U.S. patent application number 10/700484 was filed with the patent office on 2005-05-05 for high-strength sealed connection for expandable tubulars.
Invention is credited to Carcagno, Gabriel E., Santi, Nestor J..
Application Number | 20050093250 10/700484 |
Document ID | / |
Family ID | 34551223 |
Filed Date | 2005-05-05 |
United States Patent
Application |
20050093250 |
Kind Code |
A1 |
Santi, Nestor J. ; et
al. |
May 5, 2005 |
High-strength sealed connection for expandable tubulars
Abstract
A radially expandable sealed tubular joint for use in oil and
gas wells having a pair of radially expandable tubular elements
each having threading at a free end thereof and coupled to one
another to form a flush joint connection, the threading including
hooked incomplete threads located at least adjacent the free ends,
and a sealing substance extending between and adhering to the
threading of one element and the threading of the other element,
wherein after a radial expansion of the coupled pair of elements
the sealing substance remains extended between and adhered to the
threading of one element and the threading of the other element.
The sealing substance is either a greaseless elastomeric sealant
coated on one or both of the pair of elements or a pure metal
applied to each of the pair of elements.
Inventors: |
Santi, Nestor J.; (Buenos
Aires, AR) ; Carcagno, Gabriel E.; (Campana,
AR) |
Correspondence
Address: |
FITZPATRICK CELLA HARPER & SCINTO
30 ROCKEFELLER PLAZA
NEW YORK
NY
10112
US
|
Family ID: |
34551223 |
Appl. No.: |
10/700484 |
Filed: |
November 5, 2003 |
Current U.S.
Class: |
277/602 |
Current CPC
Class: |
E21B 17/042 20130101;
F16L 13/168 20130101; Y10T 29/49885 20150115; E21B 43/103 20130101;
F16L 15/06 20130101; E21B 43/106 20130101; Y10T 29/49805
20150115 |
Class at
Publication: |
277/602 |
International
Class: |
F16L 017/00 |
Claims
1. A radially expandable threaded tubular assembly comprising: a
radially expandable male threaded element having external male
threading and a first free end, the external male threading
including a first incomplete thread and a first hooked thread, the
first incomplete thread being located at least adjacent the first
free end of said male threaded element; a radially expandable
female threaded element having internal female threading and a
second free end, the internal female threading including a second
incomplete thread and a second hooked thread, the second incomplete
thread being located at least adjacent the second free end of said
female threaded element, said female threaded element being
threadedly engaged with said male threaded element; and an
elastomeric sealant extending between the external male threading
and the internal female threading and adhering to both the external
male threading and the internal female threading, said elastomeric
sealant capable of being elongated after curing while remaining
extended between and adhered to the external male threading and the
internal female threading.
2. An assembly according to claim 1, wherein said elastomeric
sealant is capable of being elongated at least about 45 percent
after curing while remaining extended between and adhered to each
of the external male threading and the internal female threading
and has an elastic modulus less than about 2.0 MPa (290
p.s.i.).
3. An assembly according to claim 1, wherein said elastomeric
sealant is capable of being elongated at least about 100 percent
after curing while remaining extended between and adhered to each
of the external male threading and the internal female threading
and has an elastic modulus less than about 1.0 MPa (145
p.s.i.).
4. An assembly according to claim 1, wherein said elastomeric
sealant is capable of being elongated at least about 400 percent
after curing while remaining extended between and adhered to each
of the external male threading and the internal female threading
and has an elastic modulus between about 0.5 MPa (73 p.s.i.) and
about 2.0 MPa (290 p.s.i.).
5. An assembly according to claim 4, wherein said elastomeric
sealant is adhered to each of the external male threading and the
internal female threading with an adhesion-to-rigid-substrate of at
least 0.35 MPa (51 p.s.i.).
6. An assembly according to claim 4, wherein said elastomeric
sealant is adhered to each of the external male threading and the
internal female threading with an adhesion-to-rigid-substrate of at
least 0.7 MPa (102 p.s.i.).
7. An assembly according to claim 6, wherein said elastomeric
sealant is a greaseless elastomeric sealant.
8. An assembly according to claim 7, wherein said greaseless
elastomeric sealant is capable of curing in the absence of oxygen
and in the absence of humidity.
9. An assembly according to claim 8, wherein said greaseless
elastomeric sealant is a polysulfide sealant or a polyurethane
sealant.
10. An assembly according to claim 9, wherein said greaseless
elastomeric sealant is a viscous paste or a liquid before curing
and is a rubber-like solid after curing.
11. An assembly according to claim 1, wherein said male threaded
element and said female threaded element threadedly engage each
other to form a flush joint connection.
12. An assembly according to claim 11, wherein each of the first
incomplete thread and the second incomplete thread has a perfect
crest and an imperfect root.
13. An assembly according to claim 12, wherein each of the first
incomplete thread and the second incomplete thread is also a hooked
thread.
14. An assembly according to claim 13, wherein the first incomplete
thread is the initial thread adjacent the first free end of said
male threaded element, and the second incomplete thread is the
initial thread adjacent the second free end of said female threaded
element.
15. An assembly according to claim 14, wherein at least one of said
male threaded element and said female threaded element includes a
torque shoulder.
16. An assembly according to claim 15, wherein the torque shoulder
is a reverse torque shoulder.
17. A radially expandable threaded tubular assembly comprising: a
radially expandable male threaded element having external male
threading and a first free end, the external male threading
including a first incomplete thread and a first hooked thread, the
first incomplete thread being located at least adjacent the first
free end of said male threaded element; a radially expandable
female threaded element having internal female threading and a
second free end, the internal female threading including a second
incomplete thread and a second hooked thread, the second incomplete
thread being located at least adjacent the second free end of said
female threaded element; a first metallic coating disposed on and
adhered to the external male threading; and a second metallic
coating disposed on and adhered to the internal female threading,
wherein said female threaded element is threadedly engaged with
said male threaded element and said first metallic coating is cold
welded to said second metallic coating.
18. An assembly according to claim 17, wherein each of said first
metallic coating and said second metallic coating is a ductile
metal and has a yielding tension less than about 100 MPa (14.5
k.s.i.).
19. An assembly according to claim 17, wherein each of said first
metallic coating and said second metallic coating is a ductile
metal and has a yielding tension less than about 20 MPa (2.9
k.s.i.).
20. An assembly according to claim 19, wherein each of said first
metallic coating and said second metallic coating allows a
principal shear strain of at least about 100 percent without
fracturing and without fissure propagation.
21. An assembly according to claim 17, wherein one of said first
metallic coating and said second metallic coating is an alloy, and
the other of said first metallic coating and said second metallic
coating is an alloy or a pure metal.
22. An assembly according to claim 17, wherein each of said first
metallic coating and said second metallic coating is a pure
metal.
23. An assembly according to claim 22, wherein the pure metal
contains 99.99 percent by weight of a single metal.
24. An assembly according to claim 23, wherein the single metal is
selected from the group consisting of Copper, Aluminum, Lead, Zinc,
Tin and Magnesium.
25. An assembly according to claim 23, wherein the single metal is
selected from the group consisting of Lead, Zinc and Tin.
26. An assembly according to claim 25, wherein each of said first
metallic coating and said second metallic coating has a thickness
at least about one-sixteenth of a gap between the engaged internal
female threading and the external male threading.
27. An assembly according to claim 26, wherein each of said first
metallic coating and said second metallic coating has substantially
the same thickness and is of the same pure metal.
28. An assembly according to claim 26, wherein at least one of said
first metallic coating and said second metallic coating has a
varying thickness, and each of said first metallic coating and said
second metallic coating is of the same pure metal.
29. An assembly according to claim 17, wherein said radially
expandable male threaded element and said radially expandable
female threaded element threadedly engage each other to form a
flush joint connection.
30. An assembly according to claim 29, wherein each of the first
incomplete thread and the second incomplete thread has a perfect
crest and an imperfect root.
31. An assembly according to claim 30, wherein each of the first
incomplete thread and the second incomplete thread is also a hooked
thread.
32. An assembly according to claim 31, wherein the first incomplete
thread is the initial thread adjacent the first free end of said
male threaded element, and the second incomplete thread is the
initial thread adjacent the second free end of said female threaded
element.
33. An assembly according to claim 32, wherein at least one of said
male threaded element and said female threaded element includes a
torque shoulder.
34. An assembly according to claim 33, wherein the torque shoulder
is a reverse torque shoulder.
35. A method of forming a sealed tubular joint, said method
comprising the steps of: providing a first radially expandable
tubular member having external male threading and a first free end,
the external male threading including a first incomplete thread and
a first hooked thread, the first incomplete thread being located at
least adjacent the first free end of the first tubular member;
providing a second radially expandable tubular member having
internal female threading and a second free end, the internal
female threading including a second incomplete thread and a second
hooked thread, the second incomplete thread being located at least
adjacent the second free end of the second tubular member; coating
at least one of the external male threading and the internal female
threading with an elastomeric sealant; coupling the first tubular
member and the second tubular member, said coupling thereby
providing a threaded connection; disposing the elastomeric sealant
between the external male threading and the internal female
threading and into adherence with each of the external male
threading and the internal female threading; curing the elastomeric
sealant, said curing thereby providing a cured elastomeric sealant
extended between and adhered to the external male threading and the
internal female threading; and radially expanding the threaded
connection, wherein the cured elastomeric sealant is capable of
being elongated while remaining extended between and adhered to the
external male threading and the internal female threading.
36. A method according to claim 35, wherein the threaded connection
is radially expanded at least about five percent based on an inside
diameter of the threaded connection.
37. A method according to claim 35, wherein the threaded connection
is radially expanded at least about fifteen percent based on an
inside diameter of the threaded connection.
38. A method according to claim 35, wherein the elastomeric sealant
is a greaseless elastomeric sealant, each of the external male
threading and the internal female threading is coated with the
greaseless elastomeric sealant in said coating step, and the cured
elastomeric sealant (i) is capable of being elongated at least
about 400 percent while remaining extended between and adhered to
the external male threading and the internal female threading, (ii)
is adhered to each of the external male threading and the internal
female threading with an adhesion-to-rigid-substrate of at least
0.7 MPa (102 p.s.i.); and (iii) has an elastic modulus between
about 0.5 MPa (73 p.s.i.) and about 2.0 MPa (290 p.s.i.).
39. A method according to claim 38, wherein the greaseless
elastomeric sealant is (i) a polysulfide sealant or a polyurethane
sealant, (ii) a viscous paste or a liquid before said curing, and
(iii) a rubber-like solid after said curing.
40. A method according to claim 35, wherein (i) the threaded
connection is a flush joint connection, (ii) each of the first
incomplete thread and the second incomplete thread has a perfect
crest and an imperfect root, (iii) each of the first incomplete
thread and the second incomplete thread is also a hooked thread,
(iv) the first incomplete thread is the initial thread adjacent the
first free end of the first tubular member and the second
incomplete thread is the initial thread adjacent the second free
end of the second tubular member, and (v) at least one of the first
tubular member and the second tubular member includes a reverse
torque shoulder.
41. A method of forming a sealed tubular joint, said method
comprising the steps of: providing a first radially expandable
tubular member having external male threading and a first free end,
the external male threading including a first incomplete thread and
a first hooked thread, the first incomplete thread being located at
least adjacent the first free end of the first tubular member;
providing a second radially expandable tubular member having
internal female threading and a second free end, the internal
female threading including a second incomplete thread and a second
hooked thread, the second incomplete thread being located at least
adjacent the second free end of the second tubular member; coating
the external male threading with a first metallic coating, the
first metallic coating being a first pure metal and adhering to the
external male threading; coating the internal female threading with
a second metallic coating, the second metallic coating being a
second pure metal and adhering to the internal female threading;
coupling the first tubular member and the second tubular member,
said coupling thereby providing a threaded connection, said
coupling cold welding the first metallic coating together with the
second metallic coating; and radially expanding the threaded
connection, wherein after said radial expansion of the threaded
connection (i) the first metallic coating remains adhered to the
external male threading, (ii) the second metallic coating remains
adhered to the internal female threading, and (iii) the first
metallic coating and the second metallic coating remain cold welded
together.
42. A method according to claim 41, wherein the threaded connection
is radially expanded at least about five percent based on an inside
diameter of the threaded connection.
43. A method according to claim 41, wherein the threaded connection
is radially expanded at least about fifteen percent based on an
inside diameter of the threaded connection.
44. A method according to claim 41, wherein (i) each of the first
pure metal and the second pure metal contains 99.99 percent by
weight of a single metal selected from the group consisting of
Copper, Aluminum, Lead, Zinc, Tin and Magnesium, (ii) the threaded
connection is a flush joint connection, (iii) each of the first
incomplete thread and the second incomplete thread has a perfect
crest and an imperfect root, (iv) each of the first incomplete
thread and the second incomplete thread is also a hooked thread,
and (v) at least one of the first tubular member and the second
tubular member includes a reverse torque shoulder.
45. An expandable sealed tubular joint comprising: a pair of
radially expandable elements each having threading at a free end
thereof and coupled to one another, the threading including hooked
incomplete threads being located at least adjacent the free ends;
and a sealing substance extending between and adhering to the
threading of one radially expandable element and the threading of
the other radially expandable element, wherein after a radial
expansion of said coupled pair of radially expandable elements said
sealing substance remains extended between and adhered to the
threading of one radially expandable element and the threading of
the other radially expandable element.
46. A joint according to claim 45, wherein said sealing substance
is a greaseless elastomeric sealant that (i) is capable of being
elongated at least about 100 percent while remaining extended
between and adhered to the threading of one radially expandable
element and the threading of the other radially expandable element,
(ii) is adhered to the threading with an
adhesion-to-rigid-substrate of at least 0.35 MPa (51 p.s.i.); and
(iii) has an elastic modulus between about 0.5 MPa (73 p.s.i.) and
about 2.0 MPa (290 p.s.i.).
47. A joint according to claim 45, wherein said sealing substance
is a pure metal containing 99.99 percent by weight of a single
metal selected from the group consisting of Copper, Aluminum, Lead,
Zinc, Tin and Magnesium, said coupled pair of radially expandable
elements form a flush joint connection, and the hooked incomplete
threads have perfect crests and imperfect roots.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a high-strength connection
for expandable members, and more particularly, to a threaded flush
joint connection for radially expandable tubulars, such as tubulars
used in the oil and gas industry.
[0003] 2. Description of Related Art
[0004] In a typical oil or natural gas well drilling environment, a
plurality of tubulars, e.g., pipes, are inserted one at a time into
a well bore hole in strings of different diameters, thus forming a
telescopic well design. The assembly of such pipes used in the oil
and gas industry is commonly performed using threaded joints or
connections, the standards for which are described and specified by
the American Petroleum Institute ("API"). These connections have
limitations when subjected to extreme loading conditions, which are
increasingly common in today's oil and gas wells. This is
especially true with connections used in a high internal or
external gas pressure environment, where the risk of leaks must be
eliminated, yet the connections must resist high mechanical loading
conditions caused by tension or other loads.
[0005] One of the newest and most demanding technologies used in
oil and gas well drilling today is "expandable technology." In
accordance with this technology, a tubular member, e.g., a pipe,
may be radially expanded by means of a mandrel after the pipe has
been lowered into a well, which mandrel is moved along the internal
diameter of a string of such pipes. Each pipe in the string is
enlarged in place to allow other pipes to be lowered and expanded
as well, so that ultimately all the pipes in the well have the same
internal diameter, thereby avoiding the reduction in internal
diameter of the ordinary telescopic well design. Today, such a
string of pipes is normally radially expanded by more than five
percent, with the industry targeting expansions of greater than
twenty percent, based on an internal diameter of the pipe being
expanded. One process of expanding tubulars is described in detail
in U.S. Pat. No. 5,348,095 to Worrall et al., which is incorporated
herein by reference. An alternative expansion method, which
utilizes rotary devices, is described in detail in U.S. Pat. No.
6,457,532 to Simpson, which is also incorporated herein by
reference. Yet another alternative method of expanding expandable
tubulars is described in substantial detail in U.S. Pat. No.
6,604,763 to Cook et al., which is also incorporated herein by
reference.
[0006] At first, the expandable tubulars or tubular members, e.g.,
pipes, and the connections to join them were mainly used for casing
remediation or similar applications, where the length of the string
of pipes was relatively small, thus allowing for low-strength
connections. However, with increasing well depths and the
consequent increase in the length of the string of pipes, an
important design element to be considered is the increased strength
of the connection needed. Previous expandable connections, such as
the connections in expandable tubular technology utilizing slotted
pipes as tubulars, needed only to withstand loads associated with
the running and expansion processes. However, as technology for the
expansion of solid (i.e., neither slotted nor perforated) tubulars
is being spread within the oil and gas industry, another tubular
connection design element that should be considered relates to the
capability of the connections to assure fluid and/or gas tightness
against internal pressure, external pressure, or both.
[0007] To provide a high-strength connection between two tubulars,
different alternatives have appeared in the oil and gas industry,
such as the so-called "upset ends" and "coupling" connections.
However, the least problematic radial expansion processes require
that the connection and the tubular members have substantially the
same wall thicknesses so that the force necessary to deform (i.e.,
radially expand) the string of pipes is substantially constant as a
mandrel, for example, is moved along the pipe string. As such, the
connections should preferably be of the type known in at least the
oil and gas industry as "flush joint" or "integral flush joint", in
which the connections are threaded within the wall thickness of the
tubular member, with a male threaded element at one end of the
tubular member and a female threaded element on the other end. The
external diameter of such a flush joint connection is the same for
both tubular members that are to be "made up," or threaded together
and torqued, to achieve a desired connection and seal. In these
flush joint connections, however, any device (e.g., an O-ring) that
is placed within the threads or at the ends of the threaded areas
of coupled tubular members diminishes the "critical area", also
known as the resistant area. For the female tubular member, this
critical area of the connection is the area defined as the circular
ring bounded by the external diameter of the connection and the
diameter of the thread root of the female member at the last
engaged thread of the male member; and for the male tubular member,
this critical area is the circular ring bounded by the diameter of
the thread root of the male member at the last engaged thread of
the female member and the internal diameter of the connection.
Therefore, devices placed within the wall thickness, such as
O-rings (see, e.g., U.S. Pat. No. 6,409,175 to Evans et al.), will
reduce this critical area and consequently the tensile resistance
of the threaded connection, which in turn limits the length of the
tubular string and the depth that can be achieved therewith as the
reduced critical area cannot withstand the required higher loading.
As such, a need exists in at least the oil and gas industry for an
expandable connection, such as a threaded flush joint connection,
having an improved critical area that can withstand today's high
loads.
[0008] To assure a threaded connection's sealing response, some
standard connections in the oil and gas industry rely on
metal-to-metal seals placed at various points in the joints
depending on the joint design, which points are selected to improve
the leak resistance of the connection. This type of seal in a
threaded joint provides a barrier to gas or liquid pressure while
the threads provide mechanical support and help or even improve
stabbing and running characteristics. One example of this type of
metal-to-metal seal is the API "Extreme-Line" joint, as defined by
API Standard 5B. Several seal design alternatives to metal-to-metal
seals have been proposed in the known art. For example, other
connections make use of a resilient seal located at a given
position along the threaded area, wherein this resilient seal
plastically deforms during make up of the connection and the
connection obtains sealability as a consequence of the thread gaps
being closed by the compression of the resilient material between
the mating elements (i.e., within the thread gaps). In another type
of connection, small gaps formed between the threads of the mating
members of the connection are filled with an API Modified Thread
Compound, which is a thread compound that is formulated in
accordance with the requirements of obsolete API Bulletin 5A2
(i.e., a grease-based compound). All of these types of sealing
mechanisms cannot work properly in an expandable threaded tubular
connection after a radial expansion thereof, as there is a tendency
for the threads of the female tubular member to shift or separate
from the threads of the male tubular member thereby creating leak
paths along the connection.
[0009] In expandable threaded connections, yet another design
aspect that should be considered is the design of the threads.
Conventional thread designs for expandable threaded connections
have included (i) "perfect threads", as shown for example in FIG.
15A, which are threads having normal (i.e., perfect) roots and
normal (i.e., perfect) crests, such as disclosed in U.S. Patent
Application Publication No. 2003/0107217A1 to Daigle et al., and
(ii) "hooked threads", as shown for example in FIG. 15B, such as
disclosed in U.S. Pat. No. 6,409,175 to Evans et al. However, a
need remains in the oil and gas industry for an expandable threaded
connection having strength greater than that obtained with these
conventional forms of threading.
[0010] Finally, some connections have been developed for use with
expandable tubulars, which are disclosed in varying detail in the
following patents and patent applications: U.S. Pat. No. 6,409,175
to Evans et al.; European Publication No. 1106778A1; and U.S.
Patent Application Publications No. 2002/0163192A1 to Coulon et
al., No. 2003/0067166A1 to Sivley, IV, and No. 2003/0107217A1 to
Daigle et al.
[0011] However, despite the conventional connections described
above for radially expandable tubular members, a need remains in
the oil and gas well drilling industry for a high strength, yet
simple to manufacture and easily made up, expandable threaded
connection that remains sealed after a radial expansion thereof and
which can sustain the increasing loads being placed on such
connections as a result of today's increasingly deeper, higher
pressure wells.
SUMMARY OF TH INVENTION
[0012] This invention addresses the foregoing needs in the art by
providing, in a preferred embodiment of the present invention, a
radially expandable threaded tubular assembly comprising (i) a
radially expandable male threaded element having external male
threading and a first free end, the external male threading
including a first incomplete thread and a first hooked thread, the
first incomplete thread being located at least adjacent the first
free end of the male threaded element; (ii) a radially expandable
female threaded element having internal female threading and a
second free end, the internal female threading including a second
incomplete thread and a second hooked thread, the second incomplete
thread being located at least adjacent the second free end of the
female threaded element, the female threaded element being
threadedly engaged with the male threaded element; and (iii) an
elastomeric sealant extending between the external male threading
and the internal female threading and adhering to both the external
male threading and the internal female threading. The elastomeric
sealant is capable of being elongated after curing while remaining
extended between and adhered to the external male threading and the
internal female threading.
[0013] In another aspect of a preferred embodiment of the present
invention, the elastomeric sealant is capable of being elongated at
least about 45 percent after curing while remaining extended
between and adhered to each of the external male threading and the
internal female threading and has an elastic modulus less than
about 2.0 MPa (290 p.s.i.). More preferably, the elastomeric
sealant is capable of being elongated at least about 100 percent
after curing while remaining extended between and adhered to each
of the external male threading and the internal female threading
and has an elastic modulus less than about 1.0 MPa (145 p.s.i.).
Even more preferably, the elastomeric sealant is capable of being
elongated at least about 400 percent after curing while remaining
extended between and adhered to each of the external male threading
and the internal female threading and has an elastic modulus
between about 0.5 MPa (73 p.s.i.) and about 2.0 MPa (290
p.s.i.).
[0014] In yet another aspect of a preferred embodiment of the
present invention, the elastomeric sealant is adhered to each of
the external male threading and the internal female threading with
an adhesion-to-rigid-substrate of at least 0.35 MPa (51 p.s.i.),
and more preferably with an adhesion-to-rigid-substrate of at least
0.7 MPa (102 p.s.i.). Additionally, the elastomeric sealant is
preferably a greaseless elastomeric sealant, which is preferably
capable of curing in the absence of oxygen and in the absence of
humidity.
[0015] In yet another aspect of a preferred embodiment of the
present invention, the greaseless elastomeric sealant is a
polysulfide sealant or a polyurethane sealant, which is preferably
a viscous paste or a liquid before curing and is a rubber-like
solid after curing. Moreover, the male threaded element and the
female threaded element most preferably threadedly engage each
other to form a flush joint connection.
[0016] In yet another aspect of a preferred embodiment of the
present invention, each of the first incomplete thread and the
second incomplete thread has a perfect crest and an imperfect root.
Also, each of the first incomplete thread and the second incomplete
thread is most preferably a hooked thread, the first incomplete
thread is preferably the initial thread adjacent the first free end
of the male threaded element, and the second incomplete thread is
preferably the initial thread adjacent the second free end of the
female threaded element. Furthermore, in yet another aspect of a
preferred embodiment of the present invention, at least one of the
male threaded element and the female threaded element includes a
torque shoulder, and most preferably a reverse torque shoulder.
[0017] In another preferred embodiment of the present invention, a
radially expandable threaded tubular assembly comprises (i) a
radially expandable male threaded element having external male
threading and a first free end, the external male threading
including a first incomplete thread and a first hooked thread, the
first incomplete thread being located at least adjacent the first
free end of the male threaded element; (ii) a radially expandable
female threaded element having internal female threading and a
second free end, the internal female threading including a second
incomplete thread and a second hooked thread, the second incomplete
thread being located at least adjacent the second free end of the
female threaded element; (iii) a first metallic coating disposed on
and adhered to the external male threading; and (iv) a second
metallic coating disposed on and adhered to the internal female
threading. The female threaded element is threadedly engaged with
the male threaded element and the first metallic coating is cold
welded to the second metallic coating.
[0018] In another aspect of a preferred embodiment of the present
invention, each of the first metallic coating and the second
metallic coating is a ductile metal and has a yielding tension less
than about 100 MPa (14.5 k.s.i.), more preferably a yielding
tension less than about 50 MPa (7.25 k.s.i.), and most preferably a
yielding tension less than about 20 MPa (2.9 k.s.i.). In addition,
each of the first metallic coating and the second metallic coating
preferably allows a principal shear strain of at least about 100
percent without fracturing and without fissure propagation.
[0019] In yet another aspect of a preferred embodiment of the
present invention, one of the first metallic coating and the second
metallic coating is an alloy, and the other of the first metallic
coating and the second metallic coating is an alloy or a pure
metal. Preferably, each of the first metallic coating and the
second metallic coating is a pure metal, and even more preferably,
the pure metal contains 99.99 percent by weight of a single metal.
Moreover, in yet another aspect of a preferred embodiment of the
present invention, the single metal is selected from the group
consisting of Copper, Aluminum, Lead, Zinc, Tin and Magnesium, and
most preferably is selected from the group consisting of Lead, Zinc
and Tin.
[0020] In yet another aspect of a preferred embodiment of the
present invention, each of the first metallic coating and the
second metallic coating has a thickness at least about
one-sixteenth of a gap between the engaged internal female
threading and the external male threading. In addition, each of the
first metallic coating and the second metallic coating preferably
has substantially the same thickness and is of the same pure
metal.
[0021] In yet another preferred embodiment of the present
invention, a method of forming a sealed tubular joint includes the
steps of (i) providing a first radially expandable tubular member
having external male threading and a first free end, the external
male threading including a first incomplete thread and a first
hooked thread, the first incomplete thread being located at least
adjacent the first free end of the first tubular member; (ii)
providing a second radially expandable tubular member having
internal female threading and a second free end, the internal
female threading including a second incomplete thread and a second
hooked thread, the second incomplete thread being located at least
adjacent the second free end of the second tubular member; (iii)
coating at least one of the external male threading and the
internal female threading with an elastomeric sealant; (iv)
coupling the first tubular member and the second tubular member,
the coupling thereby providing a threaded connection; (v) disposing
the elastomeric sealant between the external male threading and the
internal female threading and into adherence with each of the
external male threading and the internal female threading; (vi)
curing the elastomeric sealant, the curing thereby providing a
cured elastomeric sealant extended between and adhered to the
external male threading and the internal female threading; and
(vii) radially expanding the threaded connection. In this preferred
embodiment, the cured elastomeric sealant is capable of being
elongated while remaining extended between and adhered to the
external male threading and the internal female threading.
[0022] In another aspect of a preferred embodiment of the present
invention, the threaded connection is radially expanded at least
about five percent based on an inside diameter of the threaded
connection. More preferably, the threaded connection is radially
expanded at least about fifteen percent based on an inside diameter
of the threaded connection.
[0023] In another aspect of a preferred embodiment of the present
invention, the elastomeric sealant is a greaseless elastomeric
sealant, each of the external male threading and the internal
female threading is coated with the greaseless elastomeric sealant
in the coating step, and the cured elastomeric sealant (i) is
capable of being elongated at least about 400 percent while
remaining extended between and adhered to the external male
threading and the internal female threading, (ii) is adhered to
each of the external male threading and the internal female
threading with an adhesion-to-rigid-substrate of at least 0.7 MPa
(102 p.s.i.); and (iii) has an elastic modulus between about 0.5
MPa (73 p.s.i.) and about 2.0 MPa (290 p.s.i.).
[0024] In yet another preferred embodiment of the present
invention, a method of forming a sealed tubular joint includes the
steps of (i) providing a first radially expandable tubular member
having external male threading and a first free end, the external
male threading including a first incomplete thread and a first
hooked thread, the first incomplete thread being located at least
adjacent the first free end of the first tubular member; (ii)
providing a second radially expandable tubular member having
internal female threading and a second free end, the internal
female threading including a second incomplete thread and a second
hooked thread, the second incomplete thread being located at least
adjacent the second free end of the second tubular member; (iii)
coating the external male threading with a first metallic coating,
the first metallic coating being a first pure metal and adhering to
the external male threading; (iv) coating the internal female
threading with a second metallic coating, the second metallic
coating being a second pure metal and adhering to the internal
female threading; (v) coupling the first tubular member and the
second tubular member, the coupling thereby providing a threaded
connection, the coupling cold welding the first metallic coating
together with the second metallic coating; and (vi) radially
expanding the threaded connection. After the radial expansion of
the threaded connection (i) the first metallic coating remains
adhered to the external male threading, (ii) the second metallic
coating remains adhered to the internal female threading, and (iii)
the first metallic coating and the second metallic coating remain
cold welded together.
[0025] In yet another preferred embodiment of the present
invention, an expandable sealed tubular joint comprises a pair of
radially expandable elements each having threading at a free end
thereof and coupled to one another, the threading including hooked
incomplete threads being located at least adjacent the free ends;
and a sealing substance extending between and adhering to the
threading of one radially expandable element and the threading of
the other radially expandable element, wherein after a radial
expansion of the coupled pair of radially expandable elements the
sealing substance remains extended between and adhered to the
threading of one radially expandable element and the threading of
the other radially expandable element.
[0026] In another aspect of a preferred embodiment of the present
invention, the sealing substance is a greaseless elastomeric
sealant that (i) is capable of being elongated at least about 100
percent while remaining extended between and adhered to the
threading of one radially expandable element and the threading of
the other radially expandable element, (ii) is adhered to the
threading with an adhesion-to-rigid-subst- rate of at least 0.35
MPa (51 p.s.i.); and (iii) has an elastic modulus between about 0.5
MPa (73 p.s.i.) and about 2.0 MPa (290 p.s.i.).
[0027] In yet another aspect of a preferred embodiment of the
present invention, the sealing substance is a pure metal containing
99.99 percent by weight of a single metal selected from the group
consisting of Copper, Aluminum, Lead, Zinc, Tin and Magnesium, the
coupled pair of radially expandable elements form a flush joint
connection, and the hooked incomplete threads have perfect crests
and imperfect roots.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a partial sectional view of a radially expandable,
threaded, tubular, flush joint connection representing one
embodiment of the present invention.
[0029] FIG. 2 is a partial cross-sectional view of a threaded
connection of a preferred embodiment showing a coupled pin and
box.
[0030] FIG. 3 is an enlarged detailed view showing hooked
incomplete threads of a box where the incomplete threads have
normal crests and imperfect roots.
[0031] FIG. 4 is a detailed view of a thread design, which view
juxtaposes a hooked thread design with a non-hooked thread design
for purposes of illustration.
[0032] FIG. 5 is a detailed view showing external male threading of
a male threaded element coated with a sealing substance.
[0033] FIG. 6 is a detailed view showing internal female threading
of a female threaded element coated with a sealing substance.
[0034] FIG. 7 is a detailed view showing a process by which a
sealing substance is distributed or disposed between the threads of
male and female threaded elements during make up and during a
radial expansion process.
[0035] FIG. 8 is a partial cross-sectional view showing a threaded
connection between a pin and a box where the pin includes an
external torque shoulder.
[0036] FIG. 9 is a detailed view of a portion of FIG. 8, and shows
a cross-sectional view of an internal torque shoulder.
[0037] FIG. 10 schematically shows a radial expansion process
taking place on a plain end pipe.
[0038] FIG. 11 schematically shows a spring back movement at a free
end of a plain end pipe as a mandrel is removed from within the
plain end pipe.
[0039] FIG. 12 is a partial cross-sectional view showing an initial
stage of deformation produced in a radially expandable threaded
connection as a mandrel is pushed through the inside of that
threaded connection, and showing threads of the pin and box being
deformed.
[0040] FIG. 13 is a partial cross-sectional view showing a stage of
radial expansion of a threaded connection after a mandrel has
passed by the threads of a pin and a box.
[0041] FIG. 14 is an enlarged detailed view showing a pin nose of a
pin engaged with a reverse torque shoulder of a box, wherein that
pin nose has not deformed towards the inside of the threaded
connection between the pin and the box as a consequence of a
spring-back movement.
[0042] FIGS. 15A and 15B each show prior art threads, where FIG.
15A shows non-hooked perfect threads, and FIG. 15B shows hooked
perfect threads.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] FIG. 1 generally shows a radially expandable threaded
tubular assembly, which is an embodiment of the present invention.
The tubular assembly 1 generally comprises a radially expandable
male threaded element 2 having external male threading 3 and a
first free end 4, a radially expandable female threaded element 5
having internal female threading 6 and a second free end 7
(hereinafter, the external male threading 3 and the internal female
threading 6 are also collectively referred to as the "threading" of
the threaded elements 2 and 5), and a sealing substance 8, 8' (see,
e.g., FIGS. 5 and 6) extending between and adhering to the
threading (e.g., 3) of one radially expandable element (e.g., 2)
and the threading (e.g., 6) of the other radially expandable
element (e.g., 5). The male and female threaded elements 2, 5 may
be, for example, radially expandable tubing, casing, or other solid
expandable tubular, commonly known collectively within at least the
oil and gas well drilling field as oilfield tubular goods and which
are included within the scope of the terms "tubular(s)", "tubular
member(s)", and "element(s)" as used hereinafter. Similarly, in at
least the oil and gas well drilling field, the male threaded
element 2 is commonly referred to as a "pin" or "pin member" and
the female threaded element 5 is commonly referred to as a "box" or
"box member". As such, the terms "pin 2" and "box 5" are used
interchangeably hereinafter to refer to the male threaded element 2
and the female threaded element 5 respectively.
[0044] The pin 2 and box 5 are coupled together by threading the
pin 2 into the box and applying a desired, and usually
predetermined, amount of torque. This coupling or engaging together
of the pin 2 and the box 5 results in a tubular assembly 1,
hereinafter referred to as a "joint", "connection", or "threaded
connection". The pin 2 and the box 5 are properly threadedly
engaged or "made up" when, for example, such a predetermined amount
of torque is applied to the connection and a pin nose 9 (see, e.g.,
FIG. 14) of the pin 2 is in contact with an internal torque
shoulder 30 (described below) of the box 5. The threaded connection
of the pin 2 and the box 5 preferably form a flush joint
connection, as shown in FIG. 1. In the oil and gas well drilling
field, such a flush joint or flush joint connection is, for
example, a connection with male and female threads cut directly
into lengths of pipe so as to provide the same, or substantially
the same, inner diameter and outer diameter throughout the
connection as in the middle of the length of pipe once those
lengths are joined, coupled, or connected together. In conventional
oil and gas wells, the box 5 is installed facing out of the well,
and the pin 2 is installed facing down into the well, as shown in
FIG. 1. However, the present invention is also applicable to other
connection configurations, such as the pin 2 facing out of a well
with the box 5 facing down into the well, and also to a flush joint
connection where the male threaded element 2 of each of two pipes
are coupled together by a connector (e.g., a relatively short
section of pipe) having two female threaded elements 5, and vice
versa (not shown).
[0045] The details of the threading of the tubular assembly 1 will
now be described with reference to at least FIGS. 2 through 6. In a
preferred embodiment, both of the external male threading 3 and the
internal female threading 6 preferably include hooked threads and
incomplete threads. In thread design, the term "incomplete threads"
is used interchangeably with "imperfect threads". More preferably,
the threads of the pin 2 and the box 5 include hooked incomplete
threads (i.e., the threads include incomplete threads that are also
hooked). Additional details of these hooked, incomplete, and hooked
incomplete threads are discussed below with respect to preferred
embodiments of the present invention.
[0046] As shown in FIGS. 2, 3, and 14, each of the pin 2 and the
box 5 includes threads having incomplete or imperfect thread(s) 11,
12. Of note, the terms "thread", "threads", and "threading" are
used interchangeably herein, as it is to be understood, for
example, that a "thread" or "threading" may include a plurality of
"threads", and likewise "threads" may comprise "threading" or a
"thread". The incomplete threads 11 of the pin 2 and the incomplete
threads 12 of the box 5 each include "normal" or "perfect" crests
13 and imperfect roots 14. The normal or perfect crests 13 of the
incomplete threads 11 maintain the same, or substantially the same,
taper as the rest of the crests of the threads of the external male
threading 3; and the perfect crests 13 of the imperfect threads 12
maintain the same, or substantially the same, taper as the rest of
the crests of the threads of the internal female threading 6.
However, unlike the perfect crests 13, the roots 14 of the
incomplete threads 11, 12 do not have the same taper as the roots
of the rest of the threads of the pin 2 and the box 5,
respectively, which is why these roots are deemed "imperfect"
roots. Incomplete threads having normal crests and imperfect roots
are used, for example, in API "extreme line" piping, and such
incomplete threads are defined, for example, by American Petroleum
Institute (API) Standard 5B.
[0047] Furthermore, the incomplete threads 11 of the pin 2 are
located at least close to or adjacent the free end 4 of the pin 2,
and the incomplete threads 12 of the box 5 are located at least
close to or adjacent the free end 7 of the box 5, as shown, for
example, in FIG. 2. Preferably, the initial thread (i.e., the first
or the starting thread) of each of the pin 2 and the box 5 is an
incomplete thread. More preferably, the incomplete threads 11, 12
constitute at least one tenth ({fraction (1/10)}th) the length of
the total length of the threads of the pin 2 and the box 5,
respectively, starting from the free ends 4, 7.
[0048] Additional details of the preferred incomplete threads 11,
12 of the present invention are provided below with reference to
FIG. 3. FIG. 3 shows a detailed view of the free end 7 of the box 5
threadedly engaged or made up with the pin 2. As shown, the box 5
includes incomplete threads 12 formed by imperfect roots 14 and
perfect crests 13. In threading design, "perfect" roots are fully
formed roots (i.e., roots cut to a full depth consistent with the
depth of roots of adjacent threads), while "imperfect" roots are
roots that are cut to less than full depth. With incomplete threads
formed at the free end 7 of the box 5, a preferred resistant area
or preferred critical area 15 is defined in the pin 2 adjacent the
last engaged thread 16 of the box 5, which preferred critical area
15 equals the Diameter of Imperfect Threads (labeled as DIT in FIG.
3), which in this case is the diameter of the thread root 19
adjacent the last engaged thread crest of the box 5, minus the
Inside Diameter (labeled as ID) of pin 2. In other words, this
preferred critical area 15 is defined by the minimum wall thickness
of the pin 2 at the location directly opposing the last engaged
thread 16 of the box 5. However, if there were no imperfect threads
formed at the free end 7 of the box 5, then a normal critical area
17 would be defined in the pin 2 adjacent the last engaged "full"
or "perfect" thread 18 of the box 5, which normal critical area 17
equals the Diameter of Perfect Threads (labeled as DPT) minus the
Inside Diameter (ID) of pin 2. As such, the preferred critical area
15 is larger than the normal critical area 17, thus enabling the
joint to withstand higher loads (e.g., higher axial loading). As
explained above, the preferred and normal critical areas 15, 17 of
the pin 2 derive from the imperfect threads 12 of the box 5.
Likewise, the preferred and normal critical areas of the box 5
derive from the imperfect threads 11 of the pin 2.
[0049] Also as shown in FIGS. 2, 3, 4, and 14, each of the pin 2
and the box 5 preferably includes threads having a "hooked" thread
design. This hooked thread design is explained below with reference
to FIG. 4, which is a partial detailed view of a sample thread 20
on, for example, a pin, similar to the thread profile shown in FIG.
5. In FIG. 4, a hooked thread profile is juxtaposed with a
non-hooked thread profile to illustrate the differences between the
two thread forms. Load flank position arrows 21, 21' indicate the
possible positions of a load flank 23, 23' of the sample thread 20.
If an axis 24 of the load flank 23 forms an angle .alpha. (alpha)
with a line 25 that is perpendicular to the tubular member (e.g.,
pipe) longitudinal axis (not shown), then the thread profile is a
"hooked thread" or "hooked thread profile." In contrast, if the
axis 24' of the load flank 23' forms an angle .beta. (beta) with
the line 25, then the thread profile is a "non-hooked thread
profile." The sample thread 20, whether on a pin or a box, also has
a stabbing flank 22. The stabbing flank 22 of each of the box and
the pin face each other, so if one of them (e.g., the stabbing
flank of the pin) points into a well, then the other one (e.g., the
stabbing flank of the box) faces to the opposite direction (i.e.,
out of the well).
[0050] In a preferred embodiment of the present invention, each of
the external male threading 3 and the internal female threading 6
includes hooked threads. Most preferably, all of the threading of
the pin 2 and box 5 is hooked threading, including the incomplete
threads. In other words, the threading of the pin 2 and the box 5,
including the incomplete threads, is most preferably hooked, as
shown, for example, in FIG. 5, where load flank 26 is shown having
an angle .alpha. (alpha) greater than zero, in accordance with the
"hooked thread" discussion above with reference to FIG. 4.
[0051] In another aspect of the preferred embodiment, at least one
of the pin 2 and the box 5 includes a torque shoulder. As shown in
FIG. 8, the pin 2 preferably includes an external torque shoulder
29, which is formed at a location so as to receive the free end 7
of the box 5. As shown in FIG. 9, the box 5 preferably includes an
internal torque shoulder 30, which is formed at a location so as to
receive the free end 4 of the pin 2. The internal torque shoulder
30 preferably is a reverse torque shoulder (30), that is, the
internal torque shoulder 30 preferably has a negative angle, which
by hooking the pin nose 9 further prevents the pin nose 9 from
deforming toward the inside of the threaded connection. In FIG. 9,
the angle of the face of the reverse torque shoulder 30 is shown as
negative torque shoulder angle .gamma. (gamma). Angle .gamma.
(gamma) is measured between a line 32 that is perpendicular to the
tubular member (e.g., pipe) longitudinal axis (not shown) and the
face of the reverse torque shoulder 30. An arrow 31 indicates the
direction towards which the face of the reverse torque shoulder 30
is able to move to be considered a "negative" or "reverse torque
shoulder." In addition, the pin nose 9 of the pin 2, which contacts
the reverse torque shoulder 30, preferably has a correspondingly
angled face that is substantially parallel to the face of the
reverse torque shoulder 30. As such, the pin nose 9 and the reverse
torque shoulder 30 engage each other (e.g., mate like pieces of a
puzzle) to prevent the first free end 4 of the pin 2 from curling
or moving inward towards the center of the tubular assembly after
the tubular assembly has been expanded.
[0052] The sealing substance 8, 8' extending between and adhering
to the threading (e.g., 3) of one radially expandable element
(e.g., 2) and the threading (e.g., 6) of the other radially
expandable element (e.g., 5) is described below. The sealing
substance 8, 8' may be either (i) an elastomeric sealant or (ii) a
metallic coating, each of which is individually discussed in
greater detail below.
[0053] Elastomeric Sealant. As shown in FIGS. 5 and 6, where the
sealing substance 8, 8' is an elastomeric sealant, at least a
portion of the threads of the pin 2 or at least a portion of the
threads of the box 5 is coated with that elastomeric sealant.
Preferably, substantially all of the threads of both of the pin 2
and the box 5 are coated with the elastomeric sealant (see 8, 8');
however, the threads may also be coated in a differential way along
the threading to provide localized sealing points. The elastomeric
sealant (see 8, 8') is applied to the threads of the pin 2 and the
box 5 before coupling thereof. The elastomeric sealant (see 8, 8')
is applied in an amount and thickness such that when the pin 2 and
the box 5 are coupled, thus forming a threaded connection, the
elastomeric sealant (see 8, 8') extends between the external male
threading 3 and the internal female threading 6 and adheres to both
the external male threading 3 and the internal female threading 6.
The elastomeric sealant (see 8, 8') is preferably a curable
sealant, and is capable of being elongated after curing while
remaining extended between and adhered to the external male
threading 3 and the internal female threading 6.
[0054] In a preferred embodiment of the present invention, the
elastomeric sealant (see 8, 8') is capable of being elongated at
least about 45 percent after curing while remaining extended
between and adhered to each of the external male threading 3 and
the internal female threading 6 and has an elastic modulus less
than about 2.0 MPa (290 p.s.i.). More preferably, the elastomeric
sealant (see 8, 8') is capable of being elongated at least about
100 percent after curing while remaining extended between and
adhered to each of the external male threading 3 and the internal
female threading 6 and has an elastic modulus less than about 1.0
MPa (145 p.s.i.). Most preferably, the elastomeric sealant (see 8,
8') is capable of being elongated at least about 400 percent after
curing while remaining extended between and adhered to each of the
external male threading 3 and the internal female threading 6 and
has elastic modulus between about 0.5 MPa (73 p.s.i.) and about 2.0
MPa (290 p.s.i.).
[0055] The elastomeric sealant (see 8, 8') is also preferably a
"greaseless" elastomeric sealant. In other words, the preferred
elastomeric sealant (see 8, 8') of the present invention has no
grease base or component; thus, the main performance objectives of
the preferred elastomeric sealant (see 8, 8') are bonding (ability
to adhere), elongation, and sealing, and not lubrication. To
illustrate, the reference standard for API Modified Thread
Compound, which is a thread compound that is formulated in
accordance with the requirements of obsolete API Bulletin 5A2,
requires a grease base of about 36 percent by weight. Further, API
Recommended Practice (RP) 5A3 sets forth that a primary purpose of
the API Modified Thread Compound is to act as a lubricating
material between mating connectors of a threaded connection.
Because API Modified Thread Compound contains such a grease base,
the API Modified Thread Compound does not qualify as an elastomeric
sealant (see 8, 8') of the present invention.
[0056] Furthermore, in another aspect of a preferred embodiment of
the present invention, the elastomeric sealant (see 8, 8') adheres
to each of the external male threading 3 and the internal female
threading 6 with an adhesion-to-rigid-substrate of at least 0.35
MPa (51 p.s.i.). This adhesion-to-rigid-substrate is measured in
accordance with ASTM D429-02a (Method A), which is known as the
"Standard Test Methods for Rubber Property--Adhesion to Rigid
Substrates." More preferably, the elastomeric sealant (see 8, 8')
adheres to each of the external male threading 3 and the internal
female threading 6 with an adhesion-to-rigid-substrate of at least
0.5 MPa (73 p.s.i.). Most preferably, the elastomeric sealant (see
8, 8') adheres to each of the external male threading 3 and the
internal female threading 6 with an adhesion-to-rigid-substrate of
at least 0.7 MPa (102 p.s.i.). Moreover, the preferred elastomeric
sealant (see 8, 8') is capable of curing in the absence of oxygen
and in the absence of humidity, and preferably in the absence of
both oxygen and humidity. The preferred elastomeric sealant (see 8,
8') is also a viscous paste or a liquid before curing and is a
rubber-like solid after fully curing. The preferred elastomeric
sealant (see 8, 8') preferably fully cures within two days, and
more preferably fully cures in about one day or less.
[0057] In a most preferred embodiment, the elastomeric sealant (see
8, 8') of the present invention is a greaseless polysulfide sealant
or a greaseless polyurethane sealant. Examples of such most
preferred elastomeric sealants (see 8, 8'), by way of non-limiting
example, include the following commercially available sealants: (i)
THIOKOL (Registered Trademark) 2282 High Performance Polysulfide
Joint Sealant, available from PolySpec L. P., located at 6614 Gant
Road, Houston, Tex., which sealant has a published elongation
property of about 450 to 500 percent, fully cures in about one day,
and has no grease base or component; (ii) PSI-270/RC 270
Multi-Component Polyurethane Reservoir Sealant, available from
Polymeric Systems, Inc., located at 723 Wheatland Street,
Pheonixville, Pa., which sealant has a published elongation
property of 450 to 550 percent as measured in accordance with ASTM
D 412, fully cures at 75.degree. F. (24.degree. C.) in about 2
days, has a published adhesion-in-peel of 20 to 25 lb/in (3.5 kN/m
to 4.4 kN/m) in accordance with ASTM C 794, which is known as the
"Standard Test Method for Adhesion-in-Peel of Elastomeric Joint
Sealant", and has no grease base or component; and (iii) SYNTHACALK
(Trademark) GC2+ Two-Part Polysulfide Rubber Sealant, available
from Pecora Corporation, located at 165 Wambold Road, Harleysville,
Pa., which sealant has a published elongation property of 500 to
550 percent as measured in accordance with ASTM D 412, fully cures
in about one day, and has no grease base or component.
[0058] Metallic Coating. As also shown in FIGS. 5 and 6, where in
an alternative embodiment the sealing substance 8, 8' is a metallic
coating, both at least a portion of the threads of the pin 2 and at
least a portion of the threads of the box 5 are coated with a
metallic coating (see 8, 8'). Preferably, substantially all of the
threads of both of the pin 2 and the box 5 are coated with either
the same or different metallic coating (see 8, 8'); however, the
threads may also be coated in a differential way along the
threading to provide localized sealing points. The metallic coating
(see 8, 8') is applied to the threads of the pin 2 and the box 5
before coupling thereof.
[0059] More specifically, where the sealing substance 8, 8' is a
metallic coating, a first metallic coating (see 8) is disposed on
and adhered to the external male threading 3, and a second metallic
coating (see 8') is disposed on and adhered to the internal female
threading 6. Preferably, each of the first metallic coating (see 8)
and the second metallic coating (see 8') is a ductile metal with a
low yield point, having, for example, a yielding tension less than
about 100 MPa (14.5 k.s.i.). More preferably, each of the first
metallic coating (see 8) and the second metallic coating (see 8')
is a ductile metal and has a yielding tension less than about 50
MPa (7.25 k.s.i.). Most preferably, each of the first metallic
coating (see 8) and the second metallic coating (see 8') is a
ductile metal and has a yielding tension less than about 20 MPa
(2.9 k.s.i.). In addition, each of the preferred first metallic
coating (see 8) and the preferred second metallic coating (see 8')
allows a principal shear strain of at least about 100 percent
without fracturing and without fissure propagation.
[0060] In one aspect of the present invention, each of the first
metallic coating (see 8) and the second metallic coating (see 8')
is a pure metal. "Pure metal", as that term is used herein, is
intended to have its ordinary meaning as that term is used in the
metals art. Nonetheless, in a more preferred embodiment, the pure
metal contains 99.99 percent by weight of a single metal. This
single metal is a metal such as, for example, Copper, Aluminum,
Lead, Zinc, Tin and Magnesium. More preferably, the single metal is
selected from the group consisting of Lead, Zinc and Tin. As
initially applied to the threads of the pin 2 and the box 5 (i.e.,
before coupling thereof), each of the first metallic coating (see
8) and the second metallic coating (see 8') preferably has a
thickness at least about one-sixteenth of a gap that exists between
the engaged internal female threading 6 and the external male
threading 3 when the pin 2 and the box 5 are coupled together
without the sealing substance 8, 8'. Most preferably, each of the
first and second metallic coatings (see 8, 8') has substantially
the same thickness and is of the same pure metal. Each of the first
and second metallic coatings (see 8, 8') may be applied to the
threads of the pin 2 and the box 5 by the following conventional
methods (though it is not restricted to them): electrochemical,
molten metal bath, hot dip coating, spray of molten metal, metallic
powder, and vapor deposition.
[0061] Although the discussion above focused on the use of a pure
metal as the sealing substance 8, 8', one or both of the first and
second metallic coatings (see 8, 8') may alternatively be alloys.
As used herein, an alloy is a metal having impurities of up to
about five percent (5%) by weight. In other words, an alloy is a
metal that contains about ninety-five percent (95%) or more by
weight of a single metal and about five percent (5%) or less by
weight of impurities. In this context, the single metal is again a
metal such as, for example, Copper, Aluminum, Lead, Zinc, Tin and
Magnesium. As such, the threads of the pin 2 may have a pure metal
coating while the threads of the box 5 may have an alloy
coating.
[0062] Furthermore, the most preferred first and second metallic
coatings (see 8, 8') are able to recover mechanical properties at
about room temperature or lower. As used herein, in a material
properties context, "room temperature" is understood to be at about
70.degree. F. (21.degree. C.). The ability of these first and
second metallic coatings (see 8, 8') to recover mechanical
properties results from their having recrystallization temperatures
about, preferably below, room temperature. For example, the
recrystallization temperature of Zinc is 50.degree. F. (10.degree.
C.), and that of each of Tin and Lead is 25.degree. F.
(-3.9.degree. C.). As such, these metals remain strain free, or
substantially strain free, during physical manipulation thereof,
because each of the metals can reform its structure spontaneously
at room temperature. Moreover, during the recrystallization stage,
metals experience an increase in ductility and a reduction in
tensile strength, which are preferred property characteristics of
the most preferred first and second metallic coatings (see 8, 8').
As discussed below, the ability of the first and second metallic
coatings (see 8, 8') to recover mechanical properties at about room
temperature or lower allows for the first and second metallic
coatings (see 8, 8') to cold weld to each other without heat
treatment.
[0063] Most importantly, the first metallic coating (see 8) and the
second metallic coating (see 8') of the present invention are
selected such that when the female threaded element 5 is threadedly
engaged with the male threaded element 2 (i.e., made up), the first
metallic coating (see 8) cold welds to the second metallic coating
(see 8'). As used herein, the terms "cold weld" and "cold welding"
have their ordinary meaning as used in the metals art. One such
meaning of "cold weld" and "cold welding", for example, is the
forcing together of like or unlike metals at ambient temperature,
often in a shearing manner, so that normal oxide surface films are
ruptured allowing such intimate metal contact that adhesion takes
place. Thus, where the sealing substance 8, 8' is a metallic
coating, the threaded connection is sealed by the cold welding of
the first metallic coating (see 8) with the second metallic coating
(see 8'). This cold welding occurs during and as a result of the
action of coupling the coated threads of the pin 2 and the coated
threads of the box 5. Since the coupling of the pin 2 and the box 5
preferably occurs at about room temperature, metallic coatings
having the above described ability to recrystallize at about room
temperature promote more successful cold welding of the metallic
coating of the pin 2 with the metallic coating of the box 5.
[0064] Through the use of the first metallic coating (see 8) and
the second metallic coating (see 8') of the present invention, a
sealed threaded connection of radially expandable tubulars may be
made up, without the need for other substances, such as thread
compounds, between the mating surfaces of the threads of the
tubulars (e.g., the pin 2 and the box 5) to effect the seal.
Further to the cold welding discussion above, the cold welding
process may also be characterized as a mechanism of plastic
deformation that makes two surfaces (e.g., the first and second
metallic coatings) interpenetrate one another and form a metallic
bond between them. In the present invention, this cold welding or
"linear friction welding" occurs between two surfaces that bear one
against the other with a normal force that produces galling (i.e.,
the coated threads of the pin 2 bear against the coated threads of
the box 5) and supplies the metallic adhesion between the two
surfaces (i.e., between the first and second metallic coatings (see
8, 8')). This cold weld additionally acts as a sealing means by
forming a single, preferably homogeneous, sealing substance 8, 8'
out of the first and second metallic coatings (see 8, 8'), wherein
that now single sealing substance 8, 8' remains extended between
the external male threading 3 and the internal female threading 6
and adhered to both the external male threading 3 and the internal
female threading 6.
[0065] Both the cold welding process and the sealing of the
threaded connection using an elastomeric sealant are described in
more detail below with reference to FIG. 7. FIG. 7 shows a detail
of the threads 3, 6 of the pin 2 and the box 5 as the threaded
connection is made up. As shown, one of the external male threads 3
of the pin 2 is in contact with a corresponding internal female
thread 6 of the box 5, with the sealing substance 8, 8' already
formed (i.e., the sealing substance 8 on the pin 2 has become one
with the sealing substance 8' on the box 5) and extended between
and adhered to the male and female threading 3, 6. The flow of the
sealing substance 8, 8' upon engagement of the pin 2 and the box 5
is shown by means of the arrows 27 along the load flank 26 of the
external male thread 3 and corresponding flank of the internal
female thread 6. As shown in FIG. 7, the sealing substance 8, 8' is
being accumulated in the gap formed between the external male
threading 3 and the internal female threading 6. The radially
compressive effect, shown by arrows 28, that the sealing substance
8, 8' is subjected to during the make up or after a radial
expansion of the made up threaded connection is also shown in FIG.
7, which makes visible the mechanism of cold welding through which
sealing of the joint is achieved where the sealing substance 8, 8'
is the first and second metallic coatings. Where the sealing
substance 8, 8' is the elastomeric sealant, the radial compression
produces the appropriate allocation of that elastomeric sealant in
the gap(s), and, if the elastomeric sealant is applied on the
threads of both the pin 2 and the box 5, the radial compression
improves the mixing of the elastomeric sealant (see 8) on the
threads 3 of the pin 2 with the elastomeric sealant (see 8') on the
threads 6 of the box 5.
[0066] The preferred methods of assembling the sealed, radially
expandable tubular assembly 1 of the present invention are further
described below. In one aspect, the method of forming a sealed
tubular joint 1 of the present invention includes providing a first
radially expandable tubular member 2 having external male threading
3 and a first free end 4, the external male threading 3 including a
first incomplete thread (e.g., 11) and a first hooked thread (e.g.,
see FIG. 4), the first incomplete thread (e.g., 11) being located
at least adjacent the first free end 4 of the first tubular member
2; and providing a second radially expandable tubular member 5
having internal female threading 6 and a second free end 7, the
internal female threading 6 including a second incomplete thread
(e.g., 12) and a second hooked thread (e.g., see FIG. 4), the
second incomplete thread (e.g., 12) being located at least adjacent
the second free end 7 of the second tubular member 5.
[0067] In a preferred embodiment, the threads 3, 6 of the pin 2 and
the box 5 are cleaned. The threads 3, 6 may be cleaned using any
number of conventional cleaning methods known, for example, in the
oil and gas well drilling fields. Most preferably, the threads 3, 6
of the pin 2 and the box 5 are cleaned to substantially remove all
foreign material and surface corrosion. In addition, although not
necessary to obtain the sealed, radially expandable tubular
assemblies of the present invention, it may be further advantageous
to coat the threads 3, 6 of the pin 2 and/or the box 5 with primer
material, in order, for example, to improve the adhesion of the
sealing substance 8, 8' to the threads 3, 6 or to protect the
threads 3, 6 once cleaned. This primer material is selected based
on the particular sealing substance 8, 8' to be applied to the
threads 3, 6, such that the primer is compatible with that sealing
substance 8, 8' and the material composition of the pin 2 and the
box 5.
[0068] Thereafter, where the sealing substance 8, 8' is a metallic
coating, the preferred method includes coating the external male
threading 3 with a first metallic coating (see 8), the first
metallic coating being a first pure metal and adhering to the
external male threading 3; and coating the internal female
threading 6 with a second metallic coating, the second metallic
coating being a second pure metal and adhering to the internal
female threading 6. The selection of the pure metal(s) to use in
this coating application is discussed above with respect to the
sealed threaded connection itself. After coating the threads 3, 6,
the preferred method includes coupling (i.e., making up) the first
tubular member 2 and the second tubular member 5. This coupling
process causes the first metallic coating to cold weld to the
second metallic coating and vice versa. Furthermore, most
preferably, this coupling process includes applying torque to the
threaded connection such that the pin nose 9 seats against (i.e.,
mates with or engages) the internal torque shoulder 30 of the box
5. The amounts of torque to be applied and methods of determining
that amount of torque, in order to properly make up a sealed
threaded tubular connection, are well known in the oil and gas well
drilling fields. Factors that inform the proper amount of torque to
apply include, by way of non-limiting example, the size of the
tubular members, the amount, size, and type of threading on the
tubular members, the particular sealing substance used, the type of
tubular member material, and the temperature(s) of the tubular
members and sealing substance at the time of make up.
[0069] Thereafter, the preferred method includes radially expanding
the threaded connection, wherein after this radial expansion of the
threaded connection (i) the first metallic coating (see 8) remains
adhered to the external male threading 3, (ii) the second metallic
coating (see 8') remains adhered to the internal female threading
6, and (iii) the first metallic coating (see 8) and the second
metallic coating (see 8') remain cold welded together to effect a
seal. The radial expansion process preferably radially expands the
threaded connection at least about five percent based on an inside
diameter of the threaded connection, more preferably at least about
fifteen percent based on an inside diameter of the threaded
connection, and most preferably at least about 25 percent based on
an inside diameter of the threaded connection. As such, a radially
expanded threaded tubular assembly or joint 1 is obtained.
[0070] In another preferred method of forming a radially expandable
threaded tubular joint 1, where the sealing substance 8, 8' is an
elastomeric sealant, the preferred method includes coating at least
one of (and most preferably both of) the external male threading 3
and the internal female threading 6 with an elastomeric sealant
(see 8, 8'). The selection of the elastomeric sealant(s) (see 8,
8') to use in this coating application is discussed above with
respect to the sealed threaded connection itself. This elastomeric
sealant(s) (see 8, 8') may be applied to the threads using
conventional sealant application processes, which are well known in
the oil and gas well drilling fields. The preferred elastomeric
sealant(s) (see 8, 8'), as discussed above, adhere to the threads
3, 6 of the pin 2 and the box 5. After coating the threads 3, 6,
the preferred method includes coupling (i.e., making up) the first
tubular member 2 and the second tubular member 5 before the
elastomeric sealant (see 8, 8') has fully cured. This coupling
action disposes the elastomeric sealant (see 8, 8') between the
external male threading 3 and the internal female threading 6 (see,
e.g., FIG. 7), and more particularly, within the gaps between the
threads of the coupled threaded connection.
[0071] Thereafter, the preferred method includes curing the
elastomeric sealant (see 8, 8'). The curing process provides a
cured elastomeric sealant extended between and adhered to the
external male threading 3 and the internal female threading 6.
After curing, the preferred method includes radially expanding the
threaded connection, wherein after this radial expansion of the
threaded connection the elastomeric sealant (see 8, 8') remains
extended between and adhered to the external male threading 3 and
the internal female threading 6. The radial expansion process
preferably radially expands the threaded connection at least about
five percent based on an inside diameter of the threaded
connection, more preferably at least about fifteen percent based on
an inside diameter of the threaded connection, and most preferably
at least about 25 percent based on an inside diameter of the
threaded connection. As such, a radially expanded threaded tubular
assembly or joint 1 is obtained.
[0072] FIG. 10 generally shows schematically an expansion process
as it is taking place along a plain end pipe 33, which is a pipe
without threads. In FIG. 10, a mandrel 34 for use in radially
expanding the plain end pipe 33 is moving out of the plain end pipe
33 (to the left in the drawing). FIG. 11 illustrates a
"spring-back" movement at the free end 35 of the plain end pipe 33
as the mandrel 34 is removed from within that pipe 33. As a result
of the spring-back movement, the free end 35 of the plain end pipe
33 has a smaller inner diameter than the inner diameter of a
portion of the pipe 33 further up from that free end 35.
[0073] FIG. 12 shows a made up threaded tubular connection being
radially expanded, which is taking place in a direction from the
pin 2 to the box 5. As shown in FIG. 12, the mandrel 34 is pushed
along the threaded tubular connection to produce such a radial
deformation. FIG. 13 shows the threaded tubular connection of FIG.
12 after that threaded tubular connection has been expanded by the
mandrel 34. As shown, the mandrel 34 has already passed the threads
3, 6 of the pin 2 and the box 5, and has started expanding the
remaining length of the female threaded element 5. FIG. 14
illustrates in more detail an area of the threaded connection once
the mandrel 34 has passed beyond the threads of that threaded
connection, and particularly shows the pin nose 9 located at the
first free end 4 of the pin 2 after radial expansion and the
reverse torque shoulder 30. As further illustrated by FIG. 14, it
is shown that because of the reverse torque shoulder 30, the pin
nose 9 has not suffered deformation towards the inside of the
tubular member, i.e., the pin nose 9 has not suffered the
"spring-back" effect explained above with reference to FIGS. 10 and
11.
[0074] While this invention has been described with reference to
what are currently considered to be the preferred embodiments, it
is to be understood that the invention is not limited to the
disclosed embodiments. On the contrary, the invention is intended
to cover various modifications and equivalent arrangements included
within the spirit and scope of the appended claims. The scope of
the following claims is to be accorded the broadest interpretation
so as to encompass all such modifications and equivalent structures
and functions.
* * * * *