U.S. patent application number 10/528222 was filed with the patent office on 2005-10-27 for threaded connection for expandable tubulars.
Invention is credited to Costa, Scott, Menchaca, Jose, Ring, Lev.
Application Number | 20050236159 10/528222 |
Document ID | / |
Family ID | 31978781 |
Filed Date | 2005-10-27 |
United States Patent
Application |
20050236159 |
Kind Code |
A1 |
Costa, Scott ; et
al. |
October 27, 2005 |
Threaded connection for expandable tubulars
Abstract
A threaded connection for expandable tubulars.
Inventors: |
Costa, Scott; (Kingwood,
TX) ; Ring, Lev; (Houston, TX) ; Menchaca,
Jose; (Houston, TX) |
Correspondence
Address: |
Todd Mattingly
Haynes and Boone
901 Main Street
Suite 3100
Dallas
TX
75202
US
|
Family ID: |
31978781 |
Appl. No.: |
10/528222 |
Filed: |
March 18, 2005 |
PCT Filed: |
August 18, 2003 |
PCT NO: |
PCT/US03/25716 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60412371 |
Sep 20, 2002 |
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Current U.S.
Class: |
166/380 ;
166/207; 166/384 |
Current CPC
Class: |
E21B 43/106 20130101;
E21B 43/103 20130101; E21B 17/042 20130101; F16L 15/08 20130101;
F16L 15/001 20130101 |
Class at
Publication: |
166/380 ;
166/384; 166/207 |
International
Class: |
E21B 023/02 |
Claims
1. An assembly, comprising: a first tubular member comprising
external threads; and a second tubular member comprising internal
threads coupled to the external threads of the first tubular
member; wherein at least one of the first and second tubular
members define one or more stress concentrators.
2. The assembly of claim 1, further comprising: an external sleeve
coupled to and overlapping with the ends of the first and second
tubular members.
3. The assembly of claim 1, wherein one or more of the stress
concentrators comprise surface grooves formed in the surfaces of at
least one of the first and second tubular members.
4. The assembly of claim 1, wherein the stress concentrators are
defined above the internal and external threads of the first and
second tubular members.
5. A method for forming a wellbore casing, comprising: positioning
the assembly of claim 1 within a borehole that traverses a
subterranean formation; and radially expanding and plastically
deforming the assembly within the borehole.
6. A method for forming a wellbore casing, comprising: positioning
the assembly of claim 2 within a borehole that traverses a
subterranean formation; and radially expanding and plastically
deforming the assembly within the borehole.
7. A method for forming a wellbore casing, comprising: positioning
the assembly of claim 3 within a borehole that traverses a
subterranean formation; and radially expanding and plastically
deforming the assembly within the borehole.
8. A method for forming a wellbore casing, comprising: positioning
the assembly of claim 4 within a borehole that traverses a
subterranean formation; and radially expanding and plastically
deforming the assembly within the borehole.
9. An apparatus, comprising: a wellbore that traverses a
subterranean formation; and a wellbore casing positioned within and
coupled to the wellbore; wherein the wellbore casing is coupled to
the wellbore by a process comprising: positioning the assembly of
claim 1 within the wellbore; and radially expanding and plastically
deforming the assembly within the wellbore.
10. An apparatus, comprising: a wellbore that traverses a
subterranean formation; and a wellbore casing positioned within and
coupled to the wellbore; wherein the wellbore casing is coupled to
the wellbore by a process comprising: positioning the assembly of
claim 2 within the wellbore; and radially expanding and plastically
deforming the assembly within the wellbore.
11. An apparatus, comprising: a wellbore that traverses a
subterranean formation; and a wellbore casing positioned within and
coupled to the wellbore; wherein the wellbore casing is coupled to
the wellbore by a process comprising: positioning the assembly of
claim 3 within the wellbore; and radially expanding and plastically
deforming the assembly within the wellbore.
12. An apparatus, comprising: a wellbore that traverses a
subterranean formation; and a wellbore casing positioned within and
coupled to the wellbore; wherein the wellbore casing is coupled to
the wellbore by a process comprising: positioning the assembly of
claim 4 within the wellbore; and radially expanding and plastically
deforming the assembly within the wellbore.
15. A system for forming a wellbore casing, comprising: means for
positioning the assembly of claim 1 within a borehole that
traverses a subterranean formation; and means for radially
expanding and plastically deforming the assembly within the
borehole.
16. A system for forming a wellbore casing, comprising: means for
positioning the assembly of claim 2 within a borehole that
traverses a subterranean formation; and means for radially
expanding and plastically deforming the assembly within the
borehole.
17. A system for forming a wellbore casing, comprising: means for
positioning the assembly of claim 3 within a borehole that
traverses a subterranean formation; and means for radially
expanding and plastically deforming the assembly within the
borehole.
18. A system for forming a wellbore casing, comprising: means for
positioning the assembly of claim 4 within a borehole that
traverses a subterranean formation; and means for radially
expanding and plastically deforming the assembly within the
borehole.
19. A method of providing a fluid tight seal between a pair of
overlapping tubular members, comprising: forming one or more stress
concentrators within at least one of the tubular members; and
radially expanding and plastically deforming the tubular
members.
20. The method of claim 19, wherein the tubular members are
threadably coupled; and wherein the stress concentrators are formed
above the threaded coupling.
21. The method of claim 19, wherein the stress concentrators
comprise surface grooves formed in at least one of the tubular
members.
22. An assembly, comprising: a first tubular member comprising
external threads; a second tubular member comprising internal
threads coupled to the external threads of the first tubular
member, and an external sleeve coupled to and overlapping with the
ends of the first and second tubular members; wherein at least one
of the first and second tubular members define one or more stress
concentrators.
23. The assembly of claim 22, wherein one or more of the stress
concentrators comprise surface grooves formed in the surfaces of at
least one of the first and second tubular members.
24. The assembly of claim 22, wherein the stress concentrators are
defined above the internal and external threads of the first and
second tubular members.
25. A method for forming a wellbore casing, comprising: positioning
an assembly within a borehole that traverses a subterranean
formation; and radially expanding and plastically deforming the
assembly within the borehole; wherein the assembly comprises: a
first tubular member comprising external threads; a second tubular
member comprising internal threads coupled to the external threads
of the first tubular member; and an external sleeve coupled to and
overlapping with the ends of the first and second tubular members;
wherein at least one of the first and second tubular members define
one or more stress concentrators.
26. An apparatus, comprising: a wellbore that traverses a
subterranean formation; and a wellbore casing positioned within and
coupled to the wellbore; wherein the wellbore casing is coupled to
the wellbore by a process comprising: positioning an assembly
within a borehole that traverses a subterranean formation; and
radially expanding and plastically deforming the assembly within
the borehole; wherein the assembly comprises: a first tubular
member comprising external threads; a second tubular member
comprising internal threads coupled to the external threads of the
first tubular member; and an external sleeve coupled to and
overlapping with the ends of the first and second tubular members;
wherein at least one of the first and second tubular members define
one or more stress concentrators.
27. A system for forming a wellbore casing, comprising: means for
positioning an assembly within a borehole that traverses a
subterranean formation; and means for radially expanding and
plastically deforming the assembly within the borehole; wherein the
assembly comprises: a first tubular member comprising external
threads; a second tubular member comprising internal threads
coupled to the external threads of the first tubular member, and an
external sleeve coupled to and overlapping with the ends of the
first and second tubular members; wherein at least one of the first
and second tubular members define one or more stress
concentrators.
28. An assembly, comprising: a first tubular member comprising
external threads; and a second tubular member comprising internal
threads coupled to the external threads of the first tubular
member; wherein the first and second tubular members each define
one or more stress concentrators.
29. The assembly of claim 28, further comprising: an external
sleeve coupled to and overlapping with the ends of the first and
second tubular members.
30. The assembly of claim 28, wherein one or more of the stress
concentrators comprise surface grooves formed in the surfaces of at
least one of the first and second tubular members.
31. The assembly of claim 28, wherein the stress concentrators are
defined above the internal and external threads of the first and
second tubular members.
32. A method for forming a wellbore casing, comprising: positioning
the assembly of claim 28 within a borehole that traverses a
subterranean formation; and radially expanding and plastically
deforming the assembly within the borehole.
33. A method for forming a wellbore casing, comprising: positioning
the assembly of claim 29 within a borehole that traverses a
subterranean formation; and radially expanding and plastically
deforming the assembly within the borehole.
34. A method for forming a wellbore casing, comprising: positioning
the assembly of claim 30 within a borehole that traverses a
subterranean formation; and radially expanding and plastically
deforming the assembly within the borehole.
35. A method for forming a wellbore casing, comprising: positioning
the assembly of claim 31 within a borehole that traverses a
subterranean formation; and radially expanding and plastically
deforming the assembly within the borehole.
36. An apparatus, comprising: a wellbore that traverses a
subterranean formation; and a wellbore casing positioned within and
coupled to the wellbore; wherein the wellbore casing is coupled to
the wellbore by a process comprising: positioning the assembly of
claim 28 within the wellbore; and radially expanding and
plastically deforming the assembly within the wellbore.
37. An apparatus, comprising: a wellbore that traverses a
subterranean formation; and a wellbore casing positioned within and
coupled to the wellbore; wherein the wellbore casing is coupled to
the wellbore by a process comprising: positioning the assembly of
claim 29 within the wellbore; and radially expanding and
plastically deforming the assembly within the wellbore.
38. An apparatus, comprising: a wellbore that traverses a
subterranean formation; and a wellbore casing positioned within and
coupled to the wellbore; wherein the wellbore casing is coupled to
the wellbore by a process comprising: positioning the assembly of
claim 30 within the wellbore; and radially expanding and
plastically deforming the assembly within the wellbore.
39. An apparatus, comprising: a wellbore that traverses a
subterranean formation; and a wellbore casing positioned within and
coupled to the wellbore; wherein the wellbore casing is coupled to
the wellbore by a process comprising: positioning the assembly of
claim 31 within the wellbore; and radially expanding and
plastically deforming the assembly within the wellbore.
40. A system for forming a wellbore casing, comprising: means for
positioning the assembly of claim 28 within a borehole that
traverses a subterranean formation; and means for radially
expanding and plastically deforming the assembly within the
borehole.
41. A system for forming a wellbore casing, comprising: means for
positioning the assembly of claim 29 within a borehole that
traverses a subterranean formation; and means for radially
expanding and plastically deforming the assembly within the
borehole.
42. A system for forming a wellbore casing, comprising: means for
positioning the assembly of claim 30 within a borehole that
traverses a subterranean formation; and means for radially
expanding and plastically deforming the assembly within the
borehole.
43. A system for forming a wellbore casing, comprising: means for
positioning the assembly of claim 31 within a borehole that
traverses a subterranean formation; and means for radially
expanding and plastically deforming the assembly within the
borehole.
44. A method of providing a fluid tight seal between a pair of
overlapping tubular members, comprising: forming one or more stress
concentrators within each of the tubular members; and radially
expanding and plastically deforming the tubular members.
45. The method of claim 44, wherein the tubular members are
threadably coupled; and wherein the stress concentrators are formed
above the threaded coupling.
46. The method of claim 44, wherein the stress concentrators
comprise surface grooves formed in at least one of the tubular
members.
47. A method of providing a fluid tight seal between a pair of
overlapping tubular members, comprising: concentrating compressive
stresses onto the overlapping portions of the tubular members; and
radially expanding and plastically deforming the tubular
members.
48. The method of claim 47, wherein the tubular members are
threadably coupled; and wherein the compressive stresses are
concentrated onto the threaded coupling during the radial expansion
and plastic deformation.
49. A method for manufacturing an expandable member used to
complete a structure by radially expanding and plastically
deforming the expandable member comprising: forming the expandable
member from a steel alloy comprising a charpy energy of at least
about 90 ft-lbs.
50. An expandable member for use in completing a structure by
radially expanding and plastically deforming the expandable member,
comprising: a steel alloy comprising a charpy energy of at least
about 90 ft-lbs.
51. A structural completion positioned within a structure,
comprising: one or more radially expanded and plastically deformed
expandable members positioned within the structure; wherein one or
more of the radially expanded and plastically deformed expandable
members are fabricated from a steel alloy comprising a charpy
energy of at least about 90 ft-lbs.
52. A method for manufacturing an expandable member used to
complete a structure by radially expanding and plastically
deforming the expandable member, comprising: forming the expandable
member from a steel alloy comprising a weight percentage of carbon
of less than about 0.08%.
53. An expandable member for use in completing a wellbore by
radially expanding and plastically deforming the expandable member
at a downhole location in the wellbore, comprising: a steel alloy
comprising a weight percentage of carbon of less than about
0.08%.
54. A structural completion, comprising: one or more radially
expanded and plastically deformed expandable members positioned
within the wellbore; wherein one or more of the radially expanded
and plastically deformed expandable members are fabricated from a
steel alloy comprising a weight percentage of carbon of less than
about 0.08%.
55. A method for manufacturing an expandable member used to
complete a structure by radially expanding and plastically
deforming the expandable member, comprising: forming the expandable
member from a steel alloy comprising a weight percentage of carbon
of less than about 0.20% and a charpy V-notch impact toughness of
at least about 6 joules.
56. An expandable member for use in completing a structure by
radially expanding and plastically deforming the expandable member,
comprising: a steel alloy comprising a weight percentage of carbon
of less than about 0.20% and a charpy V-notch impact toughness of
at least about 6 joules.
57. A structural completion, comprising: one or more radially
expanded and plastically deformed expandable members; wherein one
or more of the radially expanded and plastically deformed
expandable members are fabricated from a steel alloy comprising a
weight percentage of carbon of less than about 0.20% and a charpy
V-notch impact toughness of at least about 6 joules.
58. A method for manufacturing an expandable member used to
complete a structure by radially expanding and plastically
deforming the expandable member, comprising: forming the expandable
member from a steel alloy comprising the following ranges of weight
percentages: C, from about 0.002 to about 0.08; Si, from about
0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from
about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al,
up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up
to about 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to
about 0.6; Co, up to about 9; and Mo, up to about 5.
59. An expandable member for use in completing a structure by
radially expanding and plastically deforming the expandable member,
comprising: a steel alloy comprising the following ranges of weight
percentages: C, from about 0.002 to about 0.08; Si, from about
0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from
about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al,
up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up
to about 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to
about 0.6; Co, up to about 9; and Mo, up to about 5.
60. A structural completion, comprising: one or more radially
expanded and plastically deformed expandable members; wherein one
or more of the radially expanded and plastically deformed
expandable members are fabricated from a steel alloy comprising the
following ranges of weight percentages: C, from about 0.002 to
about 0.08; Si, from about 0.009 to about 0.30; Mn, from about 0.10
to about 1.92; P, from about 0.004 to about 0.07; S, from about
0.0008 to about 0.006; Al, up to about 0.04; N, up to about 0.01;
Cu, up to about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb,
up to about 0.12; Ti, up to about 0.6; Co, up to about 9; and Mo,
up to about 5.
61. A method for manufacturing an expandable tubular member used to
complete a structure by radially expanding and plastically
deforming the expandable member, comprising: forming the expandable
tubular member with a ratio of the of an outside diameter of the
expandable tubular member to a wall thickness of the expandable
tubular member ranging from about 12 to 22.
62. An expandable member for use in completing a structure by
radially expanding and plastically deforming the expandable member,
comprising: an expandable tubular member with a ratio of the of an
outside diameter of the expandable tubular member to a wall
thickness of the expandable tubular member ranging from about 12 to
22.
63. A structural completion, comprising: one or more radially
expanded and plastically deformed expandable members positioned
within the structure; wherein one or more of the radially expanded
and plastically deformed expandable members are fabricated from an
expandable tubular member with a ratio of the of an outside
diameter of the expandable tubular member to a wall thickness of
the expandable tubular member ranging from about 12 to 22.
64. A method of constructing a structure, comprising: radially
expanding and plastically deforming an expandable member, wherein
an outer portion of the wall thickness of the radially expanded and
plastically deformed expandable member comprises tensile residual
stresses.
65. A structural completion, comprising: one or more radially
expanded and plastically deformed expandable members; wherein an
outer portion of the wall thickness of one or more of the radially
expanded and plastically deformed expandable members comprises
tensile residual stresses.
66. A method of constructing a structure using an expandable
tubular member, comprising: strain aging the expandable member, and
then radially expanding and plastically deforming the expandable
member.
67. A method for manufacturing a tubular member used to complete a
wellbore by radially expanding the tubular member at a downhole
location in the wellbore comprising: forming a steel alloy
comprising a concentration of carbon between approximately 0.002%
and 0.08% by weight of the steel alloy.
68. The method of claim 67, further comprising forming the steel
alloy with a concentration of niobium comprising between
approximately 0.015% and 0.12% by weight of the steel alloy.
69. The method of claim 67, further comprising: forming the steel
alloy with low concentrations of niobium and titanium; and limiting
the total concentration of niobium and titanium to less than
approximately 0.6% by weight of the steel alloy.
70. An expandable tubular member fabricated from a steel alloy
having a concentration of carbon between approximately 0.002% and
0.08% by weight of the steel alloy.
71. A method for manufacturing an expandable tubular member used to
complete a wellbore completion within a wellbore that traverses a
subterranean formation by radially expanding and plastically
deforming the expandable tubular member within the wellbore,
comprising: forming the expandable tubular member from a steel
alloy comprising a charpy energy of at least about 90 ft-lbs;
forming the expandable member from a steel alloy comprising a
charpy V-notch impact toughness of at least about 6 joules; forming
the expandable member from a steel alloy comprising the following
ranges of weight percentages: C, from about 0.002 to about 0.08;
Si, from about 0.009 to about 0.30; Mn, from about 0.10 to about
1.92; P, from about 0.004 to about 0.07; S, from about 0.0008 to
about 0.006; Al, up to about 0.04; N, up to about 0.01; Cu, up to
about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb, up to about
0.12; Ti, up to about 0.6; Co, up to about 9; and Mo, up to about
5; forming the expandable tubular member with a ratio of the of an
outside diameter of the expandable tubular member to a wall
thickness of the expandable tubular member ranging from about 12 to
22; and strain aging the expandable tubular member prior to the
radial expansion and plastic deformation of the expandable tubular
member within the wellbore.
72. An expandable tubular member for use in completing a wellbore
completion within a wellbore that traverses a subterranean
formation by radially expanding and plastically deforming the
expandable tubular member within the wellbore, comprising: a steel
alloy having a charpy energy of at least about 90 ft-lbs; a steel
alloy having a charpy V-notch impact toughness of at least about 6
joules; and a steel alloy comprising the following ranges of weight
percentages: C, from about 0.002 to about 0.08; Si, from about
0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from
about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al,
up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up
to about 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to
about 0.6; Co, up to about 9; and Mo, up to about 5; wherein a
ratio of the of an outside diameter of the expandable tubular
member to a wall thickness of the expandable tubular member ranging
from about 12 to 22; and wherein the expandable tubular member is
strain aged prior to the radial expansion and plastic deformation
of the expandable tubular member within the wellbore.
73. A wellbore completion positioned within a wellbore that
traverses a subterranean formation, comprising: one or more
radially expanded and plastically deformed expandable tubular
members positioned within the wellbore completion; wherein one or
more of the radially expanded and plastically deformed expandable
tubular members are fabricated from: a steel alloy comprising a
charpy energy of at least about 90 ft-lbs; a steel alloy comprising
a charpy V-notch impact toughness of at least about 6 joules; and a
steel alloy comprising the following ranges of weight percentages:
C, from about 0.002 to about 0.08; Si, from about 0.009 to about
0.30; Mn, from about 0.10 to about 1.92; P, from about 0.004 to
about 0.07; S, from about 0.0008 to about 0.006; Al, up to about
0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up to about
0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about 0.6;
Co, up to about 9; and Mo, up to about 5; wherein at least one of
the expandable members comprises a ratio of the of an outside
diameter of the expandable member to a wall thickness of the
expandable member ranging from about 12 to 22; wherein an outer
portion of the wall thickness of at least one of the radially
expanded and plastically deformed expandable comprises tensile
residual stresses; and wherein at least one of the expandable
tubular member is strain aged prior to the radial expansion and
plastic deformation of the expandable tubular member within the
wellbore.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is the National Stage patent
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Ser. No. 60/159,039, attorney docket no. 25791.36, filed on Oct.
12, 1999, (15) U.S. provisional patent application Ser. No.
60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999,
(16) U.S. provisional patent application Ser. No. 60/212,359,
attorney docket no. 25791.38, filed on Jun. 19, 2000, (17) U.S.
provisional patent application Ser. No. 60/165,228, attorney docket
no. 25791.39, filed on Nov. 12, 1999, (18) U.S. provisional patent
application Ser. No. 60/221,443, attorney docket no. 25791.45,
filed on Jul. 28, 2000, (19) U.S. provisional patent application
Ser. No. 60/221,645, attorney docket no. 25791.46, filed on Jul.
28, 2000, (20) U.S. provisional patent application Ser. No.
60/233,638, attorney docket no. 25791.47, filed on Sep. 18, 2000,
(21) U.S. provisional patent application Ser. No. 60/237,334,
attorney docket no. 25791.48, filed on Oct. 2, 2000, (22) U.S.
provisional patent application Ser. No. 60/270,007, attorney docket
no. 25791.50, filed on Feb. 20, 2001, (23) U.S. provisional patent
application Ser. No. 60/262,434, attorney docket no. 25791.51,
filed on Jan. 17, 2001, (24) U.S. provisional patent application
Ser. No. 60/259,486, attorney docket no. 25791.52, filed on Jan. 3,
2001, (25) U.S. provisional patent application Ser. No. 60/303,740,
attorney docket no. 25791.61, filed on Jul. 6, 2001, (26) U.S.
provisional patent application Ser. No. 60/313,453, attorney docket
no. 25791.59, filed on Aug. 20, 2001, (27) U.S. provisional patent
application Ser. No. 60/317,985, attorney docket no. 25791.67,
filed on Sep. 6, 2001, (28) U.S. provisional patent application
Ser. No. 60/3318,386, attorney docket no. 25791.67.02, filed on
Sep. 10, 2001, (29) U.S. utility patent application Ser. No.
09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001,
(30) U.S. utility patent application Ser. No. 10/016,467, attorney
docket no. 25791.70, filed on Dec. 10, 2001, (31) U.S. provisional
patent application Ser. No. 60/343,674, attorney docket no.
25791.68, filed on Dec. 27, 2001, (32) U.S. provisional patent
application Ser. No. 60/346,309, attorney docket no 25791.92, filed
on Jan. 7, 2002, (33) U.S. provisional patent application Ser. No.
60/372,048, attorney docket no. 25791.93, filed on Apr. 12, 2002,
(34) U.S. provisional patent application Ser. No. 60/380,147,
attorney docket no. 25791.104, filed on May 6, 2002, (35) U.S.
provisional patent application Ser. No. 60/387,486, attorney docket
no. 25791.107, filed on Jun. 10, 2002, (36) U.S. provisional patent
application Ser. No. 60/387,961, attorney docket no. 25791.108,
filed on Jun. 12, 2002, (37) U.S. provisional patent application
Ser. No. 60/394,703, attorney docket no. 25791.90, filed on Jun.
26, 2002, (38) U.S. provisional patent application Ser. No.
60/397,284, attorney docket no. 25791.106, filed on Jul. 19, 2002,
(39) U.S. provisional patent application Ser. No. 60/398,061,
attorney docket no. 25791.110, filed on Jul. 24, 2002, (40) U.S.
provisional patent application Ser. No. 60/405,610, attorney docket
no. 25791.119, filed on Aug. 23, 2002, (41) U.S. provisional patent
application Ser. No. 60/405,394, attorney docket no. 25791.120,
filed on Aug. 23, 2002, (42) U.S. provisional patent application
Ser. No. 60/412,177, attorney docket no. 25791.117, filed on Sep.
20, 2002, (43) U.S. provisional patent application Ser. No.
60/412,653, attorney docket no. 25791.118, filed on Sep. 20, 2002,
(44) U.S. provisional patent application Ser. No. 60/412,544,
attorney docket no. 25791.121, filed on Sep. 20, 2002, (45) U.S.
provisional patent application Ser. No. 60/412,187, attorney docket
no. 25791.128, filed on Sep. 20, 2002, (46) U.S. provisional patent
application Ser. No. 60/412,196, attorney docket no. 25791.127,
filed on Sep. 20, 2002, (47) U.S. provisional patent application
Ser. No. 60/412,542, attorney docket no. 25791.102, filed on Sep.
20, 2002, (48) U.S. provisional patent application Ser. No.
60/412,487, attorney docket no. 25791.112, filed on Sep. 20, 2002,
(49) U.S. provisional patent application no. 60/412,488, attorney
docket no. 25791.114, filed on Sep. 20, 2002, the disclosures of
which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0004] This invention relates generally to oil and gas exploration,
and in particular to forming and repairing wellbore casings to
facilitate oil and gas exploration.
[0005] Conventionally, when a wellbore is created, a number of
casings are installed in the borehole to prevent collapse of the
borehole wall and to prevent undesired outflow of drilling fluid
into the formation or inflow of fluid from the formation into the
borehole. The borehole is drilled in intervals whereby a casing
which is to be installed in a lower borehole interval is lowered
through a previously installed casing of an upper borehole
interval. As a consequence of this procedure the casing of the
lower interval is of smaller diameter than the casing of the upper
interval. Thus, the casings are in a nested arrangement with casing
diameters decreasing in downward direction. Cement annuli are
provided between the outer surfaces of the casings and the borehole
wall to seal the casings from the borehole wall. As a consequence
of this nested arrangement a relatively large borehole diameter is
required at the upper part of the wellbore. Such a large borehole
diameter involves increased costs due to heavy casing handling
equipment, large drill bits and increased volumes of drilling fluid
and drill cuttings. Moreover, increased drilling rig time is
involved due to required cement pumping, cement hardening, required
equipment changes due to large variations in hole diameters drilled
in the course of the well, and the large volume of cuttings drilled
and removed.
[0006] During oil exploration, a wellbore typically traverses a
number of zones within a subterranean formation. Wellbore casings
are then formed in the wellbore by radially expanding and
plastically deforming tubular members that are coupled to one
another by threaded connections existing methods for radially
expanding and plastically deforming tubular members coupled to one
another by threaded connections are not always reliable and do not
always produce satisfactory results. In particular, the threaded
connections can be damaged during the radial expansion process.
Furthermore, the threaded connections between adjacent tubular
members, whether radially expanded or not, are typically not
sufficiently coupled to permit the transmission of energy through
the tubular members from the surface to the downhole location.
Further, the damaged threads may permit undesirable leakage between
the inside of the casing and the exterior of the casing.
[0007] The present invention is directed to overcoming one or more
of the limitations of the existing procedures for forming and/or
repairing wellbore casings.
SUMMARY OF THE INVENTION
[0008] According to one aspect of the present invention, an
assembly is provided that includes a first tubular member including
external threads, and a second tubular member comprising internal
threads coupled to the external threads of the first tubular
member. At least one of the first and second tubular members define
one or more stress concentrators. According to another aspect of
the present invention, a method for forming a wellbore casing has
been described that includes positioning any one, portion, or
combination, of the exemplary embodiments of the assemblies of the
present application within a borehole that traverses a subterranean
formation, and radially expanding and plastically deforming the
assembly within the borehole.
[0009] According to another aspect of the present invention, an
apparatus is provided that includes a wellbore that traverses a
subterranean formation, and a wellbore casing positioned within and
coupled to the wellbore. The wellbore casing is coupled to the
wellbore by a process including: positioning any one, portion, or
combination, of the exemplary assemblies of the present application
within the wellbore, and radially expanding and plastically
deforming the assembly within the wellbore.
[0010] According to another aspect of the present invention, a
system for forming a wellbore casing is provided that includes
means for positioning any one, portion, or combination, of the
exemplary assemblies of the present application within a borehole
that traverses a subterranean formation, and means for radially
expanding and plastically deforming the assembly within the
borehole.
[0011] According to another aspect of the present invention, a
method of providing a fluid tight seal between a pair of
overlapping tubular members is provided that includes forming one
or more stress concentrators within at least one of the tubular
members, and radially expanding and plastically deforming the
tubular members.
[0012] According to another aspect of the present invention, a
method for manufacturing an expandable member used to complete a
structure by radially expanding and plastically deforming the
expandable member is provided that includes forming the expandable
member from a steel alloy comprising a charpy energy of at least
about 90 ft-lbs.
[0013] According to another aspect of the present invention, an
expandable member for use in completing a structure by radially
expanding and plastically deforming the expandable member is
provided that includes a steel alloy comprising a charpy energy of
at least about 90 ft-lbs.
[0014] According to another aspect of the present invention, a
structural completion positioned within a structure is provided
that includes one or more radially expanded and plastically
deformed expandable members positioned within the structure;
wherein one or more of the radially expanded and plastically
deformed expandable members are fabricated from a steel alloy
comprising a charpy energy of at least about 90 ft-lbs.
[0015] According to another aspect of the present invention, a
method for manufacturing an expandable member used to complete a
structure by radially expanding and plastically deforming the
expandable member is provided that includes forming the expandable
member from a steel alloy comprising a weight percentage of carbon
of less than about 0.08%.
[0016] According to another aspect of the present invention, an
expandable member for use in completing a wellbore by radially
expanding and plastically deforming the expandable member at a
downhole location in the wellbore is provided that includes a steel
alloy comprising a weight percentage of carbon of less than about
0.08%.
[0017] According to another aspect of the present invention, a
structural completion is provided that includes one or more
radially expanded and plastically deformed expandable members
positioned within the wellbore; wherein one or more of the radially
expanded and plastically deformed expandable members are fabricated
from a steel alloy comprising a weight percentage of carbon of less
than about 0.08%.
[0018] According to another aspect of the present invention, a
method for manufacturing an expandable member used to complete a
structure by radially expanding and plastically deforming the
expandable member is provided that includes forming the expandable
member from a steel alloy comprising a weight percentage of carbon
of less than about 0.20% and a charpy V-notch impact toughness of
at least about 6 joules.
[0019] According to another aspect of the present invention, an
expandable member for use in completing a structure by radially
expanding and plastically deforming the expandable member is
provided that includes a steel alloy comprising a weight percentage
of carbon of less than about 0.20% and a charpy V-notch impact
toughness of at least about 6 joules.
[0020] According to another aspect of the present invention, a
structural completion is provided that includes one or more
radially expanded and plastically deformed expandable members;
wherein one or more of the radially expanded and plastically
deformed expandable members are fabricated from a steel alloy
comprising a weight percentage of carbon of less than about 0.20%
and a charpy V-notch impact toughness of at least about 6
joules.
[0021] According to another aspect of the present invention, a
method for manufacturing an expandable member used to complete a
structure by radially expanding and plastically deforming the
expandable member is provided that includes forming the expandable
member from a steel alloy comprising the following ranges of weight
percentages: C, from about 0.002 to about 0.08; Si, from about
0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from
about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al,
up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up
to about 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to
about 0.6; Co, up to about 9; and Mo, up to about 5.
[0022] According to another aspect of the present invention, an
expandable member for use in completing a structure by radially
expanding and plastically deforming the expandable member is
provided that includes a steel alloy comprising the following
ranges of weight percentages: C, from about 0.002 to about 0.08;
Si, from about 0.009 to about 0.30; Mn, from about 0.10 to about
1.92; P, from about 0.004 to about 0.07; S, tom about 0.0008 to
about 0.006; Al, up to about 0.04; N, up to about 0.01; Cu, up to
about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb, up to about
0.12; Ti, up to about 0.6; Co, up to about 9; and Mo, up to about
5.
[0023] According to another aspect of the present invention, a
structural completion is provided that includes one or more
radially expanded and plastically deformed expandable members;
wherein one or more of the radially expanded and plastically
deformed expandable members are fabricated from a steel alloy
comprising the following ranges of weight percentages: C, from
about 0.002 to about 0.08; Si, from about 0.009 to about 0.30; Mn,
from about 0.10 to about 1.92; P, from about 0.004 to about 0.07;
S, from about 0.0008 to about 0.006; Al, up to about 0.04; N, up to
about 0.01; Cu, up to about 0.3; Cr, up to about 0.5; Ni, up to
about 18; Nb, up to about 0.12; Ti, up to about 0.6; Co, up to
about 9; and Mo, up to about 5.
[0024] According to another aspect of the present invention, a
method for manufacturing an expandable tubular member used to
complete a structure by radially expanding and plastically
deforming the expandable member is provided that includes forming
the expandable tubular member with a ratio of the of an outside
diameter of the expandable tubular member to a wall thickness of
the expandable tubular member ranging from about 12 to 22.
[0025] According to another aspect of the present invention, an
expandable member for use in completing a structure by radially
expanding and plastically deforming the expandable member is
provided that includes an expandable tubular memberwith a ratio of
the of an outside diameterof the expandable tubular member to a
wall thickness of the expandable tubular member ranging from about
12 to 22.
[0026] According to another aspect of the present invention, a
structural completion is provided that includes one or more
radially expanded and plastically deformed expandable members
positioned within the structure; wherein one or more of the
radially expanded and plastically deformed expandable members are
fabricated from an expandable tubular member with a ratio of the of
an outside diameter of the expandable tubular member to a wall
thickness of the expandable tubular member ranging from about 12 to
22.
[0027] According to another aspect of the present invention, a
method of constructing a structure is provided that includes
radially expanding and plastically deforming an expandable member;
wherein an outer portion of the wall thickness of the radially
expanded and plastically deformed expandable member comprises
tensile residual stresses.
[0028] According to another aspect of the present invention, a
structural completion is provided that includes one or more
radially expanded and plastically deformed expandable members;
wherein an outer portion of the wall thickness of one or more of
the radially expanded and plastically deformed expandable members
comprises tensile residual stresses.
[0029] According to another aspect of the present invention, a
method of constructing a structure using an expandable tubular
member is provided that includes strain aging the expandable
member; and then radially expanding and plastically deforming the
expandable member.
[0030] According to another aspect of the present invention, a
method for manufacturing a tubular member used to complete a
wellbore by radially expanding the tubular member at a downhole
location in the wellbore comprising: forming a steel alloy
comprising a concentration of carbon between approximately 0.002%
and 0.08% by weight of the steel alloy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a fragmentary cross-sectional illustration of a
first tubular threadably coupled to a second tubular.
[0032] FIG. 2 is a fragmentary cross-sectional illustration of a
first tubular threadably coupled to a second tubular.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0033] FIG. 1 illustrates a first tubular member 10 that defines a
passage 10a that includes a pin member 12 that includes stress
concentration grooves, 14a and 14b, formed in the internal surface
of the pin member, and external threads 16 that engage internal
threads 18 of a box member 20 of a second tubular member 22 that
defines a passage 22a. Stress concentration grooves, 24a and 24b,
are formed in the external surface of the box member 20 of the
second tubular member, and an external sleeve 26 is coupled to and
overlaps with the ends of the first and second tubular members, 10
and 22. The first tubular member 10, the second tubular member 22,
and the external sleeve 26 may be radially expanded and plastically
deformed using any number of conventional methods and apparatus
and/or as disclosed in one or more of the following: (1) U.S.
patent application Ser. No. 09/454,139, attorney docket no.
25791.03.02, filed on Dec. 3, 1999, (2) U.S. patent application
Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb.
23, 2000, (3) U.S. patent application Ser. No. 09/502,350, attorney
docket no. 25791.8.02, filed on Feb. 10, 2000, (4) U.S. Pat. No.
6,328,113, (5) U.S. patent application Ser. No. 09/523,460,
attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (6) U.S.
patent application Ser. No. 09/512,895, attorney docket no.
25791.12.02, filed on Feb. 24, 2000, (7) U.S. patent application
Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb.
24, 2000, (8) U.S. patent application Ser. No. 09/588,946, attorney
docket no. 25791.17.02, filed on Jun. 7, 2000, (9) U.S. patent
application Ser. No. 09/559,122, attorney docket no. 25791.23.02,
filed on Apr. 26, 2000, (10) PCT patent application serial no.
PCT/US00/18635, attorney docket no. 25791.25.02, filed on Jul. 9,
2000, (11) U.S. provisional patent application Ser. No. 60/162,671,
attorney docket no. 25791.27, filed on Nov. 1, 1999, (12) U.S.
provisional patent application Ser. No. 60/154,047, attorneydocket
no. 25791.29, filed on Sep. 16, 1999, (13) U.S. provisional patent
application Ser. No. 60/159,082, attorney docket no. 25791.34,
filed on Oct. 12, 1999, (14) U.S. provisional patent application
Ser. No. 60/159,039, attorney docket no. 25791.36, filed on Oct.
12, 1999, (15) U.S. provisional patent application Ser. No.
60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999,
(16) U.S. provisional patent application Ser. No. 60/212,359,
attorney docket no. 25791.38, filed on Jun. 19, 2000, (17) U.S.
provisional patent application Ser. No. 60/165,228, attorney docket
no. 25791.39, filed on Nov. 12, 1999, (18) U.S. provisional patent
application Ser. No. 60/221,443, attorney docket no. 25791.45,
filed on Jul. 28, 2000, (19) U.S. provisional patent application
Ser. No. 60/221,645, attorney docket no. 25791.46, filed on Jul.
28, 2000, (20) U.S. provisional patent application Ser. No.
60/233,638, attorney docket no. 25791.47, filed on Sep. 18, 2000,
(21) U.S. provisional patent application Ser. No. 60/237,334,
attorney docket no. 25791.48, filed on Oct. 2, 2000, (22) U.S.
provisional patent application Ser. No. 60/270,007, attorney docket
no. 25791.50, filed on Feb. 20, 2001, (23) U.S. provisional patent
application Ser. No. 60/262,434, attorney docket no. 25791.51,
filed on Jan. 17, 2001, (24) U.S. provisional patent application
Ser. No. 60/259,486, attorney docket no. 25791.52, filed on Jan. 3,
2001, (25) U.S. provisional patent application Ser. No. 60/303,740,
attorney docket no. 25791.61, filed on Jul. 6, 2001, (26) U.S.
provisional patent application Ser. No. 60/313,453, attorney docket
no. 25791.59, filed on Aug. 20, 2001, (27) U.S. provisional patent
application Ser. No. 60/317,985, attorney docket no. 25791.67,
filed on Sep. 6, 2001, (28) U.S. provisional patent application
serial no. 60/3318,386, attorney docket no. 25791.67.02, filed on
Sep. 10, 2001, (29) U.S. utility patent application Ser. No.
09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001,
(30) U.S. utility patent application Ser. No. 10/016,467, attorney
docket no. 25791.70, filed on Dec. 10, 2001, (31) U.S. provisional
patent application Ser. No. 60/343,674, attorney docket no.
25791.68, filed on Dec. 27, 2001, (32) U.S. provisional patent
application Ser. No. 60/346,309, attorney docket no 25791.92, filed
on Jan. 7, 2002, (33) U.S. provisional patent application Ser. No.
60/372,048, attorney docket no. 25791.93, filed on Apr. 12, 2002,
(34) U.S. provisional patent application Ser. No. 60/380,147,
attorney docket no. 25791.104, filed on May 6, 2002, (35) U.S.
provisional patent application Ser. No. 60/387,486, attorney docket
no. 25791.107, filed on Jun. 10, 2002, (36) U.S. provisional patent
application Ser. No. 60/387,961, attorney docket no. 25791.108,
filed on Jun. 12, 2002, (37) U.S. provisional patent application
Ser. No. 60/394,703, attorney docket no. 25791.90, filed on Jun.
26, 2002, (38) U.S. provisional patent application Ser. No.
60/397,284, attorney docket no. 25791.106, filed on Jul. 19, 2002,
(39) U.S. provisional patent application Ser. No. 60/398,061,
attorney docket no. 25791.110, filed on Jul. 24, 2002, (40) U.S.
provisional patent application serial no, 60/405,610, attorney
docket no. 25791.119, filed on Aug. 23, 2002, (41) U.S. provisional
patent application Ser. No. 60/405,394, attorney docket no.
25791.120, filed on Aug. 23, 2002, (42) U.S. provisional patent
application Ser. No. 60/412,177, attorney docket no. 25791.117,
filed on Sep. 20, 2002, (43) U.S. provisional patent application
Ser. No. 60/412,653, attorney docket no. 25791.118, filed on Sep.
20, 2002, (44) U.S. provisional patent application Ser. No.
60/412,544, attorney docket no. 25791.121, filed on Sep. 20, 2002,
(45) U.S. provisional patent application Ser. No. 60/412,187,
attorney docket no. 25791.128, filed on Sep. 20, 2002, (46) U.S.
provisional patent application Ser. No. 60/412,196, attorney docket
no. 25791.127, filed on Sep. 20, 2002, (47) U.S. provisional patent
application Ser. No. 60/412,542, attorney docket no. 25791.102,
filed on Sep. 20, 2002, (48) U.S. provisional patent application
Ser. No. 60/412,487, attorney docket no. 25791.112, filed on Sep.
20, 2002, (49) U.S. provisional patent application no. 60/412,488,
attorney docket no. 25791.114, filed on Sep. 20, 2002, the
disclosures of which are incorporated herein by reference.
[0034] In an exemplary embodiment, during the radial expansion and
plastic deformation of the first tubular member 10, the second
tubular member 22, and the external sleeve 26, the stress
concentration grooves, 14a, 14b, 24a, and 24b, concentrate
compressive stresses onto the threads, 16 and 18, of the pin and
box members, 12 and 20, of the first and second tubular members to
drive the threads together to thereby provide a fluid tight seal
between the threads of the pin and box members of the first and
second tubular members upon the completion of the radial expansion
and plastic deformation.
[0035] FIG. 2 is an illustration of another illustrative
embodiment.
[0036] In an exemplary embodiment, a tribological system is used to
reduce friction and thereby minimize the expansion forces required
during the radial expansion and plastic deformation of the tubular
members that includes one or more of the following: (1) a tubular
tribology system; (2) a drilling mud tribology system; (3) a
lubrication tribology system; and (4) an expansion device tribology
system.
[0037] In an exemplary embodiment, the tubular tribology system
includes the application of coatings of lubricant to the interior
surface of the tubular members.
[0038] In an exemplary embodiment, the drilling mud tribology
system includes the addition of lubricating additives to the
drilling mud.
[0039] In an exemplary embodiment, the lubrication tribology system
includes the use of lubricating greases, self-lubricating expansion
devices, automated injection/delivery of lubricating greases into
the interface between an expansion device and the tubular members,
surfaces within the interface between the expansion device and the
expandable tubular member that are self-lubricating, surfaces
within the interface between the expansion device and the
expandable tubular member that are textured, self-lubricating
surfaces within the interface between the expansion device and the
expandable tubular member that include diamond and/or ceramic
inserts, thermosprayed coatings, fluoropolymer coatings, PVD films,
and/or CVD films.
[0040] In an exemplary embodiment, the tubular members include one
or more of the following characteristics: high burst and collapse,
the ability to be radially expanded more than about 40%, high
fracture toughness, defect tolerance, strain recovery @ 150 F, good
bending fatigue, optimal residual stresses, and corrosion
resistance to H.sub.2S in order to provide optimal characteristics
during and after radial expansion and plastic deformation.
[0041] In an exemplary embodiment, the tubular members are
fabricated from a steel alloy having a charpy energy of at least
about 90 ft-lbs in order to provided enhanced characteristics
during and after radial expansion and plastic deformation of the
expandable tubular member.
[0042] In an exemplary embodiment, the tubular members are
fabricated from a steel alloy having a weight percentage of carbon
of less than about 0.08% in order to provide enhanced
characteristics during and after radial expansion and plastic
deformation of the tubular members.
[0043] In an exemplary embodiment, the tubular members are
fabricated from a steel alloy having reduced sulfur content in
order to minimize hydrogen induced cracking.
[0044] In an exemplary embodiment, the tubular members are
fabricated from a steel alloy having a weight percentage of carbon
of less than about 0.20% and a charpy-V-notch impact toughness of
at least about 6 joules in order to provide enhanced
characteristics during and after radial expansion and plastic
deformation of the tubular members.
[0045] In an exemplary embodiment, the tubular members are
fabricated from a steel alloy having a low weight percentage of
carbon in order to enhance toughness, ductility, weldability, shelf
energy, and hydrogen induced cracking resistance.
[0046] In several exemplary embodiments, the tubular members are
fabricated from a steel alloy having the following percentage
compositions in order to provide enhanced characteristics during
and after radial expansion and plastic deformation of the tubular
members:
1 C Si Mn P S Al N Cu Cr Ni Nb Ti Co Mo Example A 0.030 0.22 1.74
0.005 0.0005 0.028 0.0037 0.30 0.26 0.15 0.095 0.014 0.0034 Example
0.020 0.23 1.70 0.004 0.0005 0.026 0.0030 0.27 0.26 0.16 0.096
0.012 0.0021 B Min Example 0.032 0.26 1.92 0.009 0.0010 0.035
0.0047 0.32 0.29 0.18 0.120 0.016 0.0050 B Max Example C 0.028 0.24
1.77 0.007 0.0008 0.030 0.0035 0.29 0.27 0.17 0.101 0.014 0.0028
0.0020 Example D 0.08 0.30 0.5 0.07 0.005 0.010 0.10 0.50 0.10
Example E 0.0028 0.009 0.17 0.011 0.006 0.027 0.0029 0.029 0.014
0.035 0.007 Example F 0.03 0.1 0.1 0.015 0.005 18.0 0.6 9 5 Example
G 0.002 0.01 0.15 0.07 0.005 0.04 0.0025 0.015 0.010
[0047] In an exemplary embodiment, the ratio of the outside
diameter D of the tubular members to the wall thickness t of the
tubular members range from about 12 to 22 in order to enhance the
collapse strength of the radially expanded and plastically deformed
tubular members.
[0048] In an exemplary embodiment, the outer portion of the wall
thickness of the radially expanded and plastically deformed tubular
members includes tensile residual stresses in order to enhance the
collapse strength following radial expansion and plastic
deformation.
[0049] In several exemplary experimental embodiments, reducing
residual stresses in samples of the tubular members prior to radial
expansion and plastic deformation increased the collapse strength
of the radially expanded and plastically deformed tubular
members.
[0050] In several exemplary experimental embodiments, the collapse
strength of radially expanded and plastically deformed samples of
the tubulars were determined on an as-received basis, after strain
aging at 250 F for 5 hours to reduce residual stresses, and after
strain aging at 350 F for 14 days to reduce residual stresses as
follows:
2 Collapse Strength After Tubular Sample 10% Radial Expansion
Tubular Sample 1 - as received from 4000 psi manufacturer Tubular
Sample 1 - strain aged at 250 F. for 5 4800 psi hours to reduce
residual stresses Tubular Sample 1 - strain aged at 350 F. for 14
5000 psi days to reduce residual stresses
[0051] As indicated by the above table, reducing residual stresses
in the tubular members, prior to radial expansion and plastic
deformation, significantly increased the resulting collapse
strength--post expansion.
[0052] An assembly has been described that includes a first tubular
member including external threads, and a second tubular member
comprising internal threads coupled to the external threads of the
first tubular member. At least one of the first and second tubular
members define one or more stress concentrators. In an exemplary
embodiment, the assembly further comprises an external sleeve
coupled to and overlapping with the ends of the first and second
tubular members. In an exemplary embodiment, one or more of the
stress concentrators comprise surface grooves formed in the
surfaces of at least one of the first and second tubular members.
In an exemplary embodiment, the stress concentrators are defined
above the internal and external threads of the first and second
tubular members.
[0053] A method for forming a wellbore casing has been described
that includes positioning anyone, portion, or combination, of the
exemplary embodiments of the assemblies of the present application
within a borehole that traverses a subterranean formation, and
radially expanding and plastically deforming the assembly within
the borehole.
[0054] An apparatus has been described that includes a wellbore
that traverses a subterranean formation, and a wellbore casing
positioned within and coupled to the wellbore. The wellbore casing
is coupled to the wellbore by a process including: positioning any
one, portion, or combination, of the exemplary assemblies of the
present application within the wellbore, and radially expanding and
plastically deforming the assembly within the wellbore.
[0055] A system for forming a wellbore casing has been described
that includes means for positioning any one, portion, or
combination, of the exemplary assemblies of the present application
within a borehole that traverses a subterranean formation, and
means for radially expanding and plastically deforming the assembly
within the borehole.
[0056] A method of providing a fluid tight seal between a pair of
overlapping tubular members has been described that includes
forming one or more stress concentrators within at least one of the
tubular members, and radially expanding and plastically deforming
the tubular members. In an exemplary embodiment, the tubular
members are threadably coupled, and the stress concentrators are
formed above the threaded coupling.
[0057] In an exemplary embodiment, the stress concentrators
comprise surface grooves formed in at least one of the tubular
members.
[0058] A method for manufacturing an expandable member used to
complete a structure by radially expanding and plastically
deforming the expandable member has been described that includes
forming the expandable member from a steel alloy comprising a
charpy energy of at least about 90 ft-lbs.
[0059] An expandable member for use in completing a structure by
radially expanding and plastically deforming the expandable member
has been described that includes a steel alloy comprising a charpy
energy of at least about 90 ft-lbs.
[0060] A structural completion positioned within a structure has
been described that includes one or more radially expanded and
plastically deformed expandable members positioned within the
structure; wherein one or more of the radially expanded and
plastically deformed expandable members are fabricated from a steel
alloy comprising a charpy energy of at least about 90 ft-lbs.
[0061] A method for manufacturing an expandable member used to
complete a structure by radially expanding and plastically
deforming the expandable member has been described that includes
forming the expandable member from a steel alloy comprising a
weight percentage of carbon of less than about 0.08%.
[0062] An expandable member for use in completing a wellbore by
radially expanding and plastically deforming the expandable member
at a downhole location in the wellbore has been described that
includes a steel alloy comprising a weight percentage of carbon of
less than about 0.08%.
[0063] A structural completion has been described that includes one
or more radially expanded and plastically deformed expandable
members positioned within the wellbore; wherein one or more of the
radially expanded and plastically deformed expandable members are
fabricated from a steel alloy comprising a weight percentage of
carbon of less than about 0.08%.
[0064] A method for manufacturing an expandable member used to
complete a structure by radially expanding and plastically
deforming the expandable member has been described that includes
forming the expandable member from a steel alloy comprising a
weight percentage of carbon of less than about 0.20% and a charpy
V-notch impact toughness of at least about 6 joules.
[0065] An expandable member for use in completing a structure by
radially expanding and plastically deforming the expandable member
has been described that includes a steel alloy comprising a weight
percentage of carbon of less than about 0.20% and a charpy V-notch
impact toughness of at least about 6 joules.
[0066] A structural completion has been described that includes one
or more radially expanded and plastically deformed expandable
members; wherein one or more of the radially expanded and
plastically deformed expandable members are fabricated from a steel
alloy comprising a weight percentage of carbon of less than about
0.20% and a charpy V-notch impact toughness of at least about 6
joules.
[0067] A method for manufacturing an expandable member used to
complete a structure by radially expanding and plastically
deforming the expandable member has been described that includes
forming the expandable member from a steel alloy comprising the
following ranges of weight percentages: C, from about 0.002 to
about 0.08; Si, from about 0.009 to about 0.30; Mn, from about 0.10
to about 1.92; P, from about 0.004 to about 0.07; S, from about
0.0008 to about 0.006; Al, up to about 0.04; N, up to about 0.01;
Cu, up to about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb,
up to about 0.12; Ti, up to about 0.6; Co, up to about 9; and Mo,
up to about 5.
[0068] An expandable member for use in completing a structure by
radially expanding and plastically deforming the expandable member
has been described that includes a steel alloy comprising the
following ranges of weight percentages: C, from about 0.002 to
about 0.08; Si, from about 0.009 to about 0.30; Mn, from about 0.10
to about 1.92; P, from about 0.004 to about 0.07; S, from about
0.0008 to about 0.006; Al, up to about 0.04; N, up to about 0.01;
Cu, up to about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb,
up to about 0.12; Ti, up to about 0.6; Co, up to about 9; and Mo,
up to about 5.
[0069] A structural completion has been described that includes one
or more radially expanded and plastically deformed expandable
members; wherein one or more of the radially expanded and
plastically deformed expandable members are fabricated from a steel
alloy comprising the following ranges of weight percentages: C,
from about 0.002 to about 0.08; Si, from about 0.009 to about 0.30;
Mn, from about 0.10 to about 1.92; P, from about 0.004 to about
0.07; S, from about 0.0008 to about 0.006; Al, up to about 0.04; N,
up to about 0.01; Cu, up to about 0.3; Cr, up to about 0.5; Ni, up
to about 18; Nb, up to about 0.12; Ti, up to about 0.6; Co, up to
about 9; and Mo, up to about 5.
[0070] A method for manufacturing an expandable tubular member used
to complete a structure by radially expanding and plastically
deforming the expandable member has been described that includes
forming the expandable tubular member with a ratio of the of an
outside diameter of the expandable tubular member to a wall
thickness of the expandable tubular member ranging from about 12 to
22.
[0071] An expandable member for use in completing a structure by
radially expanding and plastically deforming the expandable member
has been described that includes an expandable tubular member with
a ratio of the of an outside diameter of the expandable tubular
member to a wall thickness of the expandable tubular member ranging
from about 12 to 22.
[0072] A structural completion has been described that includes one
or more radially expanded and plastically deformed expandable
members positioned within the structure; wherein one or more of the
radially expanded and plastically deformed expandable members are
fabricated from an expandable tubular member with a ratio of the of
an outside diameter of the expandable tubular member to a wall
thickness of the expandable tubular member ranging from about 12 to
22.
[0073] A method of constructing a structure has been described that
includes radially expanding and plastically deforming an expandable
member, wherein an outer portion of the wall thickness of the
radially expanded and plastically deformed expandable member
comprises tensile residual stresses.
[0074] A structural completion has been described that includes one
or more radially expanded and plastically deformed expandable
members; wherein an outer portion of the wall thickness of one or
more of the radially expanded and plastically deformed expandable
members comprises tensile residual stresses.
[0075] A method of constructing a structure using an expandable
tubular member has been described that includes strain aging the
expandable member, and then radially expanding and plastically
deforming the expandable member.
[0076] A method for manufacturing a tubular member used to complete
a wellbore by radially expanding the tubular member at a downhole
location in the wellbore has been described that includes forming a
steel alloy comprising a concentration of carbon between
approximately 0.002% and 0.08% by weight of the steel alloy.
[0077] 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, the
external sleeve 26 may be omitted. Furthermore, one or more of the
stress concentration grooves, 14a, 14b, 24a, and/or 24b, may be
omitted. In addition, the stress concentration grooves, 14a, 14b,
24a, and/or 24b may be provided in any geometric shape capable of
concentrating stresses. Furthermore, the stress concentration
grooves, 14a and 14b, may or may not be positioned in opposing
relation to the stress concentration grooves, 24a and 24b. In
addition, the first and second tubular members, 10 and 22, may or
may not be threadably coupled to one another, and the threads, 16
and 18, of the first and second tubular members may be any type of
threads.
[0078] 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.
* * * * *