the apparatus further includes: means for transmitting torque between the other tubular support member and the tubular support member. In an exemplary embodiment, the apparatus further includes: means for sealing the interface between the other tubular support member and the tubular support member. In an exemplary embodiment, the apparatus further includes: means for sealing the interface between the expandable tubular member and the tubular support member. In an exemplary embodiment, the apparatus further includes: means for sensing the operating pressure within the other tubular support member. In an exemplary embodiment, the apparatus further includes: means for pressurizing the interior of the other tubular support member. In an exemplary embodiment, further includes: means for limiting axial displacement of the other tubular support member relative to the tubular support member. In an exemplary embodiment, the apparatus further includes: a tubular liner coupled to an end of the expandable tubular member. In an exemplary embodiment, the apparatus further includes: a tubular liner coupled to an end of the expandable tubular member.
[00597] An apparatus for radially expanding a tubular member has been described that includes: an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device; an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member; means for transmitting torque between the expandable tubular member and the tubular support member; means for sealing the interface between the expandable tubular member and the tubular support member; another tubular support member received within the tubular support member releasably coupled to the expandable tubular member; means for transmitting torque between the expandable tubular member and the other tubular support member; means for transmitting torque between the other tubular support member and the tubular support member; means for sealing the interface between the other tubular support member and the tubular support member; means for sealing the interface between the expandable tubular member and the tubular support member; means for sensing the operating pressure within the other tubular support member; means for pressurizing the interior of the other tubular support member; means for limiting axial displacement of the other tubular support member relative to the tubular support member; and a tubular liner coupled to an end of the expandable tubular member; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
[00598] A method for radially expanding a tubular member has been described that includes positioning a tubular member and an adjustable expansion device within a preexisting structure; radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; increasing the size of the adjustable expansion device; and radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member. In an exemplary embodiment, the method further includes sensing an operating pressure within the tubular member. In an exemplary embodiment, wherein radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member includes: injecting fluidic material into the tubular member; sensing the operating pressure of the injected fluidic material; and if the operating pressure of the injected fluidic material exceeds a predetermined value, permitting the fluidic material to enter a pressure chamber defined within the tubular member. In an exemplary embodiment, at least a portion of the tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the portion of the tubular member comprises the pressurized portion of the tubular member.
[00599] A system for radially expanding a tubular member has been described that includes means for positioning a tubular member and an adjustable expansion device within a preexisting structure; means for radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; means for increasing the size of the adjustable expansion device; and means for radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member. In an exemplary embodiment, the system further includes: sensing an operating pressure within the tubular member. In an exemplary embodiment, radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member includes: injecting fluidic material into the tubular member; sensing the operating pressure of the injected fluidic material; and if the operating pressure of the injected fluidic material exceeds a predetermined value, permitting the fluidic material to enter a pressure chamber defined within the tubular member. In an exemplary embodiment, at least a portion of the tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the portion of the tubular member includes the pressurized portion of the tubular member.
[00600] A method of radially expanding and plastically deforming an expandable tubular member has been described that includes limiting the amount of radial expansion of the expandable tubular member. In an exemplary embodiment, limiting the amount of radial expansion of the expandable tubular member includes: coupling another tubular member to the expandable tubular member that limits the amount of the radial expansion of the expandable tubular member. In an exemplary embodiment, the other tubular member defines one or more slots. In an exemplary embodiment, the other tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
[00601] An apparatus for radially expanding a tubular member has been described that includes an expandable tubular member; an expansion device coupled to the expandable tubular member for radially expanding and plastically deforming the expandable tubular member; and an tubular expansion limiter coupled to the expandable tubular member for limiting the degree to which the expandable tubular member may be radially expanded and plastically deformed. In an exemplary embodiment, the tubular expansion limiter includes a tubular member that defines one or more slots. In an exemplary embodiment, the tubular expansion limiter comprises a tubular member that has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the apparatus further includes: a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device and the expansion device. In an exemplary embodiment, at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the apparatus further includes: means for transmitting torque between the expandable tubular member and the tubular support member. In an exemplary embodiment, the apparatus further includes: means for sealing the interface between the expandable tubular member and the tubular support member. In an exemplary embodiment, the apparatus further includes means for sealing the interface between the expandable tubular member and the tubular support member. In an exemplary embodiment, the apparatus further includes: means for sensing the operating pressure within the tubular support member. In an exemplary embodiment, the apparatus further includes: means for pressurizing the interior of the tubular support member.
[00602] An apparatus for radially expanding a tubular member has been described that includes: an expandable tubular member; an expansion device coupled to the expandable tubular member for radially expanding and plastically deforming the expandable tubular member; an tubular expansion limiter coupled to the expandable tubular member for limiting the degree to which the expandable tubular member may be radially expanded and plastically deformed; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device and the expansion device; means for transmitting torque between the expandable tubular member and the tubular support member; means for sealing the interface between the expandable tubular member and the tubular support member; means for sensing the operating pressure within the tubular support member; and means for pressurizing the interior of the tubular support member; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
[00603] A method for radially expanding a tubular member has been described that includes positioning a tubular member and an adjustable expansion device within a preexisting structure; radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; limiting the extent to which the portion of the tubular member is radially expanded and plastically deformed by pressurizing the interior of the tubular member; increasing the size of the adjustable expansion device; and radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member. In an exemplary embodiment, the method further includes sensing an operating pressure within the tubular member. In an exemplary embodiment, radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member includes: injecting fluidic material into the tubular member; sensing the operating pressure of the injected fluidic material; and if the operating pressure of the injected fluidic material exceeds a predetermined value, permitting the fluidic material to enter a pressure chamber defined within the tubular member. In an exemplary embodiment, at least a portion of the tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, limiting the extent to which the portion of the tubular member is radially expanded and plastically deformed by pressurizing the interior of the tubular member includes: applying a force to the exterior of the tubular member. In an exemplary embodiment, applying a force to the exterior of the tubular member includes: applying a variable force to the exterior of the tubular member.
[00604] A system for radially expanding a tubular member has been described that includes means for positioning a tubular member and an adjustable expansion device within a preexisting structure; means for radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; means for limiting the extent to which the portion of the tubular member is radially expanded and plastically deformed by pressurizing the interior of the tubular member; means for increasing the size of the adjustable expansion device; and means for radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member. In an exemplary embodiment, the method further includes: means for sensing an operating pressure within the tubular member. In an exemplary embodiment, means for radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member includes: means for injecting fluidic material into the tubular member; means for sensing the operating pressure of the injected fluidic material; and if the operating pressure of the injected fluidic material exceeds a predetermined value, means for permitting the fluidic material to enter a pressure chamber defined within the tubular member. In an exemplary embodiment, at least a portion of the tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, means for limiting the extent to which the portion of the tubular member is radially expanded and plastically deformed by pressurizing the interior of the tubular member includes: means for applying a force to the exterior of the tubular member. In an exemplary embodiment, wherein means for applying a force to the exterior of the tubular member includes: means for applying a variable force to the exterior of the tubular member.
[00605] An apparatus for radially expanding an expandable tubular member has been described that includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; a first expansion device coupled to the tubular support member; a second expansion device coupled to the tubular support member; and an expandable tubular sleeve coupled to the second expansion device. In an exemplary embodiment, the outside diameters of the first and second expansion devices are unequal. In an exemplary embodiment, the outside diameter of the first expansion device is greater than the outside diameter of the second expansion device. In an exemplary embodiment, at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the outside diameters of the first and second expansion devices are both less than or equal to the outside diameter of the expandable tubular member. In an exemplary embodiment, the outside diameter of the expandable tubular sleeve is less than or equal to the outside diameter of the expandable tubular member. In an exemplary embodiment, the apparatus further includes means for transmitting torque between the expandable tubular member and the tubular support member. In an exemplary embodiment, the apparatus further includes means for pressurizing the interior of the tubular support member. In an exemplary embodiment, the apparatus further includes means for limiting axial displacement of the expandable tubular sleeve. In an exemplary embodiment, the apparatus further includes means for limiting axial displacement of the expandable tubular member. In an exemplary embodiment, the apparatus further includes means for transmitting torque from the tubular support member to the means for limiting axial displacement of the expandable tubular sleeve. In an exemplary embodiment, the apparatus further includes means for displacing the first expansion device relative to the expandable tubular member to radially expand and plastically deform the expandable tubular member. In an exemplary embodiment, the apparatus further includes means for displacing the second expansion device relative to the expandable tubular sleeve to radially expand and plastically deform the expandable tubular sleeve. In an exemplary embodiment, the wall thickness of the expandable tubular sleeve is variable. In an exemplary embodiment, the expandable tubular sleeve includes means for sealing an interface between the expandable tubular sleeve and the interior surface of the expandable tubular member.
[00606] An apparatus for radially expanding an expandable tubular member has been described that includes: an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; a first expansion device coupled to the tubular support member; a second expansion device coupled to the tubular support member; an expandable tubular sleeve coupled to the second expansion device; means for transmitting torque between the expandable tubular member and the tubular support member; means for pressurizing the interior of the tubular support member; means for limiting axial displacement of the expandable tubular sleeve; means for limiting axial displacement of the expandable tubular member; means for transmitting torque from the tubular support member to the means for limiting axial displacement of the expandable tubular sleeve; means for displacing the first expansion device relative to the expandable tubular member to radially expand and plastically deform the expandable tubular member; and means for displacing the second expansion device relative to the expandable tubular sleeve to radially expand and plastically deform the expandable tubular sleeve; wherein the outside diameter of the first expansion device is greater than the outside diameter of the second expansion device; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation; wherein at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation; wherein the outside diameters of the first and second expansion devices are both less than or equal to the outside diameter of the expandable tubular member; wherein the outside diameter of the expandable tubular sleeve is less than or equal to the outside diameter of the expandable tubular member; wherein the wall thickness of the expandable tubular sleeve is variable; and wherein the expandable tubular sleeve comprises means for sealing an interface between the expandable tubular sleeve and the interior surface of the expandable tubular member.
[00607] A method for radially expanding a tubular member has been described that includes positioning an expandable tubular member and an expandable tubular sleeve within a preexisting structure; radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve; and radially expanding and plastically deforming at least a portion of the expandable tubular sleeve. In an exemplary embodiment, the method further includes radially expanding and plastically deforming at least a portion of the expandable tubular member while simultaneously radially expanding and plastically deforming at least a portion of the expandable tubular sleeve. In an exemplary embodiment, the method further includes radially expanding and plastically deforming another portion of the expandable tubular member after radially expanding and plastically deforming the portion of the expandable tubular sleeve. In an exemplary embodiment, at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the wall thickness of the expandable tubular sleeve is variable. In an exemplary embodiment, the method further includes sealing an interface between the exterior surface of the expandable tubular sleeve and the interior surface of the expandable tubular member.
[00608] A system for radially expanding a tubular member has been described that includes means for positioning an expandable tubular member and an expandable tubular sleeve within a preexisting structure; means for radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve; and means for radially expanding and plastically deforming at least a portion of the expandable tubular sleeve. In an exemplary embodiment, the system further includes means for radially expanding and plastically deforming at least a portion of the expandable tubular member while simultaneously radially expanding and plastically deforming at least a portion of the expandable tubular sleeve. In an exemplary embodiment, the system further includes means for radially expanding and plastically deforming another portion of the expandable tubular member after radially expanding and plastically deforming the portion of the expandable tubular sleeve. In an exemplary embodiment, at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the wall thickness of the expandable tubular sleeve is variable. In an exemplary embodiment, the system further includes sealing an interface between the exterior surface of the expandable tubular sleeve and the interior surface of the expandable tubular member. [00609] An apparatus for radially expanding an expandable tubular member has been described that includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; an adjustable expansion device coupled to the tubular support member; a non- adjustable expansion device coupled to the tubular support member; and an expandable tubular sleeve coupled to the non-adjustable expansion device. In an exemplary embodiment, at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the outside diameters of the adjustable and non-adjustable expansion devices are both less than or equal to the outside diameter of the expandable tubular member. In an exemplary embodiment, the outside diameter of the expandable tubular sleeve is less than or equal to the outside diameter of the expandable tubular member. In an exemplary embodiment, the apparatus further includes means for transmitting torque between the expandable tubular member and the tubular support member. In an exemplary embodiment, the apparatus further includes means for pressurizing the interior of the tubular support member. In an exemplary embodiment, the apparatus further includes means for limiting axial displacement of the expandable tubular sleeve. In an exemplary embodiment, the apparatus further includes means for limiting axial displacement of the expandable tubular member. In an exemplary embodiment, the apparatus further includes means for transmitting torque from the tubular support member to the means for limiting axial displacement of the expandable tubular sleeve. In an exemplary embodiment, the apparatus further includes means for transmitting torque from the tubular support member to the means for limiting axial displacement of the expandable tubular member. In an exemplary embodiment, the apparatus further includes means for displacing the adjustable expansion device relative to the expandable tubular member to radially expand and plastically deform the expandable tubular member. In an exemplary embodiment, the apparatus further includes means for pulling the adjustable expansion device through the expandable tubular member to radially expand and plastically deform the expandable tubular member. In an exemplary embodiment, the apparatus further includes fluid powered means for pulling the adjustable expansion device through the expandable tubular member to radially expand and plastically deform the expandable tubular member. In an exemplary embodiment, the apparatus further includes means for displacing the non- adjustable expansion device relative to the expandable tubular sleeve to radially expand and plastically deform the expandable tubular sleeve. In an exemplary embodiment, the apparatus further includes fluid powered means for pulling the non-adjustable expansion device through the expandable tubular sleeve to radially expand and plastically deform the expandable tubular sleeve. In an exemplary embodiment, the wall thickness of the expandable tubular sleeve is variable. In an exemplary embodiment, the expandable tubular sleeve includes means for sealing an interface between the expandable tubular sleeve and the interior surface of the expandable tubular member.
[00610] An apparatus for radially expanding an expandable tubular member has been described that includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; an adjustable expansion device coupled to the tubular support member; a non- adjustable expansion device coupled to the tubular support member; an expandable tubular sleeve coupled to the non-adjustable expansion device; means for transmitting torque between the expandable tubular member and the tubular support member; means for pressurizing the interior of the tubular support member; means for limiting axial displacement of the expandable tubular sleeve; means for limiting axial displacement of the expandable tubular member; means for transmitting torque from the tubular support member to the means for limiting axial displacement of the expandable tubular sleeve; means for transmitting torque from the tubular support member to the means for limiting axial displacement of the expandable tubular member; fluid powered means for pulling the adjustable expansion device through the expandable tubular member to radially expand and plastically deform the expandable tubular member; and fluid powered means for pulling the non-adjustable expansion device through the expandable tubular sleeve to radially expand and plastically deform the expandable tubular sleeve; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation; wherein at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation; wherein the outside diameters of the adjustable and non- adjustable expansion devices are both less than or equal to the outside diameter of the expandable tubular member; wherein the outside diameter of the expandable tubular sleeve is less than or equal to the outside diameter of the expandable tubular member; wherein the wall thickness of the expandable tubular sleeve is variable; and wherein the expandable tubular sleeve comprises means for sealing an interface between the expandable tubular sleeve and the interior surface of the expandable tubular member. [00611] A method for radially expanding a tubular member has been described that includes positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; increasing the size of the adjustable expansion device; radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve using the adjustable expansion device; and radially expanding and plastically deforming at least a portion of the expandable tubular sleeve. In an exemplary embodiment, the method further includes radially expanding and plastically deforming at least a portion of the expandable tubular member while simultaneously radially expanding and plastically deforming at least a portion of the expandable tubular sleeve. In an exemplary embodiment, the method further includes radially expanding and plastically deforming another portion of the expandable tubular member after radially expanding and plastically deforming the portion of the expandable tubular sleeve. In an exemplary embodiment, at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the wall thickness of the expandable tubular sleeve is variable. In an exemplary embodiment, the method further includes sealing an interface between the exterior surface of the expandable tubular sleeve and the interior surface of the expandable tubular member. In an exemplary embodiment, the method further includes pulling the adjustable expansion device through the expandable tubular member. In an exemplary embodiment, the method further includes pulling the adjustable expansion device through the expandable tubular member using fluid pressure.
[00612] A system for radially expanding a tubular member has been described that includes means for positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; means for increasing the size of the adjustable expansion device; means for radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve using the adjustable expansion device; and means for radially expanding and plastically deforming at least a portion of the expandable tubular sleeve. In an exemplary embodiment, the system further includes means for radially expanding and plastically deforming at least a portion of the expandable tubular member while simultaneously radially expanding and plastically deforming at least a portion of the expandable tubular sleeve. In an exemplary embodiment, the system further includes means for radially expanding and plastically deforming another portion of the expandable tubular member after radially expanding and plastically deforming the portion of the expandable tubular sleeve. In an exemplary embodiment, at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
In an exemplary embodiment, at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the wall thickness of the expandable tubular sleeve is variable. In an exemplary embodiment, the system further includes means for sealing an interface between the exterior surface of the expandable tubular sleeve and the interior surface of the expandable tubular member. In an exemplary embodiment, the system further includes means for pulling the adjustable expansion device through the expandable tubular member. In an exemplary embodiment, the system further includes means for pulling the adjustable expansion device through the expandable tubular member using fluid pressure.
[00613] An apparatus for radially expanding an expandable tubular member has been described that includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; and an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member. In an exemplary embodiment, at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the apparatus further includes an expandable tubular sleeve coupled to an end of the expandable tubular member that receives the adjustable expansion device. In an exemplary embodiment, at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
In an exemplary embodiment, the apparatus further includes means for transmitting torque between the expandable tubular member and the tubular support member. In an exemplary embodiment, the apparatus further includes means for pressurizing the interior of the tubular support member. In an exemplary embodiment, the actuator includes means for displacing the adjustable expansion device relative to the expandable tubular member to radially expand and plastically deform the expandable tubular member. In an exemplary embodiment, the actuator further includes means for pulling the adjustable expansion device through the expandable tubular member to radially expand and plastically deform the expandable tubular member. In an exemplary embodiment, the actuator further includes fluid powered means for pulling the adjustable expansion device through the expandable tubular member to radially expand and plastically deform the expandable tubular member.
In an exemplary embodiment, the apparatus further includes means for adjusting the size of the adjustable expansion device.
[00614] An apparatus for radially expanding an expandable tubular member has been described that includes an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member; an expandable tubular sleeve coupled to an end of the expandable tubular member that receives the adjustable expansion device; means for transmitting torque between the expandable tubular member and the tubular support member; means for pressurizing the interior of the tubular support member; means for adjusting the size of the adjustable expansion device; and fluid powered means for pulling the adjustable expansion device through the expandable tubular member to radially expand and plastically deform the expandable tubular member; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation; and wherein at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
[00615] A method for radially expanding a tubular member has been described that includes positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; increasing the size of the adjustable expansion device to radially expand and plastically deform at least a portion of at least one of the expandable tubular member and the expandable tubular sleeve; and radially expanding and plastically deforming at least another portion of the expandable tubular member using the adjustable expansion device. In an exemplary embodiment, at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the method further includes pulling the adjustable expansion device through the expandable tubular member. In an exemplary embodiment, the method further includes pulling the adjustable expansion device through the expandable tubular member using fluid pressure.
[00616] A system for radially expanding a tubular member has been described that includes means for positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; means for increasing the size of the adjustable expansion device to radially expand and plastically deform at least a portion of at least one of the expandable tubular member and the expandable tubular sleeve; and means for radially expanding and plastically deforming at least another portion of the expandable tubular member using the adjustable expansion device. In an exemplary embodiment, at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the system further includes means for pulling the adjustable expansion device through the expandable tubular member. In an exemplary embodiment, the system further includes means for pulling the adjustable expansion device through the expandable tubular member using fluid pressure. [00617] It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, the teachings of the present illustrative embodiments may be used to provide a wellbore casing, a pipeline, or a structural support. Furthermore, the elements and teachings of the various illustrative embodiments may be combined in whole or in part in some or all of the illustrative embodiments. In addition, one or more of the elements and teachings of the various illustrative embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments. [00618] Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.

Claims

What is claimed is:
A method of forming a tubular liner within a preexisting structure, comprising: positioning a tubular assembly within tbθ preexisting structure; and radially expanding and plastically deforming the tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined poήi'on of the tubular assembly has a lower yield point than another portion of the tubular assembly.
2. The method of claim 1 , wherein the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
3. The method of claim 1, wherein the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
4. The method of claim 1 , wherein the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
5. The method Of claim 1 , wherein the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly.
6. The method of claim 5, further comprising: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubuJar assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly.
7. The method of claim 6, wherein the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly.
8. The method of claim 1 , wherein the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly.
9. The method of claim 1, wherein the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly.
10. The method of claim 1 , wherein the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermine d portions of the tubular assembly.
11. The method of claim 1 , wherein the other pprtion of the tubular assembly comprises- an end portion of the tubular assembly.
12. The method of claim 1 , wherein the other pprtion of the tubular assembly comprises a plurality of other portions of the tubular assembly.
13. The method of claim 1 , wherein the other pbrtioπ of the tubular assembly comprises a plurality of spaced apart other portions of the tubμlar assembly.
14. The method of ctaim 1, wherein the tubulad assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings.
15. The method of claim 14, wherein the tubui; ar couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly.
16. The method of claim 14, wherein one or more of the tubular couplings comprise the predetermined portions of the tubular assembly.
17. The method of claim 14, wherein one or mφre of the tubular members comprise the, predetermined portions of the tubular assembly,
18. The method of claim 1, wherein the predetermined portion of the tubular assembly defines one or more openings.
19. The method of claim 18, wherein one or more of the openings comprise slots
20. The method of claim 18, wherein the anisofropy for the predetermined portion of the tubular assembly is greater than 1 -
21. The method of claim 1 , wherein the anisotropy for the predetermined portion of the ' tubular assembly is greater than 1.
22. The method of claim 1 , wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.15.
23. The method of claim 1 , wherein the anisotropy for the predetermined portion of the tubular assembly is greater than ; and wherein the strain hardening exponent for the- predetermined portion of the tubular assembly is gι eater than 0.12,
24. The method of claim 1 , wherein the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065 % C , 1.44 % Mn, 0.01 % P. 0.002 % S, 0.24 % SI, 0.01 % Cu, 0.01 % Ni. and 0.02 % Cr.
25. The method of claim 24, wherein the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular • assembly is at least about 65.9 ksi after the radial expansion and plastic deformation..
26. The method of claim 2 , wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
27. The method of claim 24, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion anc plastic deformation, is about 1.48.
28. The method of claim 1 , wherein the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18 % C. 1.28 % Mn, 0.017 % P. 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr.
29. The method of claim 28, wherein the yield Joint of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to he radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about.74.4 ksi after the radial expansion and plastic deformation.
30. The method of claim 28, wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
31. The method of claim 28, wherein the anisotropy of the predetermined portion of .the tubular assembly, prior to the radial expansion and plastic deformation, Is about 1.04.
32. The method of claim 1 , wherein the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08 % C, 0.82 % Mn, 0.006 % P. 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr.
33. The method of claim 32, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92.
34. The method of claim 1. wherein the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr.
35. The method of claim 34, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation. Is about 1.34.
36. The method of claim 1 , wherein the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
37. The method of claim 1 , wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
38. The method of claim 1 , wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48.
39. The method of claim 1 , wherein the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic defomnation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
40. The method of claim 1 , wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % ; greater than the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation.
41. The method of claim 1 , wherein the anisotropy of the predetermined portion of the • tubular assembly, prior to the radial expansion and plastic deformation, Is at least about 1.04.
42. The method of claim 1, wherein the anisotropy of the predetermined portion of the . tubular assembly, prior to the radial expansion and plastic defomnation, is at least about 1.92.
43. The method of claim 1 , wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34.
44. The method of claim 1, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
45. The method of claim 1 , wherein the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
46. The method of claim 1 , wherein the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12.
47. The method of claim 1 , wherein the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly.
48. The method of claim 1 , wherein the tubular assembly comprises a wellbore casing.
49. The method of claim 1, wherein the tubular assembly comprises a pipeline.
50. The method of claim 1 , wherein the tubular assembly comprises a structural support.
51. An expandable tubular member comprising a steel alloy comprising: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si, 0.01 % Cu. 0.01 % Ni, and 0.02 % Cr.
52. The tubular member of claim 51 , wherein a yield point of the tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and wherein a yield point of the tubular member Is at least about 65.9 ksi after the radial expansion and plastic deformation.
53. The tubular member of claim 51 , wherein the yield point of the tubular member after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the tubular member prior to the radial expansion and plastic deformation.
54. The tubular member of claim 51 , wherein the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.48.
55. The tubular member of claim 51 , wherein the tubular member comprises a wellbore casing.
56. The tubular member of claim 51 , wherein the tubular member comprises a pipeline.
57. The tubular member of claim 51. wherein the tubular member comprises a structural support.
58. An expandable tubular member comprising a steel alloy comprising: 0.18 % C, 1.28 % Mn. 0.017 % P. 0.004 % S, 0.29 % Si, 0.01 % Cu. 0.01 % NI, and 0.03 % Cr.
59. The tubular member of claim 58, wherein a yield point of the tubular member is at . most about 57.8 ksi prior to a radial expansion and plastic deformation; and wherein the yield point of the tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation.
60. The tubular member of claim 58, wherein a yield point of the of the tubular member after a radial expansion and plastic deformation is at least about 28 % greater than the yield pointof the tubular member prior to the radial expansion and plastic deformation.
61. The tubular member of claim 58, wherein the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.04.
62. The tubular member of claim 58, wherein the tubular member comprises a wellbore casing.
63. The tubular member of claim 58, wherein the tubular member comprises a pipeline.
64. The tubular member of claim 58, wherein'the tubular member comprises a structural support.
65. An expandable tubular member comprising a steel alloy comprising: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 %-Cu, 0.05 % Ni, and 0.05 % Cr.
66. The tubular member of claim 65, wherein the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.92.
67. The tubular member of claim 65, wherein the tubular member comprises a wellbore casing.
68. The tubular member of claim 65, wherein the tubular member comprises a pipeline.
69. The tubular member of claim 65, wherein the tubular member comprises a structural support.
70. An expandable tubular member comprising a steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P. 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr.
71. The tubular member of claim 70. wherein the anisotropy of the tubular member, prior to a radial expansion and plastic defomnation, Is about 1.34.
72. T e tubular member of claim 70, wherein the tubular member comprises a wellbore casing.
73. The tubular member of claim 70, wherein the tubular member comprises a pipeline.
74. The tubular member of claim 70, wherein the tubular member comprises a structural support.
75. An expandable tubular member, wherein the yield point of the expandable tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 65.9 ksi after the radial expansion and plastic deformation.
76. The tubular member of claim 75, wherein the tubular member comprises a wellbore casing.
77. The tubular member of claim 75, wherein tha tubular member comprises a pipeline.
78. The tubular member of claim 75. wherein the tubular member comprises a structural support.
79. An expandable tubular member, wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 40 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
80. The tubular member of claim 79. wherein the tubular member comprises a wellbore casing.
81. The tubular member of claim 79, wherein the tubular member comprises a pipeline.
82. The tubular member of claim 79, wherein the tubular member comprises a structural support.
83. An expandable tubular member, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, Is at least about 1.48.
84. The tubular member of claim 83, wherein the tubular member comprises a wellbore casing.
85. The tubular member of claim 83, wherein the tubular member comprises a pipeline.
86. The tubular member of claim 83, wherein the tubular member comprises a structural >, support.
87. An expandable tubular member, wherein the yield point of the expandable tubular member Is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation.
88. The tubular member of claim 87, wherein the tubular member comprises a wellbore casing.
89. The tubular member of claim 87, wherein the tubular member comprises a pipeline.
90. The tubular member of claim 87, wherein the tubular member comprises a structural support
91. An expandable tubular member, wherein the yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 28 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
92. The tubular member of claim 91 , wherein the tubular member comprises a wellbore casing.
93. The tubular member of claim 91 , wherein the tubular member comprises a pipeline.
94. The tubular member of claim 91 , wherein the tubular member comprises a structural support.
95. An expandable tubular member, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation. Is at least about 1.04.
96. The tubular member of claim 95, wherein the tubular member comprises a wellbore casing.
97. The tubular member of claim 95, wherein the tubular member comprises a pipeline.
98. The tubular member of claim 95, wherein the tubular member comprises a structural support.
99. An expandable tubular member, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.92.
100. The tubular member of claim 99, wherein the tubular member comprises a wellbore casing.
101. The tubular member of claim 99, wherein the tubular member comprises a pipeline.
102. The tubular member of claim 99, wherein the tubular member comprises a structural support.
103. An expandable tubular member, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic defomnation, is at least about 1.34.
104. The tubular member of claim 103, wherein the tubular member comprises a wellbore casing.
105. The tubular member of claim 103, wherein the tubular member comprises a pipeline.
106. The tubular member of claim 103, wherein the tubular member comprises a structural support.
107. An expandable tubular member, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
108. The tubular member of claim 107, wherein the tubular member comprises a wellbore casing,
109. The tubular member of claim 107, wherein the tubular member comprises a pipeline.
110. The tubular member of claim 107, wherein the tubular member comprises a structural support.
111. An expandable tubular member, wherein the yield point of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
11 . The tubular member of claim 111, wherein the tubular member comprises a wellbore casing.
113. The tubular member of claim 111, wherein the tubular member comprises a pipeline.
114. The tubular member of claim 111, wherein the tubular member comprises a structural support.
115. An expandable tubular member, wherein the expandability coefficient of the expandable tubular member, prior to the radial expansion and plastic deformation, is greater than 0.12.
116. The tubular member of claim 115, wherein the tubular member comprises a wellbore casing.
11 . The tubular member of claim 115, wherein the tubular member comprises a pipeline.
118. The tubular member of claim 115, wherein the tubular member comprises a structural support. i
119. An expandable tubular member, wherein the expandability coefficient of the expandable tubular member is greater than the expandability coefficient of another portion of the expandable tubular member. -
120. The tubular member of claim 119, wherein the tubular member comprises a wellbore casing.
121. The tubular member of claim 119, wherein the tubular member comprises a pipeline.
122. The tubular member of claim 119, wherein the tubular member comprises a structural support.
123. An expandable tubular member, wherein the tubular member has a higher ductility and a lower yield point prior to a radial expansion and plastic deformation than after the radial expansion and plastic deformation.
124. The tubular member of claim 123, wherein the tubular member comprises a wellbore casing.
125. The tubular member of claim'123, wherein the tubular member comprises a pipeline.
1 6. The tubular member of claim 123, wherein the tubular member comprises a structural support.
127. A method of radially expanding and plastically deforming a tubular assembly comprising a first tubular member coupled to a second tubular member, comprising: radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member.
128. The method of claim 1 7, wherein the tubular member comprises a wellbore casing.
129. The method of claim 127. wherein the tubular member comprises a pipeline.
130. The method of claim 127, wherein the tubular member comprises a structural • support.
131. A system for radially expanding and plastically deforming a tubular assembly comprising a first tubular member coupled to a second tubular member, comprising: means for radially expanding the tubular assembly within a preexisting structure; and means for using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member.
132. The system of claim 131 , wherein the tubular member comprises a wellbore casing.
133. The system of claim 131. wherein the tubular member comprises a pipeline.
134. The system of claim 131 , wherein the tubular member comprises a structural support
135. A method of manufacturing a tubular member, comprising: processing a tubular member until the tubular member is characterized by one or- more intermediate characteristics; positioning the tubular member within a preexisting structure; and processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics.
136. The method of claim 135. wherein the tubular member comprises a wellbore casing.
1 7. The method of claim 135, wherein the tubular member comprises a pipeline.
138. The method of claim 135, wherein the tubular member comprises a structural support.
139. The method of claim 135. wherein the preexisting structure comprises a wellbore that traverses a subterranean formation.
140. The method of claim 135, wherein the characteristics are selected from a group consisting of yield point and ductility.
141. The method of claim 135, wherein processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics comprises: radially expanding and plastically deforming the tubular member within the preexisting structure.
142. An apparatus, comprising: an expandable tubular assembly; and an expansion device coupied to the expandable tubular assembly; wherein a predetermined portion of the expandable tubular assembly has a lower yield point than another portion of the expandable tubular assembly.
143. The apparatus of claim 142, wherein the expansion device comprises a rotary expansion device.
144. The apparatus of claim 142, wherein the expansion device comprises an axially dispJaceable expansion device.
145. The apparatus of claim 142, wherein the expansion device comprises a reciprocating expansion device.
14β. The apparatus of claim 142, wherein the expansion device comprises a hydroforming expansion device.
147. The apparatus of claim 142, wherein the expansion device comprises an impulsive ■ force expansion device.
148. The apparatus of claim 1 2, wherein the predetermined portion of the tubular assembly has a higher ductility and a lower yield point than another portion of the expandable tubular assembly.
149. The apparatus of claim 142, wherein the predetermined portion of the tubular assembly has a higher ductility than another portion of the expandable tubular assembly.
150. The apparatus of claim 142, wherein the predetermined portion of the tubular assembly has a lower yield point than another portion of the expandable tubular assembly.
151. The apparatus of daim 142, wherein the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly.
152. The apparatus of claim 142, wherein the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly.
153. The apparatus of claim 142, wherein the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly.
154. The apparatus of claim 142, wherein the other portion of the tubular assembly comprises an end portion of the tubular assembly.
155. The apparatus of claim 142, wherein the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly.
156. . The apparatus of claim 142, wherein the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly.
157. The apparatus of claim 142, wherein the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings.
158. The apparatus of claim 157, wherein the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly.
159- The apparatus of claim 157, wherein one or more of the tubular couplings comprise • the predetermined portions of the tubular assembly.
160. The apparatus of dalm 157. wherein one or more of the tubular members comprise the predetermined portions of the tubular assembly.
161. The apparatus of claim 142, wherein the predetermined portion of the tubular assembly defines on© or more openings.
162. The apparatus of claim 161 , wherein one or more of the openings comprise slots.
163. The apparatus of claim 16 , wherein the anisotropy for the predetermined portion of the tubular assembly is greater than 1.
164. The apparatus of claim 142, wherein the anisotropy for the predetermined portion of. the tubular assembly, is greater than 1.
165. The apparatus of claim 142, wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12.
166. The apparatus of claim 142, wherein the anisotropy for the predetermined portion of the tubular assembly is greater than 1 ; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12.
167. The apparatus of claim 142, wherein the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr.
168- The apparatus of daim 167, wherein the yield point of the predetermined portion of the tubular assembly Is at most about 46.9 ksi.
169. The apparatus of dalm 167, wherein the anisotropy of the predetermined portion of >■ the tubular assembly Is about 1.48.
170. The apparatus of dalm 142. wherein the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr.
171. The apparatus of claim 170, wherein the yield point of the predetermined portion of • the tubular assembly is at most about 57.8 ksi.
172. The apparatus of claim 170, wherein the anisotropy of the predetermined portion of . the tubular assembly is about 1.04. 73. The apparatus of claim 142, wherein the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08 % C, 082 % Mn, 0.006 % P, 0.003 % S, 0.30 % SI, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr.
74. The apparatus of claim 173, wherein the anisotropy of the predetermined portion of the tubular assembly Is about 1.92.
175. The apparatus of claim 142, wherein the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % SI, 9.1 % Ni, and 18.7 % Cr.
176. The apparatus of daim 175, wherein the anisotropy of the predetermined portion of the tubular assembly is at least about 1.34.
177. The apparatus of daim 142, wherein the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi.
178. The apparatus of claim 142, wherein the anisotropy of the predetermined portion of the tubular assembly is at least about 1.48.
179. The apparatus of claim 142, wherein the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi.
180. The apparatus of claim 142, wherein the anisotropy of the predetermined portion of the tubular assembly is at least about 1.04. • - • <
181. The apparatus of daim 142, wherein the anisotropy of the predetermined portion of the tubular assembly is at least about 1.92.
182. The apparatus of claim 142, wherein the anisotropy of the predetermined portion of the tubular assembly is at least about 1.34.
183. The apparatus of claim 1 2, wherein the anisotropy of the predetermined portion of the tubular assembly ranges from about 1.04 to about 1.92.
184. The apparatus of claim 142, wherein the yield point of the predetermined portion of the tubular assembly ranges from about 47.6 ksi to about 61.7 ksi.
185. The apparatus of claim 142, wherein the expandability coefficient of the predetermined portion of the tubular assembly is greater than 0.12.
186. The apparatus of claim 142, wherein the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefftdent of the other portion of the tubular assembly.
187. The apparatus of claim 142, wherein the tubular assembly comprises a wellbore casing.
188. The apparatus of claim 142, wherein the tubular assembly comprises a pipeline.
189. The apparatus of claim 142, wherein the tubular assembly comprises a structural support
190. An expandable tubular member, wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 5.8 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
•191. The tubular member of claim 190, wherein the tubular member comprises a wellbore casing.
192. The tubular member of claim 190, wherein the tubular member comprises.a pipeline.
193. The tubular member of daim 190, wherein the tubular member comprises a structural support.
194. A method of determining the expandability of a selected tubular member, comprising: determining an anisotropy value for the selected tubular member, determining a strain hardening value for the selected tubular member; and multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member.
195. The method of claim 194. wherein an anisotropy value greater than 0.12 Indicates that the tubular member is suitable for radial expansion and plastic deformation.
196. The method of claim 194, wherein the tubular member comprises a wellbore casing.
197. The method of claim 194, wherein the tubular member comprises a pipeline.
198. The method of claim 194, wherein the tubular member comprises a structural support.
199. A method of radially expanding and plastically deforming tubular members, comprising: selecting a tubular member; determining an anisotropy value for the selected tubular member; determining a strain hardening value for the selected tubular member; multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member; and If the anisotropy value is greater than 0.12, then radially expanding and plastically deforming the selected tubular member.
200. The method of claim 199, wherein the tubular member comprises a wellbore casing.
201. The method of claim 199, wherein the tubular member comprises a pipeline.
202. The method of claim 199, wherein the tubular member comprises a structural support.
203. The method of claim 199, wherein radially expanding and plastically deforming the seleded tubular member comprises: Inserting the selected tubular member into a preexisting structure; and then radially expanding and plastically deforming the selected tubular member.
204. The method of claim 203, wherein the preexisting structure comprises a wellbore that traverses a subterranean formation.
205. A radially expandable tubular member apparatus comprising: a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at the joint; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.
206. The apparatus of daim 205, wherein the predetermined portion of the apparatus has a higher dudility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
207. The apparatus of daim 205, wherein the predetermined portion of the apparatus has a higher ductility prior to the radial expansion and piastic defomnation than after the radial expansion and plastic deformation.
208. The apparatus of claim 205. wherein the predetermined portion of the apparatus has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
209. The apparatus of claim 205. wherein the predetermined portion of the apparatus has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly.
210. The apparatus of claim 209, further comprising: positioning another apparatus within the preexisting structure in overlapping relation to the apparatus; and radially expanding and plastically deforming the other apparatus within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the apparatus, a predetermined portion of the other apparatus has a lower yield point than another portion of the other apparatus.
211. The apparatus of claim 210, wherein the Inside diameter of the radially expanded and plastically deformed other portion of the apparatus is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other apparatus.
212. The apparatus of claim 205, wherein the predetermined portion of the apparatus comprises an end portion of the apparatus.
213. The apparatus of claim 205, wherein the predetermined portion of the apparatus comprises a plurality of predetermined portions of the apparatus.
214. The apparatus of claim 205, wherein the predetermined portion of the apparatus comprises a plurality of spaced apart predetermined portions of the apparatus.
215. The apparatus of daim 205. wherein the other portion of the apparatus comprises an end portion of the apparatus.
216. The apparatus of claim 205, wherein the other portion of the apparatus comprises a plurality of other portions of the apparatus.
21 . The apparatus of claim 205, wherein the other portion of the apparatus comprises a plurality of spaced apart other portions of the apparatus.
218. The apparatus of claim 205, wherein the apparatus comprises a plurality of tubular members coupled to one another by corresponding tubular couplings.
219. The apparatus of claim 218, wherein the tubular couplings comprise the predetermined portions of the apparatus; and wherein the tubular members comprise the other portion of the apparatus.
220. The apparatus of claim 218, wherein one or more of the tubular couplings comprise the predetermined portions of the apparatus.
221. The apparatus of claim 218, wherein one or more of the tubular members comprise the predetermined portions of the apparatus.
222. The apparatus of claim 205, wherein the predetermined portion of the apparatus defines one or more openings.
223. The apparatus of claim 222, wherein one or more of the openings comprise slots.
224. The apparatus of claim 222, wherein the anisotropy for the predetermined portion of the apparatus is greater than 1.
225. The apparatus of claim 205, wherein the anisotropy for the predetermined portion of the apparatus is greater than 1.-
226. The apparatus of claim 205, wherein the strain hardening exponent for the predetermined portion of the apparatus Is greater than 0.12.
227. The apparatus of claim 205, wherein the anisotropy for the predetermined portion of the apparatus is greater than 1 ; and wherein the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.1 .
228. The apparatus of claim 205, wherein the predetermined portion of the apparatus comprises a first steel alloy comprising: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24' % Si, 0.01 % Cu. 0.01 % Ni, and 0.02 % Cr.
229. The apparatus of dalm 228. wherein the yield point of the predetermined portion o the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation.
230. The apparatus of claim 228, wherein the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
231. The apparatus of daim 228, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.48.
232. The apparatus of claim 205, wherein the predetermined portion of the apparatus comprises a second steel alloy comprising: 0.18 % C. 1.28 % Mn, 0.017 % P. 0.004 % S, ;■. 0.29 % Si. 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr.
233. The apparatus of daim 232, wherein the yield point of the predetermined portion of the apparatus Is at most about 57.8 ksi prior to the radial expansion and plastic defomnation; and wherein the yield point of the predetermined portion of the apparatus Is at least about 74.4 ksi after the radial expansion and plastic deformation.
234. The apparatus of claim 232. wherein the yield point of the predetermined portion of - the apparatus after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
235. The apparatus of daim 232, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.04.
236. The apparatus of daim 205, wherein the predetermined portion of the apparatus comprises a third steel alloy comprising: 0.08 % C, 0.82 % Mn. 0.006 % P, 0.003 % S, 0.30 % Si. 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr.
237. The apparatus of claim 236, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic defomnation, is about 1.92.
238. The apparatus of claim 205, wherein the predetermined portion of the apparatus comprises a fourth steel alloy comprising: 0.02 % c, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si. 9.1 % Ni, and 18.7 % Cr.
239. The apparatus of claim 238, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.34.
240. The apparatus of daim 205, wherein the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion arid plastic deformation.
241. The apparatus of claim 205. wherein the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation Is at least about 40 % greater than the yield point of the predetermined portion of the apparatus prior to the radial- expansion and plastic deformation.
242. The apparatus of claim 205, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.48. .
243. The apparatus of claim 205, wherein the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation.
244. The apparatus of claim 205. wherein the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28 % •. greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
245. The apparatus of claim 205, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.04.
246. The apparatus of claim 205, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.92.
247. The apparatus of claim 205, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, Is at least about 1.34.
248. The apparatus of claim 205, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
249. The apparatus of claim 205, wherein the yield point of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
250. The apparatus of claim 205, wherein the expandability coefficient of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is greater than 0.12.
251. The apparatus of daim 205, wherein the expandability coefficient of the predetermined portion of the apparatus is greater than the expandability coefficient of the other portion of the apparatus.
252. The apparatus of claim 205, wherein the apparatus comprises a wellbore casing.
253. The apparatus of claim 205, wherein the apparatus comprises a pipeline.
254. The apparatus of claim 205, wherein the apparatus comprises a structural support.
255. A radially expandable tubular member apparatus comprising: a first tubular member; a second tubular member engaged with the first tubular member forming a joint; a sleeve overlapping and coupling the first and second tubular members at the joint; the sleeve having opposite tapered ends and a flange engaged in a recess formed in an adjacent tubular member, and one of the tapered ends being a surface formed on the flange; wherein, prior to a radial expansion and plastic defomnation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.
256. The apparatus as defined in claim 255 wherein the recess includes a tapered wall in mating engagement with the tapered end formed on the flange.
257. The apparatus as defined in claim 255 wherein the sleeve Includes a flange at each tapered end and each tapered end is formed on a respective flange.
258. The apparatus as defined in claim 257 wherein each tubular member includes a recess.
259. The apparatus as defined in claim 258 wherein each flange Is engaged In a respective one of the recesses.
260. The apparatus as defined in daim 259 wherein each recess Indudes a tapered wall in mating engagement with the tapered end formed on a respective one of the flanges.
261. The apparatus of daim 255, wherein the predetermined portion of the apparatus has a higher ductility and a tower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
262. The apparatus of claim 255, wherein the predetermined portion of the apparatus has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
263. The apparatus of claim 255, wherein the predetermined portion of the apparatus has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
264. The apparatus of dalm 255, wherein the predetermined portion of the apparatus has a larger Inside diameter.after the radial expansion and plastic deformation than other portions of the tubular assembly.
265. The apparatus of daim 264, further comprising: positioning another apparatus within the preexisting structure in overlapping relation to the apparatus; and radially expanding and plastically deforming the other apparatus within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the apparatus, a predetermined portion of the other apparatus has a lower yield point than another portion of tha other apparatus.
266. The apparatus of claim 265, wherein the inside diameter of the radially expanded and plastically deformed other portion of the apparatus is equal to the inside diameter of the • radially expanded and plastically deformed other portion of the other apparatus.
267. The apparatus of claim 255, wherein the predetermined portion of the apparatus comprises an end portion of the apparatus.
268. The apparatus of claim 255, wherein the predetermined portion of the apparatus comprises a plurality of predetermined portions of the apparatus.
269. The apparatus of daim 255. herein the predetermined portion of the apparatus • comprises a plurality of spaced apart predetermined portions of the apparatus. •
270. The apparatus of dalm 255, wherein the other portion of the apparatus comprises an end portion of the apparatus.
2 1. The apparatus of daim 255, wherein the other portion of the apparatus comprises a ' plurality of other portions of the apparatus.
272. The apparatus of claim 255, wherein the other portion of the apparatus comprises a plurality of spaced apart other portions of the apparatus.
273. The apparatus of claim 255, wherein the apparatus comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. •274. Tha apparatus of dalm 273, wherein the tubular couplings comprise the predetermined portloπs.of the apparatus; and wherein the tubular members comprise the other portion of the apparatus.
275. The apparatus of claim 273, wherein one or more of the tubular couplings comprise-, the predetermined portions of the apparatus.
276. The apparatus of claim 273, wherein one or more of the tubular members comprise the predetermined portions of the apparatus.
277. The apparatus of daim 255, wherein the predetermined portion of the apparatus defines one or more openings.
278. The apparatus of claim 277, wherein one or more of the openings comprise slotsl
279. The apparatus of daim 277, wherein the anisotropy for the predetermined portion of the apparatus is greater than 1.
280. The apparatus of daim 255, wherein the anisotropy for the predetermined portion of ■ the apparatus is greater,.than 1.
281. The apparatus of claim 255, wherein the strain hardening exponent for the predetermined portion of the apparatus Is greater than 0.1 .
282. The apparatus of claim 255, wherein the anisotropy for the predetermined portion of,, the apparatus is greater than 1 ; and wherein the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12.
283. The apparatus of claim 255, wherein the predetermined portion of the apparatus comprises a first steel alloy comprising: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 % SI. 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr.
284. The apparatus of claim 283, wherein the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation.
285. The apparatus of claim 283. wherein the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the apparatus prior to the radial . expansion and plastic deformation.
286. The apparatus of daim 283, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.48.
287. The apparatus of claim 255, wherein the predetermined portion of the apparatus comprises a second steel alloy comprising: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004 % S, 0.29 % SI, 0.01 % Cu, 0.01 % Ni. and 0.03 % Cr.
288. The apparatus of dalm 287, wherein the yield point of the predetermined portion of the apparatus Is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at .least about 74.4 ksi after the radial expansion and plastic deformation.
289. The apparatus of claim 287, wherein the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
290. The apparatus of claim 287, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic defomnation, is about 1.04.
291. The apparatus of claim 255, wherein the predetermined portion of the apparatus comprises a third steel alloy comprising: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 % S. 0.30 % Si. 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr.
292. The apparatus of claim 291 , wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, Is about 1.92.
293. The apparatus of claim 255, wherein the predetermined portion of the apparatus comprises a fourth steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % Si, 9.1 % Ni. and 18.7 % Cr.
294. The apparatus of daim 293. wherein the anisotropy of the predetermined portion of,, the apparatus, prior to the radial expansion and plastic deformation, is about 1.34.
295. The apparatus of claim 255, wherein the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about -. 65.9 ksi after the radial expansion and plastic deformation.
296. The apparatus of claim 255, wherein the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the apparatus prior to the' radial expansion and plastic deformation.
297. The apparatus of daim 255, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.48..
298. The apparatus of daim 255, wherein the yield point of the predetermined portion of; the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about . 74.4 ksi after the radial expansion and plastic deformation.
299. The apparatus of claim 255. wherein the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation.
300. The apparatus of claim 255, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.04.
301. The apparatus of daim 255, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.92.
302. The apparatus of claim 255, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.34.
303. The apparatus of claim 255, wherein the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92-
304. The apparatus of daim 255, wherein the yield point of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
305. The apparatus of claim 255, wherein the expandability coeffident of the predetermined portion of the apparatus, prior to the radial expansion and plastic • deformation, is greater than 0.12.
306. The apparatus of daim 255, wherein the expandability coefficient of the • predetermined portion of the apparatus is greater than the expandability coefficient of the other portion of the apparatus.
307. The apparatus of dalm.255, wherein the apparatus comprises a wellbore casϊng.-
308. The apparatus of claim 255, wherein the apparatus comprises a pipeline.
309. The apparatus of claim 255, wherein the apparatus comprises a structural support.
310. A method of Joining radially expandable tubular members comprising: providing a first tubular member, engaging a second tubular member with the first tubular member to form a joint; , providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members at the Joint; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of „ the tubular assembly.
311. The method of claim 310, wherein the predetermined portion of the tubular assembty . has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
312. The method of claim 310, wherein the predetermined portion of the tubular assembl » has a higher ductility prior to the radial expansion and plastic defomnation than after the radial expansion and plastic deformation.
313. The method of daim 310, wherein the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
314. The method of claim 310, wherein the predetermined portion of the tubular assembly - has a larger inside diameter after tha radial expansion and plastic deformation than the other portion of the tubular assembly.
315. The method of claim 314, further comprising: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of tha other tubular assembly has a lower yield point than another portion of the other tubular assembly.
316. The method of claim 315, wherein the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the Inside diameter of the radially expanded and plastically deformed other portion of the other tubular, assembly. ,
317. The method of claim 310, wherein the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly.
318. The method of claim 310, wherein the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly.
319. The method of claim 310. wherein the predetermined portion of tha tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly.
320- The method of claim 310, wherein the other portion of the tubular assembly comprises an end portion of the tubular assembly.
321. The method of claim 310, wherein the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly..
322. The method of claim 310, wherein the other.portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly.
323. The method of claim 310, wherein the tubular assembly comprises a plurality of • tubular members coupled to one another by corresponding tubular couplings.
324. The method of claim 323, wherein the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly.
325. The method of claim 323, wherein one or more of the tubular couplings comprise the predetermined portions of the tubular assembly.
326. The method of daim 323, wherein one or more of the tubular members comprise the predetermined portions of the tubular assembly.
327. The method of claim 310, wherein the predetermined portion of the tubular assembly defines one or more openings.
328. The method of claim 327, wherein one or more of the openings comprise.slots.
329. The method of claim 327, wherein the anisotropy for the predetermined portion of the tubular assembly is greater than 1.
330. The method of claim 310, wherein the anisotropy for the predetermined portion of the tubular assembly is greater than 1.
331. The method of daim 310, wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12.
332. The method of claim 310, wherein the anisotropy for the predetermined portion of the tubular assembly is greater than 1 ; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12.
333. The method of claim 310, wherein the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065 % C,.1.44 % Mn, 0.01 % P, 0.002 % S, 0.24 • % Si. 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr.
334. The method of claim 333, wherein the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
335. The method of claim 333. wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly-prior to the radial expansion and plastic deformation.
336. The method of claim 333, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48.
337. The method of claim 310, wherein the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18 % C, 1.28 % Mn, 0.017 % P. 0.004 % S, 0.29 % Si, 0.01 % Cu, 0.01 % Ni. and 0.03 % Cr.
338. The method of claim 337, wherein the yield point of the predetermined portion of the- tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
339. The method of daim 337, wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
340. The method of claim 337, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04.
341. The method of claim 310, wherein the predetermined portion of the tubular assembly comprises a third steel alloy comprising; 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.O5 % Ni, and 0.05 % Cr.
342. The method of claim 341. wherein the anfeαtrapy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92.
343. The method of claim 310, wherein the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P. 0.001 % S, 0.45 % Si, 9.1 % NI, and 18.7 % Cr.
344. The method of claim 343, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34.
345. The method of claim 310, wherein the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
346. The method of claim 310, wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
347. The method of claim 310, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48.
348. The method of daim 310, wherein the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
349. The method of claim 310, wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
-350. The method of claim 310, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation. Is at least about 1.04.
351. The method of claim 310, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92.
352. The method of claim 310, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34.
353. The method of daim 310, wherein the anisotropy of the predetermined portion of the ' tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
354. The method of claim 310, wherein the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
355. The method of claim 310, wherein the expandability coefficient of the predetermined portion of the tubular assembly, prior to.the radial expansion and plastic deformation, is greater than 0.12.
356. The method of claim 310, wherein the expandability coefficient of the predetermined portion of the tubular assembly Is greater than the expandability coefficient of the other .. portion of the tubular assembly.
357. The method of daim 310, wherein the tubular assembly comprises a wellbore casing.
358. The method of claim 310, wherein the tubular assembly comprises a pipeline.
359. ' The method of claim 310, wherein the tubular assembly comprises a structural support.
360. A method of joining radially expandable tubular members comprising: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint, wherein the flange is engaged in a recess formed In an adjacent one of the tubular members; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
361. The method as defined in claim 360 further comprising: providing a tapered wall in the recess for mating engagement with the tapered end formed on the flange.
362. The method as defined In claim 360 further comprising: providing a flange at each tapered end wherein each tapered end Is formed on a respective flange.
363. The method as defined in claim 362 further comprising: providing a recess in each tubular member.
364. The method as defined in claim 363 further comprising: engaging each-flange In a respadlve one of the recesses.
365. The method as defined in claim 364 further comprising: providing a tapered wall in each recess for mating engagement with the tapered end formed on a respective one of the flanges.
366- The method of claim 360, wherein the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
367. The method of claim 360, wherein the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
368. The method of claim 360, wherein the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
369. The method of claim 360, wherein the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly.
370. The method of daim 369, further comprising: positioning another tubular assembly within the preexisting strudure in overlapping relation to the tubular assembly, and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of tha other tubular assembly has a lower yield point than pnother portion of the other tubular assembly.
371. The method of dalm 370. wherein the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly.
372. The method of claim 360, wherein the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly.
373. The method of claim 360. wherein the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly.
374. The method Of claim 360. wherein the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly.
375. The method of claim 360, wherein the other portion of the tubular assembly comprises an end portion of the tubular assembly.
376. The method of claim 360, wherein the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly.
377. The method of claim 360, wherein the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly.
378. The method of claim 360, wherein the tubular assembly comprises a plurality of., tubular members coupled to one another by corresponding tubular couplings.
379. The method of claim 378, wherein the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly.
380. The method of claim 378, wherein one or more of the tubular couplings comprise the predetermined portions of the tubular assembly.
381. The method of claim 378, wherein one or more of the tubular members comprise the- predetermined portions of the tubular assembly. . .
382. The method of dalm 360, wherein the predetermined portion of the tubular assembly defines one or more openings.
383. The method of dalm 382, wherein one or more of the openings comprise slots.
384. The method of claim 382, wherein the anisotropy for the predetermined portion of the tubular assembly Is greater than 1.
385. The method of claim 360, wherein the anisotropy for the predeteπnined portion of the tubular assembly is greater than 1.
42
386. The method of claim 360, wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12.
387. The method of claim 360, wherein the anisotropy for the predeteπnined portion of the. tubular assembly is greater than 1 ; and wherein the strain hardening exponent for the - predetermined portion of the tubular assembly is greater than 0.12.
388- The method of claim 360, wherein the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 % S. 0.24 % Si, 0.01 % Cu. 0.01 % Ni, and 0.02 % Cr.
389. The method of claim 388, wherein the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic- deformation; and wherein the yield point of the predetermined portion of the tubular assembly. Is at least about 65.9 ksi after the radial expansion and plastic deformation. .
390. The method of claim 388, wherein the yield point of the predetermined portion of he tubular assembly after the radial expansion and plastic deformation is at least about 40 % , greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic defomnation..
391. The method of claim 388. wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about.1.48.
392. The method of claim 360. wherein the predetermined portion of the tubuJar assembly comprises a second steel alloy comprising: 0.18 % C, 1.28 % Mn, 0.017 % P. 0.004 % S, 0.29 % SI. 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr.
393. The method of claim 392, wherein the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
394. The method of daim 392, wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
395. The method of claim 392, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04.
396. The method of claim 360, wherein the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08 % C, 0.82 % Mn. 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % NI, and 0.05 % Cr.
397. The method of daim 396, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. -
398. The method of claim 360, wherein the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S, 0.45 % SI, 9.1 % NI, and 18.7 % Cr.
399. The method of daim 398, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34.
400. The method of dalm 360, wherein the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
401. The method of claim 360, wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
402. The method of claim 360, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48.
403. The method of claim 360, wherein the yield point of the predetermined portion of the tubular assembly Is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly Is at feast about 74.4 ksi after the radial expansion and plastic deformation.
404. The method of claim 360, wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the
, radial expansion and plastic deformation.
405. The method of claim 360, wherein the anisotropy of the predetermined portion of the tubuJar assembly, prior to the radial expansion and plastic deformation, is at least about 1..04.
406. The method of daim 360, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92.
407. The method of daim 360, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about . 1.34.
408. The method of claim 360. wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
409. The method of claim 360, wherein the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
410. The method of claim 360. wherein the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12.
411. The method of claim 360, wherein the expandability coeffident of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly.
412. The method of claim 360. wherein the tubular assembly comprises a wellbore casing.
413. The method of claim 360, wherein the tubular assembly comprises a pipeline.
414. The method of daim 360, wherein the tubular assembly comprises a structural . support.
415. The apparatus of daim 205, wherein at least a portion of the sleeve is comprised of a frangible material.
416. The apparatus of claim 205, wherein the wall thickness of the sleeve is variable.
417. The method of claim 310, wherein at least a portion of the sleeve is comprised of a frangible material.
418. The method of claim 310, wherein the sleeve comprises a variable wall thickness.
419. The apparatus of claim 205, further comprising: means for increasing the axial compression loading capadty of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
420. The apparatus of claim 205, further comprising: means for increasing the axial tension loading capacity of the joint between the firat and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
421. The apparatus of claim 205, further comprising: means for increasing the axial compression and tension loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
422. The apparatus of claim 205. further comprising: means for avoiding stress risers in the joint between the first and second tubular members before and after a radial expansion and plastic defomnation of the first and second tubular members.
423. The apparatus of claim 205, further comprising: means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
424. The apparatus of claim 205. wherein the sleeve is drcumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
425. The method of claim 310, further comprising: maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression.
426. The apparatus of claim 205, wherein the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
427. The apparatus of claim 205, wherein the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
428. The method of claim 310, further comprising: maintaining the sleeve in drcumferβπtial tension; and maintaining the first and second tubular members In circumferential compression.
429. The method of claim 310, further comprising: maintaining the sleeve in rcumferential tension; and maintaining the first and second tubular members in drcumferential compression.
430. The apparatus of claim 419, wherein the means for increasing the axial compression loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentialty tensioned; and wherein the first and second tubular members are circumferentially compressed.
431. The apparatus of claim 420, wherein the means for increasing the axial tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is drcumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
432. The apparatus of dalm 421 , wherein the means for increasing the axial compression and tension loading capacity of tha coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members Is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. ,' »
433. The apparatus of claim 422, wherein the means for avoiding stress risers in the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
434. The apparatus of claim 423, wherein the means for indudng stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular - members is circumferentially tensioned; and wherein the first and second tubular members are clrcurπferentialry compressed.
435. An expandable tubular assembly, comprising: a first tubular member: a second tubular member coupled to the first tubular member; a first threaded connection for coupling a portion of the first and second tubular members; a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members; a tubular sleeve coupled to and receiving end portions of the first and second tubular members; and a sealing element positioned between the first and second spaced apart threaded connections for sealing an interface between the first and second tubular member, wherein the sealing element is positioned within an annulus defined between the first and second tubular members; and wherein, prior to a radial expansion and plastic deformation of the assembly, a predetermined portion of the assembly has a lower yield point than another portion of the apparatus.
436. The assembly of claim 435, wherein the predetermined portion of the assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
437. The assembly of claim 435, wherein the predetermined portion of the assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
438. The assembly of claim 435, wherein the predetermined portion of the assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
439. The assembly of daim 435, wherein the predetermined portion of the assembly has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly.
440. The assembly of claim 439, further comprising: positioning another assembly within the preexisting structure in overlapping relation - to the assembly; and radially expanding and plastically deforming the other assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the assembly, a predetermined portion of the other assembly has a lower ylθld point than another portion of the other assembly.
441. The assembly of daim 440, wherein the Inside diameter of the radially expanded and - plastically deformed other portion of the assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other assembly.
442. The assembly of claim 435. wherein the predetermined portion of the assembly - comprises an end portion of the assembly.
443. The assembly of claim 435, wherein the predetermined portion of the assembly comprises a plurality of predetermined portions of the assembly.
444. The assembly of daim 435, wherein the predetermined portion of the assembly comprises a plurality of spaced apart predetermined portions of the assembly.
445. The assembly" of claim 435, wherein the other portion of the assembly comprises an . end portion of the assembly.
446. The assembly of claim 435, wherein the other portion of the assembly comprises a plurality of other portions of the assembly.
447. The assembly of claim 435, wherein the other portion of the assembly comprises a plurality of spaced apart other portions of the assembly.
448. The assembly of daim 435, wherein the assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings.
449. The assembly of daim 448, wherein the tubular couplings comprise the predetermined portioπs-of the assembly; and wherein the tubular members comprise the other portion of the assembly. .
450. The assembly of claim 448. wherein one or more of the tubular couplings comprise the predetermined portions of the assembly.
451. The assembly of daim 448, wherein one or more of the tubular members comprise the predetermined portions of the assembly.
452. The assembly of claim 435. wherein the predetermined portion of the assembly . defines one or more openings.
453. The assembly of claim 452, wherein one or more of the openings comprise slots.
' 454. The assembly of daim 452, wherein the anisotropy for the predetermined portion of the assembly is greater than 1.
455. The assembly of daim 435, wherein the anisotropy for the predetermined portion of the assembly is greater than 1.
456. The assembly of claim 435, wherein the strain hardening exponent for the predetermined portion of the assembly is greater than 0.12.
457. The assembly of claim 435, wherein the anisotropy for the predetermined portion of the assembly is greater than 1 ; and wherein the strain hardening exponent for the predetermined portion of the assembly is greater than 0.12.
458. The assembly of claim 435, wherein the predetermined portion of the assembly comprises a first steel alloy comprising: 0.065 % C. 1.44 % Mn, 0.01 % P, 0.002 % S. .0.24 % Si, 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr.
459. The assembly of claim 458. wherein the yield point of the predetermined portion of the assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
460. The assembly of daim 458, wherein the yield point of the predetermined portion of the assembly after the radial expansion and plastic defomnation is at least about 40 % greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation.
461. The assembly of daim 458, wherein the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.48.
462. The assembly of claim 435, wherein the predetermined portion of the assembly comprises a second steel alloy comprising: 0.18 % C, 1.28 % Mn. 0.017 % P, 0.004 % S, 0.29 % SI, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr.
463. The assembly of claim 462, wherein the yield point of the predetermined portion of the assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
464. The assembly of claim 462, wherein the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation.
465. The assembly of claim 462, wherein the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation. Is about 1.04.
466. The assembly of daim 435. wherein the predetermined portion of the assembly comprises a third steel alloy comprising: 0.08 % C, 0.82 % Mn. 0.006 % P, 0.003 % S, 0.30 % Si, 0.16 % Cu, 0.05 % NI, and 0.05 % Cr.
467. The assembly of claim 466, wherein the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.92.
468. The assembly of claim 435, wherein the predetermined portion of the assembly comprises a fourth steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P. 0.001 % S, 0.45 % Si, 9.1 % Ni, and 18.7 % Cr.
469. The assembly of claim 468, wherein the anisotropy of the predetermined.portlon of the assembly, prior to the radial expansion and plastic deformation. Is about 1.34.
470. The assembly of claim 516, wherein the yield point of the predetermined portion of the assembly Is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
471. The assembly of claim 435, wherein the yield point of the predetermined portion of- the assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation.
472. The assembly of claim 435, wherein the anisotropy of the predetermined portion.of the assembly, prior to the radial expansion and plastic deformation, Is at least about 1.48/
473. The assembly of claim 435, wherein the yield point of the predetermined portion of the. assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly Is at least about 74.4 ksi after the radial expansion and plastic deformation.
474. The assembly of daim 435, wherein the yield point of the predetermined portion of the assembly after the radial expansion and plastic defomnation is at least about 28 % greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation.
475. The assembly of dalm 435, wherein the aπfsotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1-04.
476. The assembly of daim 435, wherein the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, Is at least about 1.92.
477. The assembly of claim 435, wherein the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.34.
478. The assembly of daim 435, wherein the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
' 479. The assembly of daim 435, wherein the yield point of the predetermined portion of the assembly, prior to the radial expansion and plastic defomnation, ranges from about 47.6 , ksi to about 61.7 ksi.
' 480. The assembly of claim 435, wherein the expandability coeffldent of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is greater than 0.12.
481. The assembly of claim 435, wherein the expandability coefficient of the predetermined portion of the assembly is greater than the expandability coefficient of the other portion of the assembly.
482. The assembly of daim 435,'wherein the assembly comprises a wellbore casing.
483. The assembly of daim 435, wherein the assembly comprises a pipeline.
484. The assembly of daim 435, wherein the assembly comprises a structural support.
485. The assembly of claim 435, wherein the annulus is at least partially defined by an Irregular surface.
486. The assembly of daim 435, wherein the annulus is at least partially defined by a toothed surfaca.
487. The assembly of claim 435. wherein the sealing element comprises an elastomeric material.
488. The assembly of daim 435, wherein the sealing element comprises a metallic material.
489.! The assembly of claim 435, wherein the sealing element comprises an elastomeric and a metallic material.
490. A method of Joining radially expandable tubular members comprising: providing a first tubular member; • providing a second tubular member; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members; threadably coupling the first and second tubular members at a first location; threadably coupling the first and second tubular members at a second location spaced apart from the first location; sealing an interface between the first and second tubular members between the first and second locations using a compressible sealing element, wherein the first tubular member, second tubular member, sleeve, and the sealing element define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined • portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
491. The method as defined in claim 490 wherein the sealing element includes an irregular surface.
492. The method as defined in claim 490, wherein the sealing eiement includes a toothed surface.
493. The method as defined in claim 490, wherein the sealing element comprises an elastomeric material.
494. The method as defined in claim 490, wherein the sealing element comprises a metallic material.
495. The method as defined In dalm 490, wherein the sealing.element comprises an elastomeric and a metallic material.
496. The method of claim 490, wherein the predetermined portion of the tubular assembly.- has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
497. The method of dalm 490, wherein the predetermined portion of the tubular assembly has a higher dυdillty prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. .
498. The method of claim 490. wherein the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the > radial expansion and plastic deformation. >
499. The method of claim.490 wherein the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly.
500. The method of claim 490, further comprising: positioning another tubular assembly within the preexisting structure in overiapping • relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly.
501. The method of dalm 500, wherein the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly Is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly.
502. The method of claim 490. wherein the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly.
503. The method of daim 490. wherein the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly.
504. The method of claim 490, wherein the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly.
505. ' Tha method of claim 490, wherein the other portion of the tubular assembly comprises an end portion of the tubular assembly.
506. The method of daim 490, wherein the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly.
507. ; The method of daim 490, wherein the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly.
508. The method of claim 490, wherein the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings.
509. The method of claim 508, wherein the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly.
510. The method of daim 508, wherein one or more of the tubular couplings comprise the predetermined portions of the tubular assembly.
511. The method of daim 508, wherein one or more of the tubular members comprise the predetermined portions of the tubular assembly.
512. The method of claim 490. wherein the predetermined portion of the tubular assembly defines one or more openings.
513. The method of claim 512. wherein one or more of the openings comprise slots.
514. The method of claim 51 , wherein the anisotropy for the predetermined portion of the tubular assembly Is greater than 1.
515. The method of daim 490, wherein the anisotropy for the predetermined portion of the tubular assembly is greater than 1.
516. The method of claim 490, wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12.
517. The method of daim 490, wherein the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12.
518. The method of daim 490, wherein the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065 % C, 1.44 % Mn, 0.01 % P. 0.002 % S, 0.24 % SI. 0.01 % Cu, 0.01 % Ni, and 0.02 % Cr.
519. The method of claim 518, wherein the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
520. The method of claim 518, wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
521. The method of daim 518, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48.
522. The method of claim 490, wherein the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18 % C. 1.28 % Mn, 0.017 % P, 0.004 % S, . 0.29 % Si, 0.01 % Cu, 0.01 % Ni, and 0.03 % Cr.
523. The method of claim 522, wherein the yield point of the predetermined portion of the • tubular assembly Is at most about 57.8 ksi prior to the radial expansion and plastic deformation: and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
524. The method of claim 522, wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic defomnation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
525. The method of dalm 522, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04.
626. The method of daim 490, wherein the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0 08 % C, 0.82 % Mn, 0.006 % P. 0.003,% S, 0.30 % Si, 0.16 % Cu, 0.05 % Ni, and 0.05 % Cr.
527. The method of daim 526, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92.
528- The method of claim 490, wherein the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S. 0.45 % Si. 9.1 % Ni, and 18.7 % Cr.
529. The method of claim 528, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation. Is about 1.34.
530. The method of daim 490, wherein the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic defomnation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformatiqn.
531. The method of claim 490, wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40 % greater than the yield point of the predetermined portion of the tubular assembly prior to tha radial expansion and plastic deformation.
532. The method of daim 490, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, Is at least about 1.48.
533. - The method of claim 490, wherein the yield point of the predetermined portion of the tubular assembly Is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
534. The method of claim 490, wherein the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28 % greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
535. • The method of claim 490, wherein the anisotropy of the predetermined portion "of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04.
536. The method of claim 490. wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92.
537. The method of daim 490, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34.
538. The method of claim 490, wherein the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
539. The method of claim 490, wherein the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic defomnation, ranges from about 47.6 ksi to about 61.7 ksi.
540. The method of daim 490, wherein the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12.
541. The method of claim 490, wherein the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly.
542. The method of claim 490, wherein the tubular assembly comprises a wellbore casing.
543. The method of daim 490, wherein the tubular assembly comprises a pipeline.
544. The method of daim 490. wherein the tubular assembly comprises a strudural support.
545. The apparatus of claim 205, wherein the sleeve comprises: a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members.
546. The apparatus of claim 545, wherein the first tubular member comprises a first threaded connection; wherein the second tubular member comprises a second threaded connection; wherein the first and second threaded connections are coupled to one another; wherein at least one of the tubular sleeves is positioned In opposing relation to the first threaded connection; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded connection.
547. The apparatus of claim 545, wherein the first tubular member comprises a first . threaded connection; wherein the second tubular member comprises a second threaded connection; wherein the first and second threaded connections are coupled to one another; and wherein at least one of the tubular sleeves Is not positioned in opposing relation to the first and second threaded connections.
548. The method of claim 310, further comprising: threadably coupling the first and second tubular members at a first location; ■ threadably coupling the first and second tubular members at a second location spaced apart from the first location: providing a plurality of sleeves; and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members.
549. • The method of claim 548, wherein at least one of the tubular sleeves is positioned in opposing relation to the first threaded coupling; and wherein at least one of the tubular
• sleeves is positioned in opposing relation to the second threaded coupling.
550. The method of daim 548, wherein at least one of the tubular sleeves Is not positioned in opposing relation to the first and second threaded couplings. ■ •
551 - The apparatus of daim 205, further comprising: a threaded connection for coupling a portion of the first and second tubular members; wherein at least a portion of the threaded connection is upset.
552. The apparatus of claim 551 , wherein at least a portion of tubular sleeve penetrates the first tubular member.
553. The method of claim 3 0. further comprising: threadably coupling the first and second tubular members; and upsetting the threaded coupling.
554. The apparatus of claim 205, wherein the first tubular member further comprises an annular extension extending therefrom; and wherein the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member.
555. The method of claim 310, wherein the first tubular member further comprises an annular extension extending therefrom; and wherein the flange of the sleeve defines an annular recess for receiving and mating with tha annular extension of the first tubular member.
556. The apparatus of dalm 205, further comprising: one or more stress concentrators for concentrating stresses in the joint.
557. The apparatus aβ defined In claim 556, wherein one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member.
558. The apparatus as defined in daim 556, wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member.
559. The apparatus as defined in claim 556, wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve.
560. The apparatus as defined in claim 556, wherein one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member.
561. The apparatus as defined in claim 556, wherein one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and wherein one or, more of the stress concentrators comprises one or more openings defined in the sleeve.
562. The apparatus as defined in claim 556, wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve.
563. The apparatus as defined in daim 556, wherein one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve.
564. The method of claim 310, further comprising: concentrating stresses within the joint.
565. The method as defined in claim 564, wherein concentrating stresses within the joint comprises using the first tubular member to concentrate stresses within the joint.
566. The method as defined in dalm 564, wherein concentrating stresses within the joint > comprises using the second tubular member to concentrate stresses within the joint.
567. The method as defined In claim 564, wherein concentrating stresses within the Joint comprises using the sleeve to concentrate stresses within the joint
568. The method as defined in claim 564, wherein concentrating stresses within the joint comprises using the first tubular member and the second tubular member to concentrate stresses within the joint
569. The method as defined in claim 564, wherein concentrating stresses within the joint comprises using the first tubular member and the sleeve to concentrate stresses within the joint
570. The method as defined in daim 564, wherein concentrating stresses within the joint comprises using the second tubular member and the sleeve to concentrate stresses within the joint
571. The method as defined in claim 564, wherein concentrating stresses within the joint comprises using the first tubular member, the second tubular member, and the sleeve to concentrate stresses within the joint.
572. The apparatus of claim 205, further comprising: means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members.
573. The apparatus of claim 205, further comprising: means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members.
574. The apparatus of daim 205, further comprising: means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members; and - means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members.
575. The method of claim 310, further comprising: maintaining portions of the first and second tubular member In circumferential compression following a radial expansion and plastic deformation of the first and second tubular members.
576. The method of claim 310, further comprising: concentrating stresses within the joint during a radial expansion and plastic deformation of the first and second tubular members.
577. The method of claim 310, further comprising: maintaining portions of the first and second tubular member in drcumferential compression following a radial expansion and plastic deformation of the first and second tubular members: and concentrating stresses within the joint during a radial expansion and plastic deformation of the first and second tubular members.
578. The method of claim 1 , wherein the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21.
679. The method of daim 1 , wherein the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36.
580- An expandable tubular member, wherein the carbon content of the tubular member is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the tubular -, member Is less than 0.21.
581. The tubular member of claim 580. wherein the tubular member comprises a wellbore casing.
582. An expandable tubular member, wherein the carbon content of the tubular member .is greater than 0.12 percent; and wherein the carbon equivalent value for the tubular member- is less than 0.36.
583. The tubular member of dalm 582, wherein the tubular member comprises a wellbore casing.
584. The apparatus of claim 142, wherein the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21.
585. The apparatus of daim 142, wherein the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36.
586. A method of selecting tubular members for radial expansion and plastic deformation, comprising: selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and
If the carbon content of the selected tubular member is less than or equal to 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.21 , then determining that the selected tubular member Is suitable for radial expansion and plastic defomnation.
587. A method of sβledlng tubular members for radial expansion and plastic defomnation, comprising: selecting a tubular member from a collection of tubular member, determining a carbon content of the selected tubular member; ■. determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is greater than 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.36, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
588. The apparatus of claim 205, wherein the carbon content of the predetermined portion of the apparatus is less than or equal to 0.12 percent; and wherein the carbon equivalent , value for the predetermined portion of the apparatus is less than 0.21.
589. The apparatus of daim 205, wherein the carbon content of the predetermined portion of the apparatus is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the apparatus is less than 0.36.
590. The method of claim 310, wherein the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly Is less than 0.21.
591. The method of claim 310, wherein the carbon content of the predetermined portion of the tubular assembly Is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly Is less than 0.36.
592. An expandable tubular member, comprising: a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body.
593. The expandable tubular member of claim 592, wherein the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body.
594. The expandable tubular member of claim 593, wherein the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body.
"595. The expandable tubular member of claim 593. wherein the yield point of the inner - tubular portion of the tubular body varies in an non-linear fashion as a fundion of the radial position within the tubular body.
596. The expandable tubular member of claim 592, wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body.
597. The expandable tubular member of claim 596, wherein the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body.
598. The expandable tubular member of claim 596, wherein the yield point of the outer tubular portion of the. tubular body varies in an non-linear fashion as a function of the radial position within the tubular body.
599. The.expandable tubular member of claim 592, wherein the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body.
600. The expandable tubular member of claim 599, wherein the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body.
601. The expandable tubular member of claim 599, wherein the yield point of the inner tubular portion of the tubular body varies in a linear fashion a a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies In a non-linear fashion as a function of the radial position within, he , tubular body.
602. Th© expandable tubular member of claim 599, wherein the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position ithin the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body.
603. The expandable tubular member of claim 599, wherein the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body: and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body.
604. The expandable tubular member of claim 599, wherein the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
605. The expandable tubular member of claim 599, wherein the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of Change of the yield point of the outer tubular portion of the tubular body.
606. The method of claim 1 , wherein a yield point of an inner tubular portion of at least a . portion of the tubular assembly is less than a yield point of an outer tubular portion of the portion of the tubular assembly.
607. The method of claim 606, wherein the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body.
608. The method of daim 607. wherein the yield point of the Inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body.
609. The method of daim 607, wherein the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body.
610. The method of claim 606, wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body.
611. The method of claim 610, wherein the yield point of the outer tubular portion of the tubular body varies In an linear fashion as a function of the radial position within the tubular body.
612. The method of claim 610, wherein the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body.
613. The method of claim 606, wherein the yield point of the inner tubular portion of the tubular body varies as a fundion of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body.
614. The method of daim 613, wherein the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a fundion of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies In a linear fashion as a fundion of the radial position within the tubular body.
615. The method of claim 613, wherein the yield point of the inner tubular portion of the tubular body varies In a linear fashion as a function of the radial position within the tubular . body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body.
616. The method of daim 613, wherein the yield point of the Inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body.
61 . The method of claim 613, wherein the yield point of the Inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. >.
618. The method of claim 613, wherein the rate of change of the yield point of the inner tubular portion of the tubular body Is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
619. The method of claim 613..wherein the rate of change of the yield point of the Inner tubular portion of the tubular body is different than the rate of change of the yield point of tha outer tubular portion of the tubular body.
620. The apparatus of daim 142. wherein a yield point of an inner tubular portion of at least a portion of the tubular assembly Is less than a yield point of an outer tubular portion of - the portion of the tubular assembly.
621. The apparatus of daim 620, wherein the yield point of the inner tubular portion of the ■ tubular body varies as a function of the radial position within the tubular body.
622. The apparatus of claim 621 , wherein the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body.
623. The apparatus of claim 621 , wherein the yield point of the Inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial' position within the; . . tubular body.
624. The apparatus of claim 620, wherein the yield point of the outer tubular portion of the tubular body varies as a fundion of the radial position within the tubular body.
625. The apparatus of daim 624, wherein the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a fundion of the radial position within the tubular body. '
626. The apparatus of claim 624, wherein the yield point of the outer tubular portion of the tubular body varies In an non-linear fashion as a function of the radial position within the < tubular body.
627. The apparatus of daim 620, wherein the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tυbμlar body varies as a function of the radial position within the tubular body.
628. The apparatus of claim 627, wherein the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body.
629. The apparatus of claim 627, wherein the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body.
630. The apparatus of claim 627, wherein the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a fundion of the radial position within the tubular body. . • ; ■ -
631. The apparatus of claim 627, wherein the yield point of the inner tubular portion of the tubular body varies In a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body ■ varies in a non-linear fashion as a function of the radial position within the tubular- body. ■■
632. The apparatus of claim 627, wherein the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
633. The apparatus of claim 627, wherein the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
634. The method of claim 1 , wherein prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstrudure comprising a hard phase structure and a soft phase strudure.
635. The method of claim 634, wherein prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstrudure comprising a transitional phase structure.
636. The method of claim 715, wherein the hard phase structure comprises martensite.
637. The method of claim 634, wherein the soft phase structure comprises ferrite.
638. The method of claim 634, wherein the transitional phase structure comprises retained austentite.
639. The method of claim 634, wherein the hard phase structure comprises martensite; ■ wherein the soft phase structure comprises ferrite; and wherein the transitional phase strudure comprises retained austentite.
640. The method of claim 634. wherein the portion of the tubular assembly comprising a microstructure comprising a hard phase structure and a soft phase structure comprises, by weight percentage, about 0.1 % C, about 1.2% Mn, and about 0.3% Si.
641. The apparatus of claim 142, wherein at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure.
642. The apparatus of claim 641. wherein prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a transitional phase structure.
643. The apparatus of. daim 641 , wherein the hard phase strudure comprises martensite.
644. The apparatus of claim 641 , wherein the soft phase structure comprises ferrite.
645. The apparatus of daim 641 , wherein the transitional phase structure comprises retained austentite.
646. The apparatus of daim 641 , wherein the hard phase strudure comprises martensite; wherein the soft phase structure comprises ferrite; and wherein the transitional phase structure comprises retained austentite. • 647. The apparatus of daim 641. wherein the portion of the tubular assembly comprising a microstructure comprising a hard phase structure and a soft phase structure comprises, by weight percentage, about 0.1% C, about 1.2% Mn, and about 0.3% SI.
■648. A method of manufacturing an expandable tubular member, comprising: providing a tubular member; heat treating the tubular member; and quenching the tubular member; wherein following the quenching, the tubular member comprises a microstrudure comprising a hard phase strudure and a soft phase strudure.
' 649. The method of claim 648. wherein the provided tubular member comprises, by weight percentage, 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si. 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01%Ti.
650. The method of claim 648, wherein the provided tubular member comprises, by weight 'percentage. 0.18% C. 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu. 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo. 0.03% Nb. and 0.01 %Ti.
651. The method of dalm 648, wherein the provided tubular member comprises, by weight percentage, 0.08% C. 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0:06% Cu,.0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01%Ti.
652. The method of claim 648, wherein the provided tubular member comprises a microstructure comprising one or more of the following: martensite, peariite, vanadium carbide, nickel carbide, or titanium carbide.
653. The method of claim 648, wherein the provided tubular member comprises a microstructure comprising one or more of the following: peariite or peariite striation.
654. The method of claim 648, wherein the provided tubular member comprises a microstrudure comprising one or more of the following: grain peariite. widmanstatten martensite, vanadium carbide, nickel carbide, or titanium carbide.
655. The method of claim 648, wherein the heat treating comprises heating the provided tubular member for about 10 minutes at 790 °C.
656. The method of claim 648, wherein the quenching comprises quenching the heat- - treated tubular member in water. . .
657. The method of claim 648, wherein following the quenching, the tubular member comprises a microstrudure comprising one or more of the following: ferrite, grain peariite, or martensite. , •
658. The method of claim 648, wherein following the quenching, the tubular member . comprises a microstructure comprising one or more of the following: ferrite, martensite, or bainite. \ ,
659. The method of claim 648, wherein following the quenching, the tubular member . comprises a microstructure comprising one or more of the following: bainite, peariite, or ferrite.
660. The method of claim 648, wherein following the quenching, the tubular member . comprises a yield strength of about 67ksi and a tensile strength of about 95 ksi.'
661. The method of daim 648, wherein following the quenching, the tubular member ■ comprises a yield strength of about 82 ksi and a tensile strength of about 130 ksi.
662. The method of claim 648, wherein following the quenching, the tubular member comprises a yield strength of about 60 ksi and a tensile strength of about 97 ksi.
663. The method of daim 648, further comprising: positioning the quenched tubular member within a preexisting strudure; and radially expanding and plastically deforming the tubular member within the preexisting strudure.
664. The apparatus of daim 142, wherein at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase strudure.
665. The apparatus of claim 664, wherein the portion of the tubular assembly comprises, by weight percentage, 0.065% C, 1.44% Mn, 0.01% P, 0.002% S. 0.24% Si, 0.01% Cu, .- 0.01 % NI, 0.02% Cr, 0.05% V, 0.01 % Mo, 0.01 % Nb, and 0.01 %Ti.
666. The apparatus of claim 664, wherein the portion of the tubular assembly comprises, by weight percentage, 0.18% C, 1.28% Mn, 0.017% P. 0.004% S, 0.29% SI, 0.01% Cu. .
.0.01 % Ni, 0.03% Cr, 0.04% V, 0.01 % Mo, 0.03% Nb, and 0.01 %Ti.
667. The apparatus of claim 664, wherein the portion of the tubular assembly comprises, by weight percentage, 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo. 0.01% Nb, and 0.01 %Ti.
668. The apparatus of daim 664. wherein the portion of the tubular assembly comprises a microstrudure comprising one or more of the following: martensite, peariite, vanadium carbide, nickel carbide, or titanium carbide.
669. The apparatus of claim 664, wherein the portion of the tubular assembly comprises a microstructure comprising one or more of the following: peariite or peariite striation.
670. The apparatus of claim 664, wherein the portion of the tubular assembly comprises a microstructure comprising one or more of the following: grain peariite, widmanstatten martensite, vanadium carbide, nickel carbide, or titanium carbide.
671. The apparatus of claim 664, wherein the portion of the tubular assembly comprises a microstrudure comprising one or more of the following: ferrite, grain peariite, or martensite.
672. The apparatus of claim 664, wherein the portion of the tubular assembly comprises a microstrudure comprising one or more of the following: ferrite, martensite, or bainite.
673. The apparatus of claim 664, wherein the portion of the tubular assembly comprises a microstructure comprising one or more of the following: bainite, peariite, or ferrite.
674. The apparatus of claim 664, wherein the portion of the tubular assembly comprises a yield strength of about 67ksi and a tensile strength of about 95 ksi.
675. The apparatus of daim 664, wherein the portion of the tubular assembly comprises a yield strength of about 82 ksi and a tensile strength of about 130 ksi.
676. The apparatus of daim 664, wherein the portion of the tubular assembly comprises a yield strength of about 60 ksi and a tensile strength of about 97 ksi.
677. A method of radially expanding a tubular assembly, comprising: radially expanding and plastically deforming a lower portion of the tubular assembly by pressurizing the interior of the lower portion of the tubular assembly; and then, radially expanding and plastically deforming the remaining portion of the tubular assembly by contadiπg the interior of the tubular assembly with an expansion device.
678. The method of claim 677, wherein the expansion device comprises an adjustable expansion device.
679. The method of claim 677, wherein the expansion device comprises a hydroforming expansion device.
680. The method of claim 677, wherein the expansion device comprises a rotary expansion device.
681. The method of claim 677, wherein the lower portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
682. The method of daim 681 , wherein the remaining portion of the tubular assembly has a higher dudility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic defomnation.
683. The method of claim 677. wherein the lower portion of the tubular assembly comprises a shoe defining a valveable passage.
684. A system for radially expanding. a tubular assembly, comprising: means for radially expanding and plastically deforming a lower portion of the tubular assembly by pressurizing the interior of the lower portion of the tubular assembly; and then, means for radially expanding and plastically deforming the remaining portion of the tubular assembly by contacting the Interior of the tubular assembly with an expansion device.
685. The system of claim 684, wherein the lower portion of the tubular assembly has a higher dudility and a lower yield point prior to the radial expansion and plastic deformation , than a ter the radial expansion and plastic deformation.
686. The system of claim 685, wherein the remaining portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic defomnation than after the radial expansion and plastic deformation.
687. A method of repairing a tubular assembly, comprising: positioning a tubular patch within the tubular assembly; and radially expanding and plastically deforming a tubular patch into engagement with the tubular assembly by pressurizing the interior of the tubular patch.
688. The method of claim 687, wherein the tubular patch has a higher ductility and a lower yield point prior to the radial expansion and plastic defomnation than after the radial expansion and plastic deformation.
689. A system for repairing a tubular assembly, comprising: means for positioning a tubular patch within the tubular assembly; and means for radially expanding and plastically deforming a tubular patch into engagement with the tubular assembly by pressurizing the interior of the tubular patch.
690. The system of claim 689, wherein the tubular patch has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
691. A method of radially expanding a tubular member, comprising: accumulating a supply of pressurized fluid; and controliably injecting the pressurized fluid into the interior of the tubular member. .
692. The method of claim 691 , wherein accumulating the supply of pressurized fluid comprises: monitoring the operating pressure of the accumulated fluid; and If the operating pressure of the accumulated fluid is less than a predetermined amount, Injecting pressurized fluid into the accumulated fluid.
693. The method of claim 691 , wherein controliably injecting the pressurized fluid into the interior of the tubular member comprises: monitoring the operating condition of the tubular member and if the tubular member has been radial expanded, releasing the pressurized fluid from the Interior of the tubular member.
694. An apparatus for radially expanding a tubular member, comprising: a fluid reservoir; a pump for pumping fluids out of the fluid reservoir; an accumulator for receiving and accumulating the fluids pumped from the reservoir; a flow control valve for controliably releasing the fluids accumulated within the reservoir; and an expansion element for engaging the Interior of the tubular member to define a pressure chamber within the tubular member and receiving the released accumulated fluids into the pressure chamber.
695. An apparatus for radially expanding a tubular member, comprising: an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device; and an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member; wherein at least a portion of the expandable tubular member has a higher ductility' and a lower yield point prior to the radial expansion and plastic defomnation than after the radial expansion and plastic deformation.
696. The apparatus of claim 695, further comprising: means for transmitting torque between the expandable tubular member and the tubular support member.
697. The apparatus of claim 695, further comprising: means for sealing the interface between the expandable tubular member and the tubular support member.
698. The apparatus of claim 695, further comprising: another tubular support member received within the tubular support member releasably coupled to the expandable tubular member.
699. The apparatus of claim 698, further comprising: means for transmitting torque between the expandable tubular member and the other tubular support member.
700. The apparatus of daim 698, further comprising: means for transmitting torque between the other tubular support member and the tubular support member.
701. The apparatus of daim 698, further comprising: means for sealing the interface between the other tubular support member and the tubular support member.
702. The apparatus of daim 698, further comprising: means for sealing the interface between the expandable tubular member and the tubular support member.
703. The apparatus of claim 698, further comprising: means for sensing the operating pressure within the other tubular support member.
704. The apparatus of claim 698, further comprising: means for pressurizing the Interior of the other tubular support member.
705. The apparatus of claim 698, further comprising: means for limiting axial displacement of tha other tubular support member relative to the tubular support member.
706. The apparatus of claim 698, further comprising: a tubular liner coupjed to an end of the expandable tubular member.
707. The apparatus of claim 695, further comprising: a tubular liner coupled to an end of the expandable tubular member.
708. An apparatus for radially expanding a tubular member, comprising: an expandable tubular member,. a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member, a tubular support member positioned within the expandable tubular member coupled to the locking device; an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member; means for transmitting torque between the expandable tubular member and the tubular support member; means for sealing the interface between the expandable tubular member and the tubular support member, another tubular support member received within the tubular support member releasably coupled to the expandable tubular member, means for transmitting torque between the-expaπdable tubular member and the other tubular support member; means for transmitting torque between the other tubular support member and the • tubular support member; means for sealing the interface between the other tubular support member and the tubular support member; means for sealing the Interface between the expandable tubular member and the tubular support member, means for sensing the operating pressure within the other tubular support member; means for. pressurizing the interior of the other tubular support member; means for limiting axial displacement of the other tubular support member relative to the tubular support member; and a tubu/ar liner coupled to an end of the expandable tubular member; wherein at (east a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
709. A method for radially expanding a tubular member, comprising: positioning a tubular member and en adjustable expansion device within a preexisting structure; radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; Increasing the size of the adjustable expansion device; and radially expanding and plastically deforming another portion of the tubular member by displadng the adjustable expansion device relative to the tubular member.
710. The method of claim 709, further comprising: sensing an operating pressure within the tubular member.
711. The method of claim 709, wherein radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member comprises: injecting fluidic material into the tubular member; sensing the operating pressure of the injected fluidic material; and If the operating pressure of the injected fluidic material exceeds a predetermined • value, permitting the fluidic material to enter a pressure chamber defined within the tubular member.
712. The method of claim 709. wherein at least a portion of the tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic defomnation than after the radial expansion and plastic deformation.
713. The method of daim 709. wherein the portion of the tubular member comprises the pressurized portion of the tubular member.
714. A system for radially expanding a tubular member, comprising: means for positioning a tubular member and an adjustable expansion device within a preexisting strudure; means for radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; means for increasing the size of the adjustable expansion device; and means for radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member.
715. The system of claim 714, further comprising: sensing an operating pressure within the tubular member.
716. The system of claim 714, wherein radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member comprises: injecting fluidic material into the tubular member; sensing the operating pressure of the injected fluidic material; and rf the operating pressure of the injected fluidic material exceeds a predetermined value, permitting the fluidic material to enter a pressure chamber defined within the tubular member.
717. The system of daim 714, wherein at least a portion of the tubular member has a higher dudility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
718. The system of claim 714, wherein the portion of the tubular member comprises the pressurized portion of the tubular member.
719. A method of radially expanding and plastically deforming an expandable tubular member, comprising: limiting the amount of radial expansion of the expandable tubular member.
720. The method of claim 719, wherein limiting the amount of radial expansion of the expandable tubular member comprises: coupling another tubular member to the expandable tubular member that limits the amount of the radial expansion of the expandable tubular member.
721. The method of daim 720. wherein the other tubular member defines: one or more slots.
722. The method of daim 720, wherein the other tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic defomnation than after the radial expansion and plastic deformation.
723. An apparatus for radially expanding a tubular member, comprising: an expandable tubular member, an expansion device coupled to the expandable tubular member for radially expanding and plastically deforming the expandable tubular member; and an tubular expansion limiter coupled to the expandable tubular member for limiting the degree to which the expandable tubular member may be radially expanded and plastically deformed.
724. The apparatus of daim 723, wherein the tubular expansion limiter comprises a tubular member that defines one or more slots.
725. The apparatus of claim 723, wherein the tubular expansion limiter comprises a • tubular member that has a higher dudility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
726. The apparatus of claim 723, further comprising: a locking device positioned within the expandable tubular member releasably > coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device and the expansion device.
727. The apparatus of claim 723, wherein at least a portion of the expandable tubular • member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic defomnation.
728- The apparatus of claim 726, further comprising: means for transmitting torque between the expandable tubular member and the tubular support member.
729. The apparatus of claim 726, further comprising: means for sealing the interface between the expandable tubular member and the tubular support member.
730. The apparatus of claim 726, further comprising: means for sealing the interface between the expandable tubular member and the tubular support member.
731. The apparatus of claim 726, further comprising: means for sensing the operating pressure within the tubular support member.
732. The apparatus of claim 726. further comprising: means for pressurizing the interior of the tubular support member.
733. An apparatus for radially expanding a tubular member, comprising: an expandable tubular member; an expansion device coupled to the expandable tubular member for radially expanding and plastically deforming the expandable tubular member, an tubular expansion limiter coupled to the expandable tubular member for limiting - the degree to which the expandable tubular member may be radially expanded and plastically deformed: a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; a tubular support member positioned within the expandable tubular member coupled to the locking device and the expansion device; means for transmitting torque between the expandable tubular member and the . tubular support member; means for sealing the interface between the expandable tubular member and the tubular support member; means for sensing the operating pressure within the tubular support member; and ■ means for pressurizing the interior of the tubular support member; wherein at least a portion of the expandable tubular member has a higher dudilit : and a lower yield point prior to tha radial expansion and plastic defomnation than after the radial expansion and plastic deformation.
734. A method for radially expanding a tubular member, comprising: positioning a tubular member and an adjustable expansion device within a preexisting structure; radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; limiting the extent to which the portion of the tubular member is radially expanded and plastically deformed by pressurizing the interior of the tubular member; increasing the size of the adjustable expansion device; and radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member.
735. The method of claim 734, further comprising: sensing an operating pressure within the tubular member.
736. The method of claim 734, wherein radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member comprises: injecting fluidic material Into the tubular member; sensing the operating pressure of the Injeded fluidic material; and if the operating pressure of the injected fluidic material exceeds a predetermined • value, permitting the fluidic material to enter a pressure chamber defined within the tubular member.
737. The method of claim 734, wherein at least a portion of the tubular member has a- higher ductility and a lower yield point prior to the radial expansion and plastic deformation - than after the radial expansion and plastic deformation.
738. The method of claim 734, wherein limiting the extent to which the portion of the tubular member is radially expanded and plastically deformed by pressurizing the interior of the tubular member comprises: applying a force to the exterior- of the tubular member.
739. The method of daim 738, wherein applying a force to the exterior of the tubular member comprises: applying a variable force to the exterior of the tubular member.
740. A system for radially expanding a tubular member, comprising: means for positioning a tubular member and an adjustable expansion device within a preexisting structure; means for radially expanding and plastically deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member; means for limiting the extent to which the portion of tine tubular member Is radially expanded and plastically deformed by pressurizing the interior of the tubular member; means for increasing the size of the adjustable expansion device; and means for radially expanding and plastically deforming another portion of the tubular member by displacing the adjustable expansion device relative to the tubular member.
741. The method of claim 740, further comprising: means for sensing an operating pressure within the tubular member.
742. The method of claim 740, wherein means for radially expanding and plastically - deforming at least a portion of the tubular member by pressurizing an interior portion of the tubular member comprises: means for injeding fluidic material into the tubular member; means for sensing the operating pressure of the injeded fluidic material; and - if the operating pressure of the Injected fluidic material exceeds a predetermined value, means for permitting the fluidic material to enter a pressure chamber defined within the tubular member.
743. The method of claim 740. wherein at least a portion of the tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
744. The method of claim 740, wherein means for limiting the extent to which the portion of the tubular member is radially expanded and plastically deformed by pressurizing the . interior of the tubular member comprises: > means for applying a force to the exterior of the tubular member.
745. The method of claim 738, wherein means for applying a force to the exterior of the tubular member comprises: means for applying a variable force to the exterior of the tubular member.
746. A system for radially expanding a tubular member, comprising: means for accumulating a supply of pressurized fluid; and means for controliably injeding the pressurized fluid into the interior of the tubular member.
747. The system of claim 746. wherein means for accumulating tha supply of pressurized fluid comprises: weans for monitoring the operating pressure of the accumulated fluid; and if the operating pressure of the accumulated fluid is less than a predetermined amount, means for Injecting pressurized fluid into the accumulated fluid.
748. The system of claim 726, wherein means for controliably injecting tha pressurized fluid into the interior of the tubular member comprises: means for monitoring the operating condition of the tubular member; and if the tubular member has been radial expanded, means for releasing the pressurized fluid from the interior of the tubular member.
749. An apparatus for radially expanding an expandable tubular member, comprising: an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an aduator positioned ithin the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; a first expansion device coupled to the tubular support member; a second expansion device coupled to the tubular support member; and an expandable tubular sleeve coupled to the second expansion device.
750. The apparatus of claim 749, wherein the outside diameters of the first and second expansion devices ana unequal.
751. The apparatus of claim 750, wherein the outside diameter of the first expansion device is greater than the outside diameter of the second expansion device.
752. The apparatus of claim 749, wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
753. The apparatus of claim 749, wherein at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
754. The apparatus of dalm 749, wherein the outside diameters of the first and second expansion devices are both less than or equal to the outside diameter of the expandable tubular member.
755. The apparatus ,of claim 749. wherein the outside diameter of the expandable tubular sleeve is less than or equal to the outside diameter of the expandable tubular member.
756. The apparatus of claim 748, further comprising: means for transmitting torque between the expandable tubular member and the, tubular support member.
757. The apparatus of claim 748, further comprising: means for pressurizing the interior of the tubular support member.
758. The apparatus of dalm 748, further comprising: means for limiting axial displacement of the expandable tubular sleeve.
759. The apparatus of claim 748, further comprising: means for limiting axial displacement of the expandable tubular member.
760. The apparatus of claim 758, further comprising: means for transmitting torque from the tubular support member to the means for , limiting axial displacement of the expandable tubular sleeve.
761. The apparatus of claim 748, further comprising: means for displacing the first expansion device relative to the expandable tubular member to radially expand and plastically deform the expandable tubular member.
762. The apparatus of claim 748, further comprising: means for displacing the second expansion device relative to the expandable tubular sleeve to radially expand and plastically deform the expandable tubular sleeve.
763. The apparatus of dalm 748, wherein the wall thickness of the expandable tubular sleeve is variable.
764. The apparatus of claim 748, wherein the expandable tubular sleeve comprises means for sealing an Interface between the expandable tubular sleeve and the.interior surface of the expandable tubular member. , .
765. . An apparatus for radially expanding an expandable tubular member, comprising:: . an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled. to the actuator; a first expansion device coupled to the tubular support member; a second expansion device coupled to the tubular support member; an expandable tubular sleeve coupled to the second expansion device; means for transmitting torque between the expandable tubular, member and the - tubular support member; means for pressurizing the interior of the tubular support member; means for limiting axial displacement of the expandable tubular sleeve; , means for limiting axial displacement of the expandable tubular member; means for transmitting torque from the tubular support member to the means for limiting axial displacement of the expandable tubular sleeve; means for displacing the first expansion device relative to the expandable tubular. member to radially expand and plastically deform the expandable tubular member; and means for displacing the second expansion device relative to the expandable tubular sleeve to radially expand and plastically deform the expandable tubular sleeve; wherein the outside diameter of the first expansion device Is greater than the outside diameter of the second expansion device; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic defomnation than after the radial expansion and plastic deformation; wherein at least a portion of the expandable tubular sleeve has a higher dudility and a lower yield point prior to the radial expansion and plastic deformation than ; after the radial expansion and plastic deformation; wherein the outside diameters of the first and second expansion devices are both less than or equal to the outside diameter of the expandable tubular member, . wherein the outside diameter of the expandable tubular sleeve is less than or equal to the outside diameter of the expandable tubular member; wherein the wall thickness of the expandable tubular sleeve is variable; and wherein the expandable tubular sleeve comprises means for sealing an interface between the expandable tubular sleeve and the interior surface of the expandable tubular member.
766. A method for radially expanding a tubular member, comprising: positioning an expandable tubular member and an expandable tubular sleeve within . a preexisting strudure; radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve; and radially expanding and plastically deforming at least a portion of the expandable tubular sleeve.
767. The method of daim 766, further comprising: radially expanding and plastically deforming at least a portion of the expandable tubular member while simultaneously radially expanding and plastically deforming at least a portion of the expandable tubular sleeve.
768. The method αf claim 766, further comprising: radially expanding and plastically deforming another portion of the expandable tubular member after radially expanding and plastically deforming the portion of the expandable tubular sleeve.
769. The method of dalm 766, wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic . deformation than after the radial expansion and plastic deformation.
770. The method of claim 766, wherein at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
771. The method of claim 766, wherein the wall thickness of the expandable tubular sleeve is variable.
772. The method of claim -766. further comprising:' sealing an interface between the exterior surface of the expandable tubular sleeve- and the interior surface of the expandable tubular member.
773. A system for radially expanding a tubular member, comprising: means for positioning an expandable tubular member and an expandable tubular sleeve within a preexisting strudure; means for radially expanding and plastically deforming at least a portion of the expandable' tubular member onto the expandable tubular sleeve; and means for radially expanding and plastically deforming at least a portion of the . ■ expandable tubular sleeve.
774. The system of claim 773, further comprising: meaπs for radially expanding and plastically deforming at least a portion of the - . expandable tubular member while simultaneously radially expanding and plastically deforming at least a portion of the expandable tubular sleeve.
775. The system of claim 773, further comprising: means for radially expanding and plastically deforming another portion of the expandable tubular member after radially expanding and plastically deforming the portion of the expandable tubular sleeve.
776. The system of claim 773, wherein at least a portion of the expandable tubular member has a higher dudility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
777. The system of claim 773, wherein at least a portion of the expandable tubular sleeve has a higher dudility and a lower yield point prior to tha' radial expansion and plastic defomnation than after the radial expansion and plastic deformation.
778. The system of daim 773, wherein the wall thickness of the expandable tubular sleeve Is variable.
779. The system of claim 773, further comprising: sealing an interface between the exterior surface of the expandable tubular sleeve and the interior surface of tine expandable tubular member.
780. An apparatus for radially expanding an expandable tubular member, comprising: an expandable tubular member, a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; ' ' a tubular support member positioned within the expandable tubular member coupled to the actuator, an adjustable expansion device coupled to the tubular support member; a non-adjustable expansion device coupled to the tubular support member; and an expandable tubular sleeve coupled to the non-adjustable expansion device.
78 . The apparatus of daim 780, wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
782. The apparatus of claim 780, wherein at least a portion of the expandable tubular sleeve has a higher dudility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
783. The apparatus of claim 780, wherein the outside diameters of the adjustable and non-adjustable expansion devices are both less than or equal to the outside diameter of the expandable tubular member.
784. The apparatus of claim 780, wherein the outside diameter of the expandable tubular sleeve is less than or equal to the outside diameter of the expandable tubular member.
785. The apparatus of claim 780, further comprising: means for transmitting torque between the expandable tubular member and the tubular support member.
786. The apparatus of daim 780, further comprising: means for pressurizing the interior of the tubular support member.
787. The apparatus of claim 780, further comprising: means for limiting axial displacement of tha expandable tubular sleeve.
788 The apparatus of claim 780, further comprising: means for limiting axial displacement of the expandable tubular member.
789. The apparatus of daim 787, further comprising: means for transmitting torque from the tubular support member to the means for limiting axial displacement of the expandable tubular sleeve.
790. The apparatus of daim 788, further comprising: means for transmitting torque from the tubular support member to the means for limiting axial displacement of the expandable tubular member.
791. The apparatus of claim 780, further comprising: means for displacing the adjustable expansion device relative to the expandable tubular member to radially expand and plastically deform the expandable tubular member.
792. The apparatus of claim 791 , further comprising: means for pulling the adjustable expansion device through the expandable tubular member to radially expand and plastically deform the expandable tubular member.
793. The apparatus of claim 792, further comprising: fluid powered means for pulling the adjustable expansion device through the expandable tubular member to radially expand and plastically deform the expandable tubular member.
794. The apparatus of claim 780, further comprising: means for displadng the non-adjustable expansion device relative to the expandable tubular sleeve to radially expand and plastically deform the expandable tubular sleeve.
795. The apparatus of claim 794, further comprising: fluid powered means for pulling the non-adjustable expansion device through the expandable tubular sleeve to radially expand and plastically deform the expandable tubular sleeve.
796. The apparatus of claim 780, wherein tha wall thickness of the expandable tubular . . sleeve is variable. ~"
797. The apparatus of claim 780, wherein the expandable tubular sleeve comprises means for sealing an interface between the expandable tubular sleeve and the interior surface of the expandable tubular member.
798. An apparatus for radially expanding an expandable tubular member, comprising: an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an aduator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the aduator; an adjustable expansion device coupled to the tubular support member; a non-adjustable expansion device coupled to the tubular support member; an expandable tubular sleeve coupled to the non-adjustable expansion device; means for transmitting torque between the expandable tubular member and the tubular support member; means for pressurizing the interior of the tubular support member; means for limiting axial displacement of the expandable tubular sleeve; means for limiting axial displacement of the expandable tubular member; means for transmitting torque from the tubular support member to the means for limiting axial displacement of the expandable tubular sleeve; means for transmitting torque from the tubular support member to the means for - limiting axial displacement of the expandable tubular member; fluid powered means for pulling the adjustable expansion device through the expandable tubular member to radially expand and plastically deform the expandable tubular member; and fluid powered means for pulling the non-adjustable expansion device through the . expandable tubular sleeve to radially expand and plastically deform the expandable tubular sleeve; wherein at least a portion of the expandable tubular member has a higher ductility. and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation; wherein at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation; wherein the outside diameters of the adjustable and non-adjustable expansion devices are both less than or equal to the outside diameter of the expandable tubular member, wherein the outside diameter of the expandable tubular sleeve is less than or equal to the outside diameter of the expandable tubular member; herein the wall thickness of the expandable tubular sleeve is variable; and wherein the expandable tubular sleeve comprises means for sealing an interface between the expandable tubular sleeve and the interior surface of the expandable tubular member.
799. A method for radially expanding a tubular member, comprising: positioning an expandable tubular member, an expandable tubular sleeve, and an -• adjustable expansion device within a preexisting strudure; - increasing the size of the adjustable expansion device; radially expanding and plastically deforming at least a portion of the expandable tubular member onto the expandable tubular sleeve using the adjustable expansion device: and radially expanding and plastically deforming at least a portion of the expandable tubular sleeve.
800. The method of dalm 799, further comprising: radially expanding and plastically deforming at least a portion of the expandable tubular member while simultaneously radially expanding and plastically deforming at least a portion of the expandable-tubular sleeve.
801. The method of claim 799, further comprising: i radially expanding and plastically deforming another portion of the expandable tubular member after radially expanding and plastically deforming the portion of the expandable tubular sleeve.
802. The method of claim 799, wherein at least a portion of the expandable tubular member has a higher dudility and a lower yield point prior to the radial expansion and plastic defomnation than after the radial expansion and plastic deformation.
803. The method of claim 799. wherein at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
804. The method of claim 799, wherein the wall thickness of the expandable tubular sleeve is variable.
805. The method of claim 799, further comprising: sealing an Interface between the exterior surface of the expandable tubular sleeve and the interior surface of the expandable tubular member.
806. The method of claim 799, further comprising: pulling the adjustable expansion device through the expandable tubular member. -
807. The method of claim 885, further comprising: pulling the adjustable expansion device through the expandable tubular member using fluid pressure.
808. A system for radially expanding a tubular member, comprising: means for positioning an expandable tubular member, an expandable tubular sleeve. and an adjustable expansion device within a preexisting strudure; means for increasing the size of the adjustable expansion device; means for radially expanding and plastically deforming at least a portion of the . expandable tubular member onto the expandable tubular sleeve using the adjustable expansion device; and means for radially expanding and plastically deforming at least a portion of the ; expandable tubular sleeve.
809. The. system of claim 808, further comprising: means for radially expanding and plastically deforming at least a portion of the expandable tubular member while simultaneously radially expanding and plastically deforming at least a portion of the expandable tubular sleeve.
810. The system of daim 808, further comprising: • means for radially expanding and plastically deforming another portion of the expandable tubular member after radially expanding and plastically deforming the portion of the expandable tubular sleeve.
811. The system of daim 808, wherein at least a portion of the expandable tubular member has a higher dudility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic defomnation.
812. The system of daim 808, wherein at least a portion of the expandable tubular sleeve has a higher dudility and a lower yield point prior to the radial expansion and plastic, deformation than after the radial expansion and plastic deformation.
813. The system of daim 808. wherein the wall thickness of the expandable tubular sleeve Is. variable.
814. The system of daim 808, further comprising: means for sealing an Interface between the exterior surface of the expandable tubular sleeve and the Interior surface of the expandable tubular member.
815. The system of claim 808, further comprising: means for pulling the adjustable expansion device through the expandable tubular member.
816. The system of dalm 815. further comprising: means for pulling the adjustable expansion device through the expandable tubular member using fluid pressure.
817. The apparatus of daim 780, further comprising: ' - a perforated sleeve coupled to the expandable tubular member that receives the adjustable expansion device.
818. The method of daim 799, further comprising: preventing debris from damaging the adjustable expansion device.
819. The system of claim 808, further comprising: means for preventing debris from damaging the adjustable expansion device.
820. An apparatus for radially expanding an expandable tubular member, comprising: an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an aduator positioned within the expandable tubular member coupled to the locking , device; a tubular support member positioned within the expandable tubular member coupled to the actuator; and an adjustable expansion device positioned within the expandable tubular member coupled to the tubular support member.
821. The apparatus of claim 820, wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
822. The apparatus of claim 820, further comprising an expandable tubular sleeve coupled to an end of the expandable tubular member that receives the adjustable expansion device.
823. The apparatus of claim 822, wherein at least a portion of the expandable tubular sleeve has a higher ductility and a lower yield point prior to the radial expansion and plastic - deformation than after the radial expansion and plastic deformation. - i
824. The apparatus of claim 820, further comprising: means for transmitting torque between the expandable tubular member and the tubular support member.
825. The apparatus of claim 820, further comprising: means for pressurizing the Interior of the tubular support member.
826. The apparatus of dalm 820, wherein the actuator comprises: means for displacing the adjustable expansion device relative to the expandable tubular member to radially expand and plastically deform the expandable tubular member.
827. The apparatus of claim 826, wherein the actuator further comprises: means for pulling the adjustable expansion device through the expandable tubular member to radially expand and plastically deform the expandable tubular member.
828. The apparatus of claim 827, wherein the aduator further comprises: fluid powered means for pulling the adjustable expansion device through the expandable tubular member to radially expand and plastically deform the expandable tubular member.
829. The apparatus of claim 827, further comprising: ' means for adjusting the size of the adjustable expansion device.
830. An apparatus for radially expanding an expandable tubular member, comprising: an expandable tubular member; a locking device positioned within the expandable tubular member releasably coupled to the expandable tubular member; an actuator positioned within the expandable tubular member coupled to the locking device; a tubular support member positioned within the expandable tubular member coupled to the actuator; an adjustable expansion device positioned within the expandable tubular member . coupled to the tubular support member; an expandable tubular sleeve coupled to an end of the expandable tubular member that receives the adjustable expansion device; means for transmitting torque between the expandable tubular member and the tubular support member; means for pressurizing the Interior of the tubular support member; and means for adjusting the size of the adjustable expansion device; fluid powered means for pulling the adjustable expansion device through the expandable tubular member to radially expand and plastically deform the expandable tubular member; wherein at least a portion of the expandable tubular member has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation; and wherein at least a portion of the expandable tubular sleeve has a higher dudility and a lower yield point prior to the radial expansion and plastic defomnation than after the radial expansion and plastic deformation.
831. A method for radially expanding a tubular member, comprising: positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting strudure; increasing the size of the adjustable expansion device to radially expand and plastically deform at least a portion of at least one of the expandable tubular member and the expandable tubular βleeve; and radially expanding and plastically deforming at least another portion of the expandable tubular member using the adjustable expansion device.
832. The method of claim 831 , wherein at least a portion of the expandable tubular member has a higher dudility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
833. The method of daim 831 , wherein at least a portion of the expandable tubular sleeve has a higher dudility and a lower yield point prior to the radial expansion and plastic i deformation than after the radial expansion and plastic deformation.
834. The method of daim 831. further comprising: pulling the adjustable expansion device through the expandable tubular member.
835. The method of daim 831 , further comprising: pulling the adjustable expansion device through the expandable tubular member using fluid pressure.
836. A system for radially expanding a tubular member, comprising: means for positioning an expandable tubular member, an expandable tubular sleeve, and an adjustable expansion device within a preexisting structure; means for increasing the size of the adjustable expansion device to radially expand • and plastically deform at least a portion of at least one of the expandable tubular member and the expandable tubular sleeve; and means for radially expanding and plastically deforming at least another portion of the expandable tubular member using the adjustable expansion device.
837. The system of daim 836, wherein at least a portion of the expandable tubular member has a higher dudility and a lower yield point prior to the radial expansion and plastic defomnation than after the radial expansion and plastic deformation.
838. The system of claim 836, wherein at least a portion of the expandable tubular sleeve has a higher dudility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
839. The system of claim 836, further comprising: means for pulling the adjustable expansion device through the expandable tubular member.
840. The system of daim 836, further comprising: means for pulling the adjustable expansion device through the expandable tubular member using fluid pressure.
PCT/US2004/028831 2003-09-05 2004-09-07 Radial expansion system WO2005024170A2 (en)

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US50043503P 2003-09-05 2003-09-05
US60/500,435 2003-09-05
US58537004P 2004-07-02 2004-07-02
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PCT/US2004/028888 WO2005079186A2 (en) 2003-09-05 2004-09-07 Expandable tubular
PCT/US2004/029025 WO2005028803A2 (en) 2003-09-05 2004-09-07 Expandable tubular

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